Wire EDM Makino UPN-01
Wire EDM Makino UPN-01
ULTRA PRECISION WIRE EDM TECHNOLOGY THAT DELIVERS ACCURACY AND UNATTENDED OPERATION OF SMALL WIRES
The UPN-01 represents the next leap forward in technology for ultra-precision machining and surface finish capability of small/fine wire operations. The machine features a unique horizontal wire drive system layout that enhances wire threading performance, and is capable of reliably threading start holes as small as 0.001” (0.03mm), and can operate with wire sizes ranging from 0.004” (0.100mm) down to 0.0006” (0.015mm) in diameter.
The UPN-01 is capable of achieving sub-micron level accuracy, which is made possible using the machines Pneumatic Static Pressure Guideways and Linear Motor motion technology. These two advanced motion control systems are combined to minimize mechanical friction and mechanical inertia to ensure consistent ultra-precision increment movements. The UPN-01 uses a 0.0000004” (0.01µm or 10 nanometer) scale feedback system, which provides a minimum programmable increment of 0.000004” (0.1µm) that is capable of achieving a mechanical movement roundness of 0.000008” (0.2µm).
The UPN-01 uses an oil di-electric system that provides greater control of the machining spark gap, which improves part accuracy, surface finish, and metallurgical quality. The machine can achieve surface finishes down as low as 0.17µmRz. The entire work zone is also enclosed and is temperature controlled to minimize thermal changes to the machine and work piece during long hours of operation.
The UPN-01 features an integrated high precision rotary C-Axis that serves as a mean to automatically tool change the work piece for extended operations. The rotary C-Axis is also used to repeatedly index and position the work piece to ultra-high precision tolerances, and has an indexing accuracy of ±2 Arc Seconds (±0.00056 degrees). The machine is also equipped with an automatic slug ejection system that further extends unattended machining capabilities. The slug ejection system will remove any core or slug details, which will are allowed to fall freely to the bottom of the work tank where it will not cause any interference or crash potential.
The UPN-01 also features Makino’s new Hyper i control system, which features a user-friendly interface similar to that found on tablets and Smartphones, making operation very intuitive and straightforward. A large 24” (60cm) class HD touch-screen display provides a commanding view for operation, and the Hyper i control also features many helpful intelligent tools for the operator. Digital onboard electronic manuals, instructional training videos, and advanced process control functions provide the operator with all of the resources necessary to remain highly productive.
The UPN-01 is ideal for micro-machining and ultra-precision applications, and is ideal for manufacturers of fiber optics, electronic connectors, and medical components. The advanced capabilities of the machine also find use in print nozzle, miniature gear, and micro molding industries.
Wire Electric Discharge Machine
Numbers matter. That’s why, with more than 140 patents, Makino is the world leader in EDM technology, providing faster processing times and superior surface finishes for even the most complex and involved part geometries.
By combining innovative Makino machine tools and software with game-changing support from Makino Engineering Services, shops of every size are competing and winning the kind of work that matters on the global EDM stage. The flexibility of Makino technology and proven turnkey engineering solutions allows for EDM solutions at all levels to help further reduce operational costs.
BellyWIZARD™ is an exclusive Makino wire EDM technology that automatically selects the optimum machining parameters for those applications that, top to bottom, require exceptionally straight parts. BellyWIZARD meets today’s manufacturing demands for lower costs, reduced lead-times and tighter tolerance by providing up to 40 percent improvement in part straightness with fewer passes than conventional wire EDM technology.
Additional Information:
Reduce Belly/Bow
One of the most difficult challenges faced by wire EDM operators is the machining of vertically straight workpieces to very close tolerances. Inaccuracies are usually at their worst in the center of the vertical span of a workpiece. These inaccuracies are typically defined as a “belly” or “bow” in the workpiece. Such an error occurs 90 percent of the time during the initial rough-cut operation.
The advantage of using BellyWIZARD wire EDM technology is that it reduces the belly or bow in workpieces during these roughing operations. By reducing the belly or bow in the rough cut, thus cutting closer to the final net shape, this technology reduces or eliminates the need for additional skim-pass machining.
When skim-pass machining is necessary to achieve finer surface finishes, BellyWIZARD helps to reduce the total cycle time and consumable costs by reducing the amount of error (belly/bow) and remaining material on the final part, thus leading to faster skimming times.
Improved Compensation
BellyWIZARD technology is built into the E-code, so that parameters change automatically with workpiece height. The technology compensates for changes in the wire caused by eroded wear and wire lag. This compensation is done by automatically machining on a slight taper in the rough cut and through adaptive servo movements. The result is that BellyWIZARD produces straighter and more accurate parts without increased wire consumption. The improvement in part straightness can be as much as 40 percent over conventional wire EDM technology. This reduction in both total cycle time and production costs makes your shop more profitable.
H.E.A.T. (High-Energy Applied Technology) is a Makino advancement in wire EDM technology that dramatically reduces cutting times while maintaining exceptional part straightness with one- or two-pass cutting accuracy.
• H.E.A.T. cuts parts 18 to 44 percent faster than conventional wire EDM approaches while holding tolerances of straightness to 0.0005″ (T.I.R.) with one pass and 0.0002″ (T.I.R.) with two passes.
• H.E.A.T. increases skim speeds by 50 to 100 percent in real-world applications and conditions including poor flushing situations, non-sealed nozzle applications, parts with uneven surface thickness and through holes as well as parts up to 6 inches tall.
• H.E.A.T. delivers high-speed performance in difficult, real-world EDM production environments, especially job shops specializing in medical, aerospace and similarly demanding parts.
New H.E.A.T. addresses all types of available wires for cutting tool steels:
• Brass and coated wires
• Paraffin and non-paraffin wires
• High zinc
H.E.A.T. generator enhancements:
• BellyWIZARD™ – Unmatched part straightness
• CornerWIZARD™ – Excellent geometry control
• PowerWIZARD™ – Superior wire-break prevention/optimized machining speed and flushing control
SurfaceWIZARD™ is an important innovation from Makino that improves performance in difficult, real-world production of EDM parts for medical, aerospace and other applications where precision and exceptional surface quality is required. SurfaceWIZARD is particularly useful in parts with variable shape, thickness or sudden changes in thickness, such as a stepped part. It also produces excellent results cutting through cross-drilled holes or other similar detail.
Before SurfaceWIZARD, burning parts of this kind would often leave “witness” lines, the telltale lines left at the transition from one-step thickness to the next. To remove witness lines, a part would require either bench work or secondary operations, each of which increases production costs and slows delivery. SurfaceWIZARD technology virtually eliminates witness lines and maintains part straightness.
Benefits of SurfaceWIZARD:
• Minimizes witness lines that occur due to material thickness and stepped changes
• Eliminates wire-break issues
• Improves part straightness
• Achieves more consistent, higher-quality surface finish
• Suppresses errors caused by changes in machining condition variables by employing new generator and adaptive control technologies
