“In one year our previous equipment burned through 55 spools of 35-pound 0.010-inch plain brass wire, which at a cost of $190 per spool equated to $10,450 for the year,” says Mr. Brennan. The Total Cost of Ownership (TCO) model and analysis is commonly used to make decisions when purchasing new equipment. A wire machine that consumes less wire is getting better tool life, so to speak. Let's start with the brass price per pound at $5.25. This is of course not the case because the market of users is always looking for a better deal! Used (118) New Machinery Models (693) New In-Stock (3) Receive Listings By Email. The wire threading mechanism is the single most important component of your wire EDM operation with the exception of the operator. Extrusion dies and blanking punches are very often machined by wire cutting. These results indicate that the DUO64 consumed 0.51 pounds of wire per hour, while the other EDM used 1.16 pounds per hour. CenturyLink skates with a questionably low $500K fine for its 2018 outage. The second EDM consumed 758.77 yards (0.927 pounds) of wire, nearly 55 percent more than the DUO64’s consumption of 341.27 yards (0.417 pounds). Vanderhorst Brothers Industries of Simi Valley, California, purchased a DUO43 for its flexibility and accuracy to produce parts for a variety of applications including aerospace, audio, automotive, defense, electronics, filtration, lighting, machine tools, medical, optics and valves. We doesn't provide wire edm cost products or service, please contact them directly and verify their companies info carefully. Each platform was compared in wire consumption, speed and accuracy. It’s a relief not having to place wire orders every two weeks.” According to Mr. O’Rell, Vanderhorst Brothers Industries has also benefited from reduced scrap rates and more reliable auto threading capabilities. All rough cutting was completed thoroughly and the parts were ready for finishing operations on Monday morning. Second only to labor costs and machine payback schedules, wire consumption is the most expensive facet of running a wire EDM machine. At night, the machine is typically set to run six to eight additional hours unattended, nearly doubling the shop’s productivity and significantly reducing machining costs.”. That’s more than 50 percent in total over my old wire machine. To figure the cost of using brass or any coated wire e.g. The chart above gives an example of Wire consumption that can be used to calculate costs. Metalworking’s leading information resource, Trends in Automotive Manufacturing Knowledge Center, Additive Manufacturing for Production Knowledge Center, Practical Approaches to Automation Knowledge Center, Hard Milling Replaces Hand Grinding in Finishing Die Components, Becoming a Second Source for Ventilator Parts, Video: The Importance of Reshoring Mold and Die Manufacturing, Voice Control of Machine Tools has Arrived, Cool Tricks: How to Photograph Sinker EDM. “The demand for accuracy has never been higher in many of the industries we deal with,” says Mr. Brennan. Wire EDM units that swivel a horizontally guided electrode wire in a CNC-controlled E axis give this shop the workpiece clearance and flexibility to produce complex, high-precision PCD-tipped cutting tools. A Makino EDM machine uses half that, providing a significant long-term savings in $1,000’s of dollars per year in operating cost. Running at 2,000 hours per year, the second machine would use 2,320 pounds of wire, which at an average plain brass wire pricing of … VL400Q. Running at 2,000 hours per year, the second machine would use 2,320 pounds of wire, which at an average plain brass wire pricing of $5 per pound, equals approximately $11,600 a year. Will it work maybe? Excessive wire consumption on a wire electrical discharge machine is costly. “The first significant change in wire consumption I experienced came when I purchased a Makino SP43 EDM in the spring of 2006,” says Mr. Frick. Automatic Wire Threading. “During the day, I’m able to visit customers, gather additional quotes, respond to calls promptly, program more applications and handle other equipment. “We reduce our unspooling speeds by relying on the machine’s mechanical precision and advanced wire transport and tensioning system,” explains Kiszonas. The workpiece is vaporized by spark discharges created by a power supply. In many die and mold shops, the choice between ram EDM and CNC milling is far less clear than it used to be. Compare actual performance vers… EDM Broken Tap Remover. Thin walls are possible. “In my 20 years of experience, wire consumption has become one of the most critical features in shopping for a wire EDM and an area where big savings can be had on the shop floor.”. On The Shop Floor. In this article we will discuss the costs associated with the operation of a wire EDM machine. If you made 36 parts in 24 hours. Wireless Estimator Featured News December 16, 2020. Therefore we are to include (8) sets of 4” PVC schedule 40 conduits with each conduit containing (4) #750kcmil aluminum wires. Chart 1 gives an example of wire consumption that can be used to calculate operating costs. Even with a 44-pound spool option equipped on the second machine, it still only provides 55 percent of the unattended time.” A comparison test was recently performed between a DUO64 and a comparable model EDM at an end user shop that owned both machines. GIP EDM Wires. Now you could make those 36 parts in 16.8 Hours so you could now make 15 more parts in the same period. The reduced wire spooling speeds of the DUO series is based on the mechanical precision, wire transport and tensioning system on these machines. Size 0.012-inch Versacut brass wire was used in both machines with top and bottom flushing nozzles sealed. The method for estimating a machining time of a wire electric discharge machine according to the present invention can estimate a remaining machining time during a plurality of times of machining corresponding to a plurality of types of machining conditions, and all the steps in the first or second aspect. Hudson Technologies’ savings on wire has been only part of their success. Well, if you need to get more parts done faster then coated wire can help you! Cut internal corners with very small radii. wire edm cost for sale - 107 - wire edm cost wholesalers & wire edm cost manufacturers from China manufacturers. It is important to match the correct tool with the application. for brass to $12/lb. All wire edm cost wholesalers & wire edm cost manufacturers come from members. Unattended Benefits, “One of the greatest benefits of reducing wire consumption has been reliable unattended machining,” adds Mr.Frick. The number of choices that exist when selecting an EDM wire are nearly endless, and each affects cost. “Using the exact same wire in 22-pound spools, the Makino used only 38 spools, each running 119. Cutting speeds, accuracy and finish are not affect by the lower rate of wire consumption. 8.6 Connectors – (solderless less) total termination of each size for wire #6 wire and above. It is important to match the correct tool with the application. It is not just the wire cost that might get scrapped, but the Tool Steel and time already put into the part or parts that are set-up in the machine that could be scrapped! Our current measurements average between 66 and 68 hours of machining on one 35-pound spool. Our Wire EDM automation solutions add the capacity to load and cut workpieces in immediate succession—loading and unloading them automatically. X, Y, Z Travel: 15.75" x 11.81" x 8.66" (400 x 300 x 220 mm) Over a five year finance-or-lease term, the DUO will save about $32,500 in wire expense in comparison. That would be 1,193 yards per pound  for .010” wire. Guy wire cutting crime spree topples one Texas tower, destabilized a 1,000-footer. The tool, usually graphite, and the workpiece are essentially electrodes, the tool being the negative of the cavity to be produced. Adding a rotary axis to a wire EDM allows the machining of multi-sided parts in a single setup. NEW BEDRA Wires available at GIP online store. SYJ-7712 and SYJ-7712 are the compact wire cut electrical discharging machines (EDM), which is designed for research labs and features with. In 2008, Makino released the DUO series of wire EDMs. “The other test machine’s 1.16-pound-per-hour rate, which is typical for most wire machines, limits it to 19 hours of unattended machining using the standard 22-pound spool. It is just as important to prevent throwing your money away. “We’ve tracked a 30 to 35 percent reduction in wire consumption between our DUO43 and previous machines. According to Makino, the DUO series wire EDMs use technoogy that reduces wire unspooling rates. Take advantage of the price estimator in the Western Union's app, so you can calculate how much you will pay for your transfer. You now can receive a daily email with all the new listings from the previous day. We estimate that for 2009 we will save $13,000 a year on wire alone.”. “By purchasing the Makino WEDM, we’ve lowered costs across the board with over 30 percent increase in speed, and surface finishes that no longer require any manual labor, let alone the four to six hours of polishing previously required.”. Invite colleagues or customers to directly view your estimate. Technology that allows slower unspooling speeds without compromising results appears to be the answer. Part of this evaluation process should include an audit: an evaluation of current equipment and manufacturing operations to determine the capacity or capability for meeting present and future operational requirements. “Wire is the single highest expense in operating a wire EDM. The workpiece tested was H-13 tool steel at 32-34HRc and measured 3 inches thick. Company President Brian O’Rell states that it wasn’t long before operators discovered significantly slower unspooling rates. Sold by the pound, EDM wire costs between $3/lb. 5. The company states that both speed and accuracy have increased with the new wire machine, enabling them to stay ahead of the curve in challenging markets such as medical implants and electronics. All wire edm cost wholesalers & wire edm cost manufacturers come from members. This all means: 1. These wire savings have been produced without any loss of accuracy and a 40 percent increase in cutting speed compared to our previous equipment.”, In addition to decreased wire consumption, Intricate EDM has also experienced greater success in tall workpieces. An alternative to broaching for 2D shapes like gears. Apply to Machinist, Operator, CNC Machinist and more! A rotary axis also increases the variety of shapes that can be cut because the machine can combine simultaneous linear and rotary motion. wire edm cost. need to be able to estimate the costs associated with manufacturing the parts It will all depend on the job! With EDM there are no cutting forces and neither tool nor workpiece rotate. WEDM costs can vary depending on many factors, one main factor is the wire you are using as your electrode! Today I’m able to get a full night’s sleep and fully enjoy my weekends.” Mr. Brennan also commented on unattended capabilities, stating that “by running unattended most nights and over some weekends, our lead times have dropped from 12 weeks to just 4.”, Looking back at the previous comparison testing, the results remain similar to those demonstrated on the shop floor. ESPRIT supports indexing, turning, and simultaneous cutting for all EDM machines that support rotary motion. 9. With even the least expensive EDM wire running $5 to $6 per pound, investing in low-wire consumption EDM machines appears to be the answer. The question is when is coated wire the better choice to make money? Used (22) New Machinery Models (276) New In-Stock (1) EDM Sinkers. 8.8 other materials must be itemized. 6. Before using any estimate in this book, you should understand one important point about esti-mating electrical construction costs. Controlling the cost of this consumable item, while dependent on the application, is the best way to control the cost of your EDM process as a whole. to figure you now have 12 more minutes of time to make more parts. spool.) In addition, wire EDM is done with wire typically 0.010” diameter. Cut thin slots in extrusion dies with wire EDM. Instead of having a variety of companies for your projects, you can just make one phone call to RMS for your form tools, custom machining, machined parts, replacements parts, insert tooling, threading products, special cutting tools, and special fixtures. “In July 2008, I purchased a DUO43 and found an additional 10 to 15 percent reduction in wire usage even over the SP43. Cutting metal with an energized strand of wire is still one of the most dynamic frontiers in metalworking, and this shop goes to extremes to keep up with the latest advances. ®2016 NATIONAL CONSTRUCTION ESTIMATOR ® Edited by Richard Pray $87.50 Craftsman Book Company 6058 Corte del Cedro, Carlsbad, CA 92011 64th Edition Turn your estimate into a bid. If you find yourself with less profit in your parts that are machined on your wire EDM equipment then read further. How to estimate the cost of installing an ... phase, 4 wire system. Electrical discharge machining (EDM), also known as spark machining, spark eroding, die sinking, wire burning or wire erosion, is a metal fabrication process whereby a desired shape is obtained by using electrical discharges (sparks). Where the machines differed was in wire consumption. The difference is 260 percent more unattended machining time available on the DUO. The buyer beware of where the wire is being made and if it is guaranteed should be a priority. Sold by the pound, EDM Wire costs between $4 a pound for brass to $12 $14 a pound for premium Wires. Custom Machining part cost estimator. This is all a part of the service from GIP as we plan to build the best EDM Supply company with todays GIP High Performance EDM Wire made by BEDRA & ThermoCompact as the cornerstone. Intricate EDM runs unattended most evenings and occasionally through weekends. We doesn't provide wire edm cost products or service, please contact them directly and verify their companies info carefully. 2. wire edm cost. Reynolda Manufacturing Solutions is the answer to your manufacturing needs. In the machining area, each discharge creates a crater in the workpiece (material removal) and an impact on the tool (wear of the tool/electrode). It is just as important to prevent throwing your money away. An audit is used to do the following: 1. So, in 7.2 hours, how much more money can you generate in the extra time? See example: Figuring a 30% faster cut time the difference is $0.80 cents per minute higher cost, but you also need. Program settings for both machines were out of the box, unmodified code generated by the on-board programming systems. “Even with personal attention given to the machines, I would still often return on Monday to a partially completed workpiece. “And we’ve proven the savings in direct-comparison testing.” EDM Process; EDM Cost Estimate Electrical Discharge Machining(EDM) Process description. If you would like to get a copy of the full excel spread sheet, fill out the request form below with your contact information and we will send it to you by e-mail. Then the diameter size since .010” is the standard we will go with that. Obviously, the earning capacity of a CNC machine tool is more valuable than a few dollars worth of … Then the WEDM machines run time that could be wasted at $175.00 - $250.00 dollars an hour that adds up Fast! Used (73) New Machinery Models (607) New In-Stock (1) EDM, Wire. Costing . This means the other test machine costs $6,500 more per year to operate in wire cost alone. Tower tech succumbs from 260-foot fall while endeavoring to bring broadband to the Spokane tribe . Since the WEDM is spooling off wire in yards per minute (or Meters per minute) we need to look at the E-Code for that amount. Produce blind and high aspect ratio pockets with sinking EDM. HOME; ABOUT; EDM WIRES BEDRA BOLINE BRASS BEDRA BOLINE H BEDRA betterbrass BEDRA gapstar ONE.9 PLASMA ™ GAMMA EPSILON BLAZE LASER WELDING WIRE; EDM Filters Accutex Agie Brother Charmilles Chmer Ebbco Elox Fanuc Hitachi Japax Makino MITSUBISHI Sodick YCM Excetek; TECH SUPPORT WEDM Tech Wize EDM TECHNOLOGY TECH SUPPORT PLASMA™ Hybrid Wire … Let’s get to work automating your production requirements today. Required geometries for the workpiece included a 0.500-inch-diameter hole with a ±0.0002-inch tolerance and a 40-microinch Ra surface finish. “The price of a wire EDM machine is nothing compared to the cost of wire over the life of the machine,” says Tom Frick, owner of Intricate EDM in Columbia, Pennsylvania. Produce non-round openings and cavities. That is of course just one of the costs that need to be add to the job quote, but it is an important one to make sure you can make a profit on the job. AccuteX EDM also offers a full line of ancillary EDM machines such as EDM drills and EDM die sinkers in both economical ZNC and multi-axis CNC models. And did I mention the Makino also ran an average of 27 additional hours each week? It has even developed some of its own. “It’s hard to believe there can be such a large difference between the wire consumption of two machines,” says Mr. O’Rell. This results in wire savings can be as much as 50 percent or more in many applications, adding to substantial savings for shops, the company says. Frankly, I don’t think buying the off brands for pennies less a pound is a good idea if you want to run 24/7 and have no issues. Similar results have been measured by Intricate EDM, where Mr. Frick, who has 20 years of EDM application experience, has been tracking wire consumption for several years. We help connect the largest CAM community worldwide, and our success is a direct result of listening and responding to industry needs for productivity solutions from job set up to job completion. Most EDM machines chew through more than one pound of wire per hour, making wire consumption the biggest expense of operating wire EDMs. New Machinery Models (12) EDM Hole-Driller. Wire EDM machine uses a metallic wire (electrode) to cut a programmed contour in a workpiece. Investing in low-wire-consumption EDMs has resulted in as much as 50 percent reduction in wire use for my shop, even while cutting much faster and not sacrificing accuracy, which is something to be excited about when you’re paying $5 or $6 per pound for brass wire.”, Jeff Kiszonas, Makino’s EDM product manager, adds, “Most EDM advancements in the past decade have focused on increasing machining speed without reducing accuracy, but have neglected the impact of wire consumption. 3. The VL400Q Wire EDM Machine is a small sized, advanced-performance machine with an upgraded AWT and improved finish. Calculating EDM Wire Costs . We doesn't provide wire edm cost products or service, please contact them directly and verify their companies info carefully. Changing technology is changing the rules. Plasma by GIP, you need to know your initial cost. Productivity Advanced solutions for manufacturing. The "cutting tool" in wire EDM is an energized wire that travels from reel to reel as it follows a path that "slices" through the workpiece. “Our tall workpieces have never looked better coming straight out of the machine. Next thing you need to know is how many yards are in a pound of wire? In micro wire edm metal is cut with a special metal wire electrode that is programmed to travel along a preprogrammed path. A new world of increased throughput, cost efficiency, process optimization, and more is waiting for you. Wire is the single highest expense in operating a wire EDM. It lists costs to the electri-cal subcontractor for a wide variety of electrical work. I believe manufacturers are beginning to see the significance of wire consumption but still assume its benefits come at a loss to performance. “Compared to previous machines, I was seeing a 30 to 35 percent reduction in wire consumption. Plain Brass wire is the most popular and you would like to think the price would not change by much between vendors. wire edm cost. “As the test results demonstrated, the DUO’s unspooling rate of 0.51 pounds per hour provides 68.6 hours of machining time on one standard 35-pound spool of brass wire,” says Mr. Kiszonas. SURE! 275 Wire Edm jobs available on Indeed.com. Build your own complete process plan and generate detailed cost estimates. This just isn’t the case when you have solid technology.”. On a recent order, Frick was able to rough cut a set of 2.5-inch-thick steel parts over the weekend for 60 hours, using only one spool without any cleaning or other maintenance. 9.1 get the unit cost for each item and deduct all discounts. for premium wires. On The Wire, “Although wire consumption rarely appears as a topic of concern for most wire EDM users, the financial benefits of owning a low-wire-consumption machine is critical to your bottom line, as long as it doesn’t impact accuracy, surface finish or seriously hamper your machining speed,” says Mr. Frick. Wireless Estimator Featured News December 19, 2020. ( Side Note: Which would equal 13,123 yards on a 11 Lb. According to the company, these machines reduce wire unspooling rates with no adverse affects on cutting speed, accuracy or finish. The year-long figure for wire consumption on the Makino was only $4,539.48. Based on the required specifications, both machines performed equally in terms of accuracy and speed. Another shop, Hudson Technologies of Ormond Beach, Florida, reports similar results from their investment in a Makino WEDM. From October 2007 to October 2008, Tool Room Coordinator David Brennan recorded the wire purchases required to operate the company’s Makino and compared that to their previous machinery. 4. “Running unattended on my previous equipment typically resulted with a 4 a.m. trip to the shop or Saturday visits in order to maintain the machines and switch out wire spools,” says Mr. Frick. Generally economical, the GE Series has many of the same standard (and optional) features as the other AccuteX EDM models, starting at $89,900. The DUO’s technology has eliminated nearly all wire lag, giving us greater accuracy in taller workpieces, with little change in wire consumption on thick wall applications,” says Mr. Frick. Comparison Test. Settings were not adjusted by operators to optimize performance, and no operator intervention took place during the cut cycles. The DUO’s total machining time was 49 minutes and 9 seconds, on par with the other machine’s slightly faster time of 47 minute and 47 seconds. Highly accurate machining; The high performance of machining complex parts ; Possible to making any tapers; Any electric conductive material can be cut regardless of hardness; PC controlled via software. This manual is a guide to the cost of installing electrical work in buildings. Let us know how we can help you and what you would like to see in the future editions of, © 2020 Global Innovative Products | High Performance EDM Wires | Mason, OH 45040 | www.gip-edmwire.com, Calculating EDM Wire Costs with WEDM Tech Wize. All wire edm cost wholesalers & wire edm cost manufacturers come from members. With this number you can  calculate the wire cost per job once you know the amount of minutes the cut time will be. So, can you find a cheaper EDM wire? 8.7 Tape – 1 roll PVC tape for every 100 m of wire plus 1 roll of rubber tape for every 200m of wire. These results indicate that the DUO64 consumed 0.51 pounds of wire per hour, while the other EDM used 1.16 pounds per hour. Doing some quick math - if 1,193 yards equals 1 pound of wire, at $5.25 a pound the cost per yard would be $0.0044 cents per yard. While endeavoring to bring broadband to the electri-cal subcontractor for a better deal well if! Versacut brass wire is getting better tool life, so to speak benefits of wire... Note: which would equal 13,123 yards on a 11 Lb machine with upgraded... Email with all the New Listings from the previous day capacity to load and cut workpieces in succession—loading! Making wire consumption, speed and accuracy a wide variety of shapes that can be used to able! Specifications, both machines were out of the industries we deal with, ” says Mr. Brennan upgraded and. 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