The installation of EDM ensures productivity gains for the British subcontractor


Electric discharge machining The installation of EDM ensures productivity gains for the British subcontractor

By Alexander Stark

As a member of the Volz Group, Volz Engineering has ambitious growth plans. The Rochdale-based company recently invested in a new CMM, two 3-axis machining centers, a turning center and most recently, a Mistubishi MV2400S wire EDM machine from the Engineering Technology Group (ETG).

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New Mitsubishi MV2400S EDM at Volz Engineering.

(Source: ETG)

The Volz Group manufactures HVAC filters for commercial and industrial applications as well as the manufacture of machines to produce filters and associated components such as filter frames and clips. Volz Engineering’s growth strategy includes plans for a dedicated design and manufacturing division, production of filter frames and also two machine shops; one for contract manufacturing and another dedicated to highly automated filtration production machines in which the company specializes. The four divisions will complement and expand the existing facilities which will also include a press tool and accessory manufacturing department.

With the expansion strategy and a continued need for press tools and filtration automation machines, the Greater Manchester company witnessed the indifferent performance of a 25-year-old Mitsubishi EDM machine. Recalling the situation, the Managing Director of Volz Engineering, Alan Reeson, said: “Our the previous EDM machine was unreliable and expensive to maintain – as is the case with any machine of this age. ETG did a fantastic job maintaining the machine, but we realized we needed a 21st century upgrade.

Taking delivery of the new Mitsubishi MV2400S wire EDM in October, the new machine was a revelation to the 15 employees of Volz Engineering. As Reeson continues: “EDM is an integral part of our business as it serves both the press tool departments and the automated machines. “

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Of course, the acquisition was based on more than the previous service and support provided by ETG. Reeson adds: “Above all, the new Mitsubishi can turn off the lights, giving us 24/7 production. We are currently running a shift, but the ability to configure the machine to run unattended overnight is a huge plus. It is the merit of the thread that has the ability to rethread and reposition itself automatically and continue to work, so that the machine does not lose hours of production if the thread breaks. In addition, the setup time is 60% faster on the new Mitsubishi MV2400S than on the previous machine. We now set up and complete tasks in less than an hour.

The new Mitsubishi MV2400S accepts parts with dimensions up to 1050 x 820 x 305 mm on the X, Y and Z axes with a maximum component capacity of up to 1500 kg that can fit on the 840 x 560 mm table. The machine can use wire diameters from 0.1 to 0.3mm and is supplied with tubular shaft drives with linear scales, M800 controller with 19 ” touch screen monitor, manual driver with configurable LCD monitor , an AE II digital generator and a switching system filter.

The G50 Competition incorporates the new Eagle Powerspark One control system.

Another factor on this new machine is the ability to read DXF files. Not only does this allow us to send files directly from the desktop to the machine; it also gives us control over the configuration. The parts and issue number assigned to parts and programs can be strictly tracked through our database and through the Mitsubishi machine, eliminating the risk of operator error. In addition, as the machine is fully CNC controlled, our operators can go directly from model to machine without deviating from the required task.

One factor that attracted the company to the Mitsubishi MV2400S was the twelve year position warranty, as Reeson puts it: “The twelve year position warranty is a real sign of quality. There will be very few or no machine tool manufacturers who would be willing to offer such customer engagement – that’s the hallmark of a quality machine.

As the machine has been running for less than a week at Volz Engineering, it is currently not possible to quantify the productivity improvements compared to the previous wire EDM machine. Although, the machine is expected to run 50 percent faster than its predecessor. As Reeson concludes: “The technology, generator and all of the other features of this machine will reap huge productivity benefits for our business. The ability to operate unmanned is a major advantage, as are the reduced configurations, improved programming, and ease of use. Another key factor, as with any new machine tool, is efficiency. The Mitsubishi MV2400S has a significantly lower operating cost than the previous machine with lower power consumption and consumable consumption and hence lower operating costs. For example, the old machine had a wire consumption rate of 2.7 hours per kilogram compared to 4 hours per kilogram with the MV2400S, a saving of over 25%. When the operating hours are more productive on the last machine, this rate is probably well over 25%. “

(Reference: 47886013)


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