Electrical Discharge Machining EDM set up ensures productiveness positive factors for British subcontractor

From Alexander Stark

As a part of the Volz Group, Volz Engineering has bold development plans. The Rochdale primarily based firm has just lately invested in a brand new CMM, two 3-axis machining centres, a turning centre and most just lately, a Mistubishi MV2400S wire EDM machine from the Engineering Know-how Group (ETG).

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New Mitsubishi MV2400S EDM at Volz Engineering.
New Mitsubishi MV2400S EDM at Volz Engineering.

(Supply: ETG)

The Volz Group manufactures HVAC filters for industrial and industrial purposes in addition to manufacturing the equipment for producing the filters and related elements equivalent to filter frames and clips. The expansion technique at Volz Engineering consists of plans for a devoted design and manufacturing division, filter body manufacturing and in addition two machine outlets; one for subcontract manufacture and one other devoted to the extremely automated filtration manufacturing machines the corporate specialises in. The 4 divisions will add to and develop present amenities that additionally embrace a press instrument and fixture manufacturing division.

With the growth technique and a continued requirement for press instruments and filtration automation equipment, the Higher Manchester enterprise was witnessing detached efficiency from a 25-year-old Mitsubishi EDM machine. Recalling the scenario, Volz Engineering Managing Director, Alan Reeson says: “Our earlier EDM machine was unreliable and dear to keep up — as is the case of any machine of such an age. ETG did a incredible job of sustaining the machine, however we realised that we would have liked a twenty first Century improve.”

Taking supply of the brand new Mitsubishi MV2400S wire EDM in October, the brand new machine has been a revelation for 15 worker Volz Engineering. As Reeson continues: “EDM is an integral a part of our enterprise because it providers each the press instrument and automatic equipment departments.”


In fact, the acquisition was primarily based on extra than simply the earlier service and assist ETG had offered. Reeson provides: “At first, the brand new Mitsubishi can run lights out giving us 24/7 manufacturing. We at present run one shift, however the facility to set the machine as much as run unmanned in a single day is a big benefit. It is a credit score to the wire having the ability to routinely re-thread and re-position itself and proceed working, so the machine doesn’t lose manufacturing hours if the wire breaks. Moreover, the set-up time is 60 p.c quicker on the brand new Mitsubishi MV2400S than the earlier machine. We are actually organising and operating jobs in lower than one hour.”

The brand new Mitsubishi MV2400S accommodates workpiece dimensions as much as 1050 by 820 by 305 mm in X, Y and Z axes with a most element capability as much as 1500 kg that may match on the 840 by 560 mm desk. The machine can utilise wire diameters from 0.1 to 0.3 mm and it’s provided with tubular shaft drives with linear scales, the M800 management with 19” full-touch display screen monitor, hand pilot with configurable LCD monitor, digital AE II generator and a filter switching system.

One other issue on this new machine is the flexibility to learn DXF information. Not solely does this permit us to ship information instantly from the workplace to the machine; it additionally provides us configuration management. Components and the allotted difficulty quantity for the elements and programmes will be adopted strictly by our database and thru the Mitsubishi machine – eliminating the chance for operator error. Moreover, because the machine is absolutely CNC managed, our operators can go straight from the mannequin to the machine with out deviating from the required process at hand.”

One issue that drew the corporate to the Mitsubishi MV2400S was the twelve-year positional guarantee, as Reeson says: “The twelve-year positional guarantee is a real signal of high quality. There can be only a few if any machine instrument producers that may be ready to supply such a buyer dedication — it’s the mark of a top quality machine.”

Because the machine has been operating lower than per week at Volz Engineering, quantifying productiveness enhancements over the earlier wire EDM machine will not be at present possible. Though, it’s anticipated the machine will carry out 50 p.c quicker than its predecessor. As Reeson concludes: “The know-how, the generator and the entire different options of this machine will reap large productiveness rewards for our enterprise. The flexibility to run unmanned is a serious profit, as is the decreased set-ups, improved programming and ease of use. One other key issue, as with every new machine instrument is effectivity. The Mitsubishi MV2400S has a considerably decrease operating value than the earlier machine with decrease energy consumption and decrease consumable consumption and subsequently operating prices. For instance, the outdated machine had a wire consumption price of two.7 hours per kilogram in comparison with 4 hours per kilogram with the MV2400S — that’s greater than a 25 p.c saving. When the operating hours are extra productive on the newest machine, that price might be nicely above 25 p.c.”


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