Experienced with wire-cut EDM systems for generations

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Dimensional accuracy

For the clocked machining of circular parts overnight they also purchased an additional powered axis. “The practical thing about this is that it has the same interfaces as the two older machines, so it can be used on all three machines,” Hornung adds. The servo-controlled B axis integrated in the machine CNC control permits wire-cutting of the rotating workpiece. Consequently, cutting a block into several parts and multi-sided machining can be carried out in a single clamping.

“The accuracy of wire EDM has been setting the pace for decades. There are now so many machining methods, ranging from laser cutting and water jet cutting through to 3D printing. While many other methods have been superseded by these new technologies, wire-cutting is still out on its own,” Andreas Hornung, managing director of Hornung notes.

Hornung’s customers mainly come from Stuttgart and include big-name manufacturers like Daimler, Bosch and ZF. The most complicated components are now sent to Spain. The accuracy of the finished items is in the 2µm range – despite the difficulties imposed by the often hot Swabian summers. There haven’t been any problems, incidentally, with acclimatising to the machine.

“The great thing about the user interface is that it’s got something for everyone. Anyone can operate it – using the mouse, keyboard or touchscreen,” says Manfred Weller, in charge of wire-cut EDM at Hornung and involved in wire-cutting for over 20 years. Although a simple keystroke is rarely all it takes for most jobs, Weller admits: “The machines from Mitsubishi Electric make a lot of tasks easier, but for our work decades of expertise are usually necessary. Only then can the customer’s drawings and ideas be converted into a finished component.”

On the basis of Weller’s experience, each new Mitsubishi Electric generation takes less time for machining than its predecessor. And this has an effect on wire usage and ultimately on energy consumption. Although energy efficiency was not the main reason for buying the machine, it’s still an important factor for Hornung.

With the new machine of the MV Series, the company is quite a bit faster, which is due among other things to the automatic wire threader. Such integrated functions as the Corner Master also contribute to this. But what ultimately counts for Hornung, however, is the machine’s precision. The surface quality of the workpieces, which can be of any commonly used material, is as fine as Ra 0.13 µm. “I initially thought these values were reserved for the glossy brochures, but our practical experience has confirmed them,” Weller states.

Even after ten years, wire EDM has lost nothing of its fascination for Hornung. “No two workpieces are ever the same. How will the curve turn out? How will the wire perform? And you’ve only got one attempt once the plate has been clamped,” says Hornung, describing the daily thrill of machining. “At the same time, the opportunities for machining workpieces are endless.” Hornung is therefore convinced that wire-cutting will stay out on its own in the coming decades.

ETMM Magazine

March 2017 product gallery

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