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High Speed Wire Cutting Machines

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Molybdenum Wire Cutting Machines 

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High Speed WEDM (HS-WEDM)

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 Reciprocating Wire EDM Cutting Machine

 

 

Compared to normal wire cutting machines (with copper/bras wire), Molybdenum High speed wire cutting machines are :

 

2 ~8 times faster cutting 

60~75% Lower investment

70~95% Lower working Costs

Cutting even the hardest materials

Wire breakage is almost none exisiting

 

OUR 3 MACHINE LIMITATIONS BECOMES OUR ADVANTAGES!

 
Limit 1 : Cutting Wire Diameter Ø 0,18mm (radius 0,09) is the standard wire diameter
Limit 2 : BEST Surface Roughness is Ra = 0,8µm (Class N6 - ▼▼▼ - √ 32) 
Limit 3 : No automatic re-wiring

The 3 limitations giving us some disadvantages at high precision mold/die cutting compared to

normal brass/Cu wire cutting machines, becomes at AM parting only extra advantages.

 

Limit 1 : Cutting Wire Diameter Ø 0,18mm (radius 0,09) is the standard wire diameter

This 0,18 mm wire diameter is much less than the ones used in normal wire cutting machines, in additive manufacturing business. There are used mostly 0.30 mm wire, as cu/brass wire melts much faster and do not resisit well this hard irregular material! The losses of normal wire cutting machine are almostdouble from our high speed wire cutting machine.

Limit 2 : BEST Surface Roughness is Ra = 0,8µm (Class N6 - ▼▼▼ - √ 32) 

The surface roughnes we can reach is too good. We only need to CUT-OFF.  Speed is here the determining factor, not surface quality!

Limit 3 : No automatic re-wiring

As we only need to cut along a plate we never need rewireing!! We have no cavities, and our wire almost never break compared to normal Cu/Brass wire cutting machines!

Copper/Brass

Tensile strength

Copper/Brass

Copper = 200/250N/mm²
Soft Brass = 375 N/mm²
Hard Brass = 1180N/mm²

Elongation

Copper/Brass

Copper/brass 7-9%

 

MELTING POINT

Copper/brass

very low melting point : 1085°C

 

Molybdenum

Tensile strength

Molybdenum

Molybdenum = 1724 N/mm²

7 to 8 times stronger

Elongation

Molybdenum

Molybdenum 1,8 %

80% less

MELTING POINT

Molybdenum

very high melting point : 2625°C
2,4 times higher than Cu

Thermal Conductivity

Copper

very high thermal conductivity : 401 W/(m·K) 

Electrical Resistivity

Copper

very good conductive : 16,78 nΩ·m

Thermal Conductivity

Copper

lower thermal conductivity : 138 W/(m·K) 

Electrical Resistivity

Molybdenum

less good conductive : 53,4 nΩ·m

Elongation

When a metal wire can be stretched easily (big elongation %) then the wire becomes thinner and weaker. Also with a wire that stretches in a wire cutting machine, the sides of the cut will never be as straight as when cutting with a non-stretching wire.

Molybdenum wire does not stretch (almost nothing) and this results in :

  • Straighter cuts and straighter sides
  • Less corner over- and underrun problems
  • Is stronger as it keeps its original diameter
  • keeps more diameter precision as it does not chenge by pulling on the wire
  • Can handle bigger parts height than Cu/brass wire by keeping the side straightness

 

Tensile strength

A wire with higher tensile strength is a guarantee to be stronger. As Molybdenum wire is 7~8 stronger than Cu/brass wire, Molybdenum wire can handle much bigger pulling forces.  The harder you pull on a wire the straighter the wire stay with following results in wire cutting:

  • .This gives much better results in side-straightness of the workpieces. 
  • You are able to cut much higher parts AND respecting the side-straightness
  • Much less problems with corner deformation (over- and underrun)
  • By the much higher pulling force that can be applied, we can pull the wire MUCH faster through the cutting groove, even till 50 times faster. Like this the wire generates a good cleaning effect by evacuating the "debris" very fast with the high speed movement. Also the wire has no time to heat up and melt with result that broken wire is a raare thing for molybdenum wire cutting machines

Melting point

Melting Point of common used metals

Aluminium (6061-T6) 582 - 650°C
Brass 900 - 940°C
Copper 1085°C
Inconel (718) 1260 - 1336 °C
Stainless Steel (410) 1482 - 1532°C
Tool Steel (06) 1500°C
Molybdenium 2625°C
Tungsten Carbide (K-68) 3360

In Normal wire cutting machines, the cu/brass wire is the weakest element in the system.

As copper melts at 1085°C, the wire is alwys melting much faster than the material to cut. Increased current, short circuit with wire and workpiece, bad fluching, .. always end with wire breakage!

With our Molybdenium Wire technology with a melting point of 2625°C, the wire is the strongest element. Most of the workpieces melt much faster than the wire at higher currents, short circuit or bad flushing. Wire breakage is rarely happening with our technology.

Also with our patented drive wheels in Zirconium, we are able to handle much bigger currents than any other machine with moly technology. We are able to transfert very high curents into our wire and workpiece, so that we reach very high cutting speeds (till 300 mm²/min is possible) without wire damage.

The speed of wire moving is till 50 times faster than normal wire cutting machines, and it is moving so fast up/down that there is no time to burn and break!

Our wire even resists for short time to cut dry, without coolant. 

And the wire is re-used continiously! More economical is NOT possible.

 

Soon much more info

Save big on wire cost

Save bigger on 3D printing machine cost

The price of a wire EDM machine is nothing compared to the cost of wire over the life of the machine. “Wire is the single highest expense in operating a wire EDM.

One of the highest operating costs for any wire EDM is the cost of the wire the machine consumes during a cut. Although wire consumption rarely appears as a topic of concern for most wire EDM users, the financial benefits of owning a Molybdenum wire-cutting machine can be critical to a manufacturer’s bottom line.

EDM brass/copper wire, at its current cost of approximately 8-15 Euro a kilo, is the single highest cost related to the use of WEDM technology. The faster a machine unspools wire, the more it costs to operate that machine.

On average, most Copper/brass WEDMs unspool wire at a rate of 750 grams to 1.1 kg per hour. And although these higher rates can be reduced by slowing the unspool speed, manufacturers must deal with increased breakage with additional adverse effects to speed, accuracy and surface finish. Under these unreliable conditions, increased cycle times and maintenance can oftentimes negate or even surpass the cost saving of slower wire feeds.

Cutting this high operating cost by 40 percent to 50 percent equates to an EDM wire saving value of about €8,000 to €10,000 per machine, per shift, per year! However, if this cost saving in consumables is offset by high maintenance costs and lost production time, there is no advantage. The ability to improve EDM wire saving while increasing productivity through reliability can have a significant impact on overall profit.

Investing in a Novicut M-II wire EDM will allow you to regain control over your EDM department and generate good profit.  When you are facing extended lead-times and part inconsistencies due to outsourcing and the unreliability of your older machines, then it’s urgent time to think on an investment that run unattended throughout the day, over nights and even weekends. We can ensure that quality will be again to your standards and saving money hand over fist on operational costs will be again in reach.

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 can be critical to a manufacturer’s bottom line. With the revolutionary Molybdenium wire cutting system with zirconium guiding wheels, you will be able to saving of up to 70 percent in many applications while maintaining precision and surface quality (Ra<0.8µ).

Because Novick builds mechanical accuracy into these machines, the on-board computers are required to perform axis movement error compensations less frequently. This allows the control to address higher priorities, like activating Novick patented Fuzzy logic technology and performing the multitude of calculations required for it to work properly.

EDM wire, at its current cost of approximately €8-15 a kg, is the single highest cost related to the use of WEDM technology. The faster a normal machine unspools wire, the more it costs to operate that machine. For shops that run a WEDM for 2,000 hours per year, or one full shift, settings can experience about €10,000 each year in EDM wire saving per machine.