Leading precision mould tool, fixturing and subcontract manufacturing specialist extols the virtues of its latest advanced wire EDM machine tool investment.
GF Machining Solutions, the milling, EDM, laser and Additive Manufacturing (AM) machine tool manufacturer and automation and tooling systems’ specialist, has recently supplied a new, state-of-the art wire EDM machine to Mechlam Precision Tooling Ltd., a precision mould tool, fixturing and subcontract manufacturing specialist based in Haydock.
The machine, an AgieCharmilles CUT P 350 Pro, was installed at the company’s 8,000sq. ft. facility in October 2022 and is being used to machine a range of high-precision components, that include complex and highly accurate mould tools, inserts and associated parts, for the company’s growing customer base.
The acquisition of the CUT P 350 Pro has significantly increased, and improved, Mechlam Precision’s wire EDM capacity and capabilities.
The machine’s ultra-fast processing speeds combined with quick and easy job preparation and set-up, plus its ability to consistently hit tight, tied-up geometric and dimensional tolerances, have been more than instrumental in helping the company secure more high-value work from new and existing customers, and strengthen its position within many customers’ supply chains.
Says Martin Atherton, Mechlam Precision’s managing director:
“We are always looking to improve and, as such, regularly invest in advanced manufacturing technologies to help make us more productive…more efficient…and more competitive.
“Our new CUT P 350 Pro is a case in point and has helped transform our wire EDM operations enabling us to make precision parts faster, better and more economically than before.”
Investment rationale and decision
With business from many of Mechlam Precision’s customers, specifically in the automotive, aerospace and medical sectors, returning to pre-pandemic levels, the company needed to act quickly and decisively to meet the upturn in demand for its high-quality machining services.
Explains Martin Atherton:
“Our existing wire EDM resource, specifically an older machine that we had acquired some years earlier, was becoming unreliable and was creating production bottlenecks and pinch-points that, if left unchecked, would impact on our ability to meet customers’ lead times.”
To overcome the issue, Mechlam Precision decided to upgrade its wire EDM capabilities and approached a number of machine tool suppliers with its plans.
Although Mechlam Precision has good, long-standing relationships with GF Machining Solutions, having invested in a number of the company’s milling and EDM machines in the past, the decision was made to invite three wire EDM machine tool manufacturers to present their ideas and take part in a test cut to prove the efficacy of their proposals and demonstrate the performance of their machines.
Explains Martin Atherton:
“The part selected for the trial cut was an existing mould tool insert that we have machined in the past, and that we knew inside-out.
“We were particularly interested in how the machines proposed by each manufacturer would meet the high accuracy and surface requirements as well as the total processing time (from set up through to machining) involved to complete the part.”
The results of the test cut were illuminating.
GF Machining Solutions’ CUT P 350 Pro machine used for the test cut came out ‘head and shoulders’ above the other two machines in terms of speed (set up and part cycle time) and precision.
“The test cut results plus GF Machining Solutions’ industry-leading back-up and support were major factors in us placing the order for the CUT P 350 Pro”, says Martin Atherton.
Since being installed, back in October 2022, Mechlam Precision has been ‘blown away’ by the CUT P 350 machine’s continued performance, flexibility, reliability and efficiency.
CUT P 350 Pro: Machine features and innovative technologies
The CUT P 350 Pro is a high-end wire EDM machine that features a number of market-leading and proprietary technological innovations.
The machine is compact and boasts X-, Y- and Z-axis travels of 350mm x 250mm x 220mm respectively and can handle workpieces up to 1000mm x 550mmx 220mm in size and up to 750kg in weight.
The CUT P 350 Pro has a rigid design and build and is equipped with GF Machining Solutions’ QUADRAX system which delivers unrivalled stability (and therefore accuracy) during machining operations.
Says Martin Atherton:
“The mould tools, mould inserts and precision parts we machine are characterised by their high accuracies (+/- 2 microns) and surface finishes (Ra 0.08µm).
“The machine’s QUADRAX system ensures we are able to meet these stringent quality requirements, even during long machining runs.”
The CUT P 350 Pro features GF Machining Solutions’ Spark Track and digital generator technology – both designed to improve customers’ productivity, performance and process reliability.
Says Martin Atherton:
‘The machine is equipped with ISPS (Intelligent Spark Protection System) and iWire: together they have had, and continue to have, a significant impact on our performance.”
ISPS
ISPS monitors the spark environment in real time, adjusting the spark intensity according to individual part characteristics and features.
This technological innovation reduces the potential for wire breakage during machining operations – ensuring machine uptime and optimised production.
Says Martin Atherton:
“ISPS helps reduce wire breakages that can be caused by poor flushing and/or unstable machining conditions.
“As a consequence, machining operations do not need to be stopped to allow for wire re-threading and our production schedules are uninterrupted.”
ISPS is particularly beneficial during lights-out, unattended operations where wire breakages can severely disrupt and compromise production planning and manufacturing output.
iWire
Running in conjunction with ISPS is the machine’s iWire innovation which, adjusts wire speeds (feed rates) according to individual part characteristics.
The bottom line with iWire is that less wire is used (consumed) to machine complex parts – and this delivers real consumables’ savings to the customer.
Explains Martin Atherton:
“IWire helps us reduce the cost per part, and this enables us to be more competitive.”
Another innovation, available on all new GF Machining Solutions’ machine tools, is rConnect – a remote and secure diagnostic and trouble-shooting facility, that provides customers with instant and secure assistance in real time.
Continues Martin Atherton:
‘rConnect is a really useful tool.
“If we experience any machine or machining issues or if we specifically need applications help and advice, the rConnect facility gives us instant access to GF Machining Solutions’ service engineers who are on hand to provide immediate expert input and assistance.
Since being acquired, Mechlam Precision’s new CUT P 350 Pro has been operating around the clock.
The machine has helped, and is helping, the company secure new, high-value machining contracts and is a key component in Mechlam Precision’s drive and ambition to create a truly world-class machining resource and become a ‘preferred partner’ with many of its customers.
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