View
238
Download
4
Category
Preview:
Citation preview
Series
K-KL2-0-C0038-C NA1109 Printed in Japan (MDOC)
Wire-cut EDM SYSTEMS
* Not all models are supported for all countries and regions.* Machine specifications differ according to the country and region, so please check with your dealer.* Processing data provided in this brochure is for reference only.
MITSUBISHI WIRE EDM
HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPANNAGOYA WORKS: 1-14, YADA-MINAMI, 5-CHOME, HIGASHI-KU, NAGOYA 461-8670, JAPAN
Revised publication, effective Sep. 2011.Superseding publication K-KL2-0-C0038-B May 2011.Specifications are subject to change without notice.
Wire-cut EDM SystemsNA Series
NA
Series
Reaching for the leading edge of Monozukuri (Excellent-product development/manufacturing) together with you
There are things which only Mitsubishi Electric, the leader in electrical-discharge machines, can do.
Introducing the wire-cut EDM, which combines the innovative technology style from drive systems to control systems and power systems.
The NA Series, surpassing common knowledge to open up the next era.
Three advantagesfor the next era
High qualityA refined design makes impossible accuracies possible
Economy & EcologyEnhanced efficiency reduces operating costs from energy used to consumables
UsabilityAn ultimate operability is extremely operator-friendly
1 2
NA1200
NA2400
Outline drawing Table diagram(Unit: mm (in)) (Unit: mm (in))
*1: 0.25 wire DD guides come as standard for the USA market.
Machine specifications (standard specifications)
Mac
hine
uni
tD
iele
ctric
fluid
rese
rvoi
r
Model Maximum workpiece dimensions (W×D×H) Maximum workpiece weight Table dimensions Machining travel (X×Y×Z) Machining travel (U×V) Max. taper angleWire diameterWeight
NA1200810(31.9)×700(27.6)×215(8.5)
500(1100)650(25.6)×550(21.7)
400(15.7)×300(11.8)×220(8.7)±60(2.4)×±60(2.4)
15 (at max. 200mm(7.9"))0.1(.004) to 0.3(.012)*1
2500(5500)
[mm](in)[kg](lb)
[mm](in)[mm](in)[mm](in)
[ °][mm](in)
[kg](lb)Tank capacityFiltration methodFiltered particle sizeWater purifier (DI resin)Dielectric fluid chiller unitWeight (when dry)
450(119)Paper filter (two)
310(0.35)
Unit cooler300(660)
[ ](US gal)
[µm][ ](cu.ft.)
[kg](lb)
Required air pressureFluid rate
13.50.5 to 0.7(70 to 100)
75(2.6) or more
[kVA][Mpa](psi)
[ (cu.ft.)/min]Required air rate
General input
*1: 0.25 wire DD guides come as standard for the USA market.
*2: 120 (31.7 gal) of separate dielectric fluid is required for the subtank (mounted on machine body).
Machine specifications (standard specifications)
Mac
hine
uni
tD
iele
ctric
fluid
rese
rvoi
r
Model Maximum workpiece dimensions (W×D×H) Maximum workpiece weight Table dimensions Machining travel (X×Y×Z) Machining travel (U×V) Max. taper angleWire diameterWeight
NA24001050(41.3)×820(32.3)×305(12.0)
1500(3300)880(34.6)×670(26.4)
600(23.6)×400(15.7)×310(12.2)±75(3.0)×±75(3.0)
15 (at max. 260mm(10.2"))0.1(.004) to 0.3(.012)*1
3800(8377)
[mm](in)[kg](lb)
[mm](in)[mm](in)[mm](in)
[ °][mm](in)
[kg](lb)Tank capacityFiltration methodFiltered particle sizeWater purifier (DI resin)Dielectric fluid chiller unitWeight (when dry)
800*2 (211)Paper filter (two)
310(0.35)
Unit cooler350(770)
Required air pressureFluid rate
13.50.5 to 0.7(70 to 100)
75(2.6) or moreRequired air rate
General input
Layout drawing (Unit: mm (in))
650(25.6)
320(
12.6
)
550(
21.7
)
100(3.9)
100(3.9)
100(3.9)
50(2.0)
50(2.0)8×50=400(8×19.7=15.8)
50(2.0)
480(18.9)
100(
3.9)
100(
3.9)
100(
3.9)
6×50
=300
(6×1
9.7=
11.8
)
380(
15.0
)
115(
4.5)
115
(4.5
)
50(2
.0)
420(16.5)115(4.5) 115(4.5)
400(15.7) Travel300(
11.8
) Tra
vel
50 (2.0
)
44-M8 tapped holes
Table mounting holes
Outline drawing Table diagram(Unit: mm (in)) (Unit: mm (in))
Layout drawing (Unit: mm (in))
50 (2.0)
50(2.0)
50 (2.0)
50 (2.0)
480(
18.9
)50 (2.
0)50 (2.
0)10
×50
=50
0(10
×1.
97=
19.7
)10
0(3
.9)
100
(3.9
)10
0(3
.9)
100
(3.9
)50 (2.
0)
680(
26.8
)
130(
5.1)
420(
16.5
)13
0(5.
1)
72-M8 tapped holes
Table mounting holes
880(34.6)
130(5.1)620(24.4)130(5.1)
50(2.0)
100(3.9)
100(3.9)
100(3.9)
100(3.9)
680(26.8)50(2.0)
50(2.0) 40
(1.6)
50(2.0)
50(2.0)40
(1.6)12×50=600(12×1.97=23.6)
50(2.0)
50(2.0)
600(23.6) Travel
400(
15.7
) Tr
avel
Default machine dimensionsWidth: 1700mm(66.9") Height: 1965mm(77.4")
High-grade model combines high accuracy and ease of use
High-grade model combines high accuracy and ease of use With larger capacity.
A: Clean tank drain portFitted with PT1/2 screw valve (52mm(2.0") from floor)B: Dirty tank drain portFitted with PT1 screw valve (52mm(2.0") from floor)C: Power supply port200/220VAC±10%50/60Hz, 13.5kVAD: Primary air side0.5 to 0.7MPa, 75 /min(2.6cu.ft./min) or more1/4 hose connection (hose sleeve outer diameter: ø9mm(.35"))
Default machine dimensionsWidth: 2045mm(80.5")Height: 2100mm(82.7")
A: Clean tank drain portFitted with PT1/2 screw valve (52mm(2.0") from floor)B: Dirty tank drain portFitted with PT1 screw valve (52mm(2.0") from floor)C: Power supply port200/220VAC±10%50/60Hz, 13.5kVAD: Primary air side0.5 to 0.7MPa, 75 /min(2.6cu.ft./min) or more1/4 hose connection (hose sleeve outer diameter: ø9mm(.35"))
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
[ ](US gal)
[µm][ ](cu.ft.)
[kg](lb)
[kVA][Mpa](psi)
[ (cu.ft.)/min]
588(
23.1
)
1243
(48.
9)
1700(66.9)
2015
(79.
3)
50(2
.0)
537(21.1) 1902(74.9)
850(33.5)850(33.5)
200st(7.9)
200st(7.9)
1235
(48.
6)13
7(5.
4)53
3(21
.0)
150st(5.9)
150st(5.9)
267(10.5)
1195 (47.0)
2706(106.5)
1905
(75.
0)
950(
37.4
)
Die
lect
ric fl
uid
chill
er u
nit:1
663(
65.5
)F
ilter
:137
4(54
.1)
993(
39.1
)
555(21.9)
313(12.3)
1325(52.2) 555(21.9)
920 (36.2)
300st(11.8)
472(18.6)
220s
t(8
.7)
400st(15.7)
150st(5.9)
1767
(69.
5)
2172(85.5)
50(2.0)
D
A
C
B
ø100(3.9)
2655
(104
.5)
216(8.5)
2009
(79.
1)97
(3.8
)
600(23.6)
2172(85.5)110(4.3)
600(
23.6
)
740(29.1)
min.30
0(11.8
)min
.200(7
.9)
min.400 (15.7)
1140
(44.
9)
94(3.7)
320(12
.6)
min.800(31.5): When 20kg(44.1lb) wire spool unit is mounted
Machinebody
Dielectric fluid reservoir
Dielectric fluidchiller unit mounted
Power supply
Wire collection box DI resin
Operation panel (monitor)
Levelling bolt (×3)
min.300(11.8)
20kg(44.1lb) wire spool unit (option)
815(
32.1
)61
0(24
.0)
1338
(52.
7)
70(2
.8)
825(32.4)
2547(100.3)
Die
lect
ric fl
uid
chill
er u
nit:1
670(
65.7
)F
ilter
:153
5(60
.4)
1120
(44.
1)
815(
32.1
)
310S
T(1
2.2)
400ST(15.7)
3050(120.1)796(31.3)
1767
(69.
5)
533(
21.0
)12
0(4.7
)
300ST(11.8)
300ST(11.8)
313(12.3)
555(21.9)
1387
(54.
6)2150
(84.
6)
950(
37.4
)
155(6.1)
807(31.8)1740(68.5)915(36.0)
1170 (46.1)976 (38.4)
2254(88.7)
388(15.3) 754(29.7)680(26.8) 760(29.9)
110(4.3)
477(18.8)
600ST(23.6)
C
D
B
A
1280(50.4)142(5.6)
434
(17.
1)25(1.0)
403(15.8)
min.690(27.2)(When 20kg(44.1lb) / 50kg(110lb) wire spool unit is mounted)
min.300(11.8)
min.2
00(7.
9)mi
n.300
(11.8)
600(23.6)50(2.0)
Levelling bolt (×5)
600(
23.6
)50
(2.0
)23
85(9
3.9)
ø100(3.9)
3050
(120
.1)
2702(106.4)min.400(15.7)
600st(23.6)
400s
t(15
.7) Machine body
Power supply
Wire collection box
DI resin
Dielectric fluid reservoir
Dielectric fluidchiller unit mounted
Operation panel (monitor)
20kg(44.1lb) wire spool unit (option)50kg(110lb)
wire spool unit (option)
3 4
Machining samples
Samples Revolutionizing monozukuri (product creation) with high-accuracy machining which focuses on quality required for the next generation
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
Round machining
High-accuracy pitch machining
High-accuracy punch machining
High-accuracy fit machining of thick workpiece
High-accuracy fit machining
* The listed machining results are all based on in-house conditions and measurements.(Note) JIS B0601: '01 and ISO 4287: '97/ISO 1302: '02 compliant (Rz conventional notation Ry)
* The listed machining results are all based on in-house conditions and measurements.(Note) JIS B0601: '01 and ISO 4287: '97/ISO 1302: '02 compliant (Rz conventional notation Ry)
High-accuracy connector machining
Long stroke, high-accuracy pitch machining
Tungsten carbide punch machining
Fit machining of taper shape
Wide-angle taper machining
• High machining accuracy is realized with the OPT-drive system’s high responsiveness
• EM control suppresses possible bumps or undercuts at the approach point created during multiple skim cuts, attaining a higher degree of roundness
ModelFunction usedElectrode materialWorkpieceWorkpiece thicknessSurface roughness
NA1200OPT-drive system, EM control
ø0.2(.008")/BS
STEEL (PD613)
50mm(2.0'')
Rz2.0µm(79µ"Rz) / Ra0.25µm(10µ"Ra)
• A machining accuracy of ±2µm (.00008”) is possible when using the L/D machining mode with Fine Wire. This core pin example requires a 0.15mm (.006”) pin width.
Model
Function used
Electrode materialWorkpieceWorkpiece thicknessSurface roughness
NA1200High accuracy, fine wire machining specifications
ø0.05(.002")/SP
STEEL (PD613)Height: 20mm(0.8"), width: 2mm(.08")Rz0.9µm(35µ"Rz) / Ra0.1µm(4µ"Ra)
• Wide-angle taper machining with an angle of up to 45° is possible using the Angle Master option
Model
Function used
Electrode materialWorkpieceWorkpiece thicknessSurface roughness
NA2400
Angle Master
ø0.25(.010")/MEGA-T
STEEL (SKD61)
20mm(0.8")
Rz5.0µm(197µ"Rz) / Ra0.63µm(25µ"Ra')
• The UV-axis OPT-drive system realizes highly accurate tapered machining with an angle of 7°
• New corner machining control (CM3) improves a shape accuracy of corner areas, so the mold can slide smoothly
Model
Function used
Electrode material
Workpiece
Workpiece thicknessSurface roughness
NA2400High accuracy, fine machining specifications, corner controlø0.25(.010")/BS
STEEL (SKD-11)
150mm(5.9”)
Rz2.3µm(91µ"Rz) / Ra0.3µm(12µ"Ra)
• Highly accurate pitch machining is possible using the OPT-drive system and X/Y independent construction method
ModelFunction usedElectrode materialWorkpieceWorkpiece thicknessSurface roughness
NA1200OPT-drive system
ø0.2(.008")/BS
STEEL (PD613)
20mm(0.8'')
Rz2.0µm(79µ"Rz) / Ra0.25µm(10µ"Ra)
• Even when machining large plates with a stroke of 300mm (11.8") or more, the OPT-drive system enables highly accurate machining. ±3µm (.00012”) is possible.
ModelFunction usedElectrode materialWorkpieceWorkpiece thicknessSurface roughness
NA2400OPT-drive system
ø0.2(.008")/BS
STEEL (PD613)
20mm(0.8'')
Rz2.0µm(79µ"Rz) / Ra0.25µm(10µ"Ra)
• A surface roughness of Rz1.0µm (.00004") or less and a machining accuracy of ±1µm(.00004") are possible using Digital-FS for tungsten carbide punch machining
ModelFunction usedElectrode materialWorkpieceWorkpiece thicknessSurface roughness
NA1200Digital-FS
ø0.2(.008”)/BS
Tungsten carbide (G8)
70mm(2.8”)
Rz0.8µm(31µ"Rz) / Ra0.1µm(4µ"Ra)
• A shape accuracy of ±1µm (.00004") or less is realized
• High-grade machining to a surface roughness of Rz1.0µm or less is possible with Digital-FS
ModelFunction usedElectrode materialWorkpieceWorkpiece thicknessSurface roughness
NA1200Digital-FS
ø0.2(.008")/BS
STEEL (SKD11)
50mm(2.0'')
Rz0.7µm(28µ"Rz) / Ra0.1µm(4µ"Ra)
• Thick workpieces can be machined with a high straightness accuracy using the Digital-V power supply
• Highly accurate machining with a straightness accuracy of 6µm (.0002") is possible even with 300mm (11.8") - thick workpieces
ModelFunction usedElectrode materialWorkpieceWorkpiece thicknessSurface roughness
NA2400Digital-V power supply
ø0.3(.012")/BS
STEEL (SKD11)
300mm(11.8'')
Rz4.8µm(189µ"Rz) / Ra0.6µm(24µ"Ra)
• Corners can be machined to a high accuracy of ±1µm (.00004") using new corner machining control (CM3)
• Highly accurate fit machining with a fit clearance of 2µm (.00008") is possible
ModelFunction usedElectrode materialWorkpieceWorkpiece thicknessSurface roughness
NA1200Corner control
ø0.2(.008")/BS
STEEL (SKD11)20mm(0.8'') (die), 60mm(2.4'') (punch)Rz2.0µm(79µ"Rz) / Ra0.25µm(10µ"Ra)
5 6
Highly accurate drive systems
High quality
Integratedrectangular table
OPT-drive system
Highly rigid structure
Servo amplifier
Drive section
ADVANCE control unit
Drive section
<NA1200 is shown>
Optimum structure matches machining applications
Optimum structure to matchmachining applications
NA1200
NA1200• X/Y-axis independent construction method combines table
movement and column movement
• This structural design eliminates axis overhang, enhancing machining accuracy
NA2400• Drive method which combines table fixing and column
movement incorporated
• Fixed table, and movable-column design eliminates the need to move large workpiece, enabling a higher degree of machining accuracy
Excellent frame design provides higher-dimensional performance
OPT-drive system• Shape machining accuracy is greatly improved by the
synergetic effect of high-speed optical communication and motor technology
• Optimum system uses Mitsubishi Electric servo amplifier and control units
Highly rigid structure• Newly designed with CAE analysis, the machine structure is
highly rigid with a low center of gravity
• Ribs are optimally arranged to suppress the structure’s deformation during axis movement
UV-axis OPT-drive system*• The UV-axis can also be fitted with the OPT-drive system
• High-accuracy taper machining is possible
* Compatible models: NA1200/NA2400 (option).
Integrated rectangular table• A highly rigid one-piece stainless steel table is used for easy
workpiece setup
• Workpieces can be machined to a high accuracy at any position
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
NA2400
7 8
Analyzed shape curve
Optimum surface roughness Rz0.4µm (.000016") Ra0.03µm (.000001")Tungsten 10mmt ø0.2 (.008")/BS
Oxidization of workpiece surface
0 5 10 15 20
100mmt
200mmt
Straightness accuracy (both sides) µm
Workpiece: Steel
No. of cuts: 5 cuts
Electrode material: ø0.25mm(.010")
Mitsubishi Electric conventional EDM
Digital-AE
Comparison of straightness accuracy in finish machining
Oil machiningWater machining
CrackCrack
Comparison of water- and oil- machined surfaces
Comparison of AE and conventional machining
* The photo shows a comparison under adverse conditions where electrolysis occurs easily.
Conventional machining AE machining
Titanium alloy
Conventional machining AE machining
Brass
Conventional machining AE machining
Aluminum
−0.250µm
0.250µm
High-accuracy power systems
High quality
New technologyThe discharge rate relative to the workpiece thickness is monitored by the electrical-discharge position control
Conventional technology• Machining conditions are optimized• Number of cuts are increased• The upper/lower dimension difference is
compensated mechanically (taper angle)
AE machiningAE machining
Workpiece topWorkpiece top Workpiece topWorkpiece top
Machined surfaceMachined surface
Conventional machiningConventional machining
Merging high speed and high accuracyRefined power supply control technology
High-speed anti-electrolysis power supply (AE power supply)
• Electrolytic corrosion is suppressed to prevent the formation of softened layers
• Compatible with all power circuits from rough machining to finish machining
• High-speed, safe unmanned machining possible using water
Shape control power supply (Digital-AE II)
• Digitally control 3D shapes with the world's only (as of April '11) , electrical-discharge position control
• Reduce the total machining time by improving straightness accuracy during rough, intermediate and finishing processes
Super-fine finishing power supply (Digital-FS)
• Optimum surface roughness of Rz0.4µm
• Machining with the workpiece set directly on the table (dedicated jig not required)
• Machining range not limited (entire XY stroke area)
• Achieves both surface roughness and straightness accuracy
• Extends die life and improves die releasing properties
Sha
pe c
ontr
olpo
wer
sup
ply
Machined surfaceMachined surface
Edg
eM
achi
ned
surf
ace
Mac
hine
dcr
oss-
sect
ion
Mac
hine
dsu
rfac
eM
achi
ned
cros
s-se
ctio
n
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
9 10
Die-shaped machining samples Comparison of corner accuracies
Conventional corner control CM3
(R0.2mm)(.008")
(R0.15mm)(.006")
Shape error: 2 to 3µm Shape error: 1µm
Conventional tension control TS master
In-corner 60˚
In-corner 90˚
Machined surface
after polishing
Analysis of
machined surface
before polishing
Stepped shapemachining
Stepped shapemachining
Cross-cavity shapemachining
Examples of PM machining applications
Dimple
Example of cornermachining
Wire ø0.2 (.008")/BSWorkpiece 20mmt steel Surface roughness Rz3.9µm
2µm
250µm
2µm
250µmEM control: concave section depth within surface roughness
No control: concave section depth approx. 4µm
Conventional control: Step, straightness -3µm to +7µm (-.0001 to +.0003")
7µm(.0003")
3µm(.0001")
1µm(.00004")2µm
(.00008")
SL control: Step, straightness +2µm (+.00008") or less
7.0µm(.0003")
-7.0µm(-.0003")
Wire electrode: ø0.2 (.008")/BSWorkpiece: SKD-11.60mm (2.4")No. of cuts, surface roughness: 6 cuts, Rz1.7µm
<Machining condition> <Comparison of straightness>
<Test shape>
B:4mm(.16")
A:5mm(.20")
SectionA
SectionB
3µm(.0001")
3µm(.0001")
3µm(.0001")
5µm(.0002")
UsingOM control
WithoutOM control
(Both sides)
High-accuracy control system
High quality Advanced knowledge-base system controls cutting-edge machine performance
Corner machining control (CM3 control: Corner Master3)
• Improve machining accuracy at extremely small in-corners and out-corners
• Realize highly accurate shape machining even in complicated geometry with several types and sizes of corners
• Corner accuracy can be easily controlled by the operator
Wire tension control (TS Master)
• Suppress tension fluctuation to realize stable machining
• Suppress lines on the machined surface after polishing
Under-cut (dimple) reduction control(EM control: Entrance Master)
• Reduces dimples at the approach section
• Allows shape adjustment from convex to concave
• Greatly reduces polishing time
Machining surface step/straightness control(SL control: Stepless control)
• Greatly improves the step finish and wall straightness for workpieces with varying thickness
• Finish complicated parts to a high accuracy
Dimensional error control(OM control: Orbit Master)
• OM control is designed to attain a uniform electrical discharge gap regardless of the corner shape
• This improves the radial shape error and greatly improves the total part accuracy
Fully-automatic rough machining control(PM control: Power Master)
• No need to set machining conditions or have EDM machining know-how
• Automatically recognizes machining conditions
• Makes adjustments for the optimum machining condition
<3D-PM>
• Analyzes 3D data and recognizes shape characteristics
• Eliminates transition lines which appear easily in stepped machining areas
• Improves machining speed with nozzle close conditions
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
11 12
Machine system function and operation
Mechanism
Example of NA2400
NA2400
Creating a comfortable, reassuring operating environment
3-sided elevating work-tank (NA2400)
• 3-sided elevating work-tank allows easy loading of large workpieces
• The machine table can be reached from three sides making workpiece setups quick and easy
• Multiple workpiece setups are made easy by the open access to the machine table
Hand lift mode (NA2400)
• Top surface of the working tank can be lowered approx. 60mm (2.4") from the top of the table
• Table access is improved when loading/unloading using a hand lift
Increased machining stroke• Ample stroke for large workpieces
X600 (23.6") × Y400mm (15.7") (NA2400)
X400 (15.7") × Y300mm (11.8") (NA1200)
High-accuracy taper machining (Angle Master)
• Angle Master function realizes high-grade machining of large tapers
• Optimum taper specifications are automatically set to match the wire electrode angle
All stainless-steel structure• Workpiece mounting table
• Lower machine arm
• Seal plate
• Work-tank and dielectric fluid reservoir
Seal plate self-cleaning mechanism• Forced flush self-cleaning mechanism prevents sludge from
sticking to the stainless-steel seal plate
• A simple jet wash nozzle provides the operator with the ability to quickly rinse down the work area after each job is completed
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
13 14
Machine system function and operation
Mechanism
High-speed auto-threaderHigh-speed auto-threader
Innovative design for improving productivity
High-speed auto-threader: AT2• High-speed, highly reliable 10-second automatic
threading
Compact head design• The new compact head design greatly improves how close the
nozzle can get to stepped workpieces or clamping fixtures such as vises and ruler systems
One-touch lever clamp mechanism• New one-touch lever clamping system provides quick, easy,
and accurate power feed indexing
• The clamp lever accurately locates the power feeder with repeatable torque, unlike systems that use a set-screw method
Diamond guide• A round diamond guide is used to provide the best accuracy for
both straight and taper cutting applications
• Both upper and lower guides can be replaced by simply unscrewing the flush cups (no tools required)
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
Jet off wire insertion (AT Master)*• The automatic wire threading range has been increased to
provide capability for wire breakage point insertion, top/bottom countersunk hole insertion, slit insertion, small diameter initial hole and submerged threading
• By using the AT Master guide kit and AT Enhance Mode setting, the auto-threading performance can be improved where using, jet stream on, causes enough turbulence to prohibit threading.
* Applicable models: All models (option).Applicable wire diameter: ø0.2, 0.25BS. (.008, .010” BS)Fine-Hole search functionFine-Hole search function
15 16
ADVANCE control intelligence and ease of use
Ultimate Control
Easy-ADVANCE New advanced ergonomic design
3D-ADVANCE Advanced 3D data for machine control
Net-ADVANCE Advanced support service using Internet technology
*1: Parasolid is a registered trademark of UGS PLM Solutions Co., Ltd.
*ME pack is a pack of machining process including offset, machining speed and adaptive control setting.
e-manuals
Machining know-how
Machining conditions download
Enlargement of 3D models using a mouse
Taking the interface to new heights with three advanced levels
Easy-to-read screen and outstanding operability• 15-inch LCD and touch panel
• Simple menu configuration eliminates deep nesting
Providing the newest systems, manuals and machining conditions• The latest system software, manuals and machining conditions, etc., are provided through the Internet
• Users can download the latest version and upgrade their system
• Reads and display 3D CAD data (Parasolid format *1) with a built-in 3D CAM
• Extracts 3D model contours with a built-in 3D CAM
• Creates NC data including machining condition with a built-in 2D CAM
• Utilizing ME pack available in built-in 2D CAM
• Analizes shape features for improved machining performance with a 3D-PM (refer to following page for details)
Ergonomic design• Smooth operations with mouse
• Easy-to-use screen, keyboard and mouse position
Creates NC data including machining condition with easy operation (machining condition search function) • Creates NC data with machining condition easily by an interactive
operation
• The job schedule adjustment, used schedule call back, and extra job addition is now supported by the ME pack
Quick simple workpiece Setup (Work alignment function)• By measuring the workpiece flatness with a dial indicator, the wire
tilt can be automatically compensated to match the angle of the part rather than taking time to indicate it in perfectly flat
• Even when using multiple workpieces, the flatness can be automatically compensated in each workpiece coordinate system without editing the program
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
17 18
CAM
Check
Setup
MachiningCompletion
3D-PM
CAD/CAM systemin use
*1 This is not a function to create or edit the 3D model.*2 The 2D CAM is based on CamMagicW, but is limited to basic 2D CAM functions.*3 Parasolid is a registered trademark of UGS PLM Solutions Co., Ltd.
3D CAD data(Parasolid format *3)
Machining-defined data(CamMagic format)
2D CAD data input(DXF format, IGES format)
NC data
3D adaptive control EDM
3D-ADVANCE
Advanced 3D datafor machine control
Machining directionBlind hole
Large step
Upper/lower nozzles are closed
Conventional machining 3D-PM machining
3D CAD
2D CAD
CAM
Extensive utilization of 3D CAD data for machine control
Read 3D data• 3D CAD data (Parasolid format *3) can be
read and displayed in original format and design information can be taken directly to the site
Built-in 3D CAM *1
• Extract contour lines with the height designated in 3D data
• Transmit the contour lines to the built-in 2D CAM
• Analyzes 3D data and recognizes shape characteristics• Eliminates transition lines while improving machining performance• Eliminates streaks which appear easily in stepped machining areas• Improves machining speed when nozzles are closed
Built-in 2D CAM *2
• Create NC data from contour lines
• Simple CamMagic operations
• Revise drawings and define additional machining on the EDM
Program check/monitor• Overlay and display 3D data during the NC data
path check
• Overlay and display 3D data on the monitor screen even while machining
• Check the status at a glance 3D Viewer• Reference the 3D image display at any time,
even during setup
High compatibility with CamMagic- Common operability- Mutual use of
Machining-defined data
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
19 20
Efficiency
Conventionalmodel
NA
Conventionalmodel
NA
Conventionalmodel
NA
0
100
2040
6080
0
100
2040
6080
Conventionalmodel
NA
0
100
2040
6080
0
100
2040
6080
The above data is a comparison with designated machining conducted by Mitsubishi Electric using the conventional Mitsubishi FA Series.
Machining time reduced by up to 30%
Digital V power supply improves machining
performance in all ranges.
Major power-usage reductions during continuous
operation are achieved through the use of multifaceted
cost reductions and the union of new technology.
Wire consumption rate reduced by up to 44%
The new control system (Intelligent Master) optimally controls the
wire speed during machining.
Total power consumption (CO2 emission conversion rate)
reduced by up to 69%
Machining power consumption (CO2 emission
conversion rate) reduced by up to 55%
The combination of the above technology and the new "Sleep
Mode" function greatly reduces the total energy used, including
during idling.
* The right graph gives the values when the idle time is contained and the same machining amounts are compared. And NA uses Sleep mode at the idle time.
* The left graph gives the values when the same machining amounts are compared.
Multiple use of main tension roller
Spacer Spacer
EDM work
22:00End of day’s work
[Fluid system shut down time]
6:00Wake-up
[Fluid system start up time]
8:00Start of day’s work
EDM workSleep Mode RecoveryTemperatureadjustment
Saves electricity rates by supplying only the minimum required amount of power
Supplies power and supplies the dielectric fluid to the bottom of the table
Supplies dielectric fluid to the bottom of the table
Temperature has been adjusted so machine can be used immediately
Economy & Ecology Pursuing efficiency while realizing low costs and environmental awareness
New energy-saving mode (Sleep Mode)
• The new energy-saving mode can be scheduled according to the current job ending time and your next day start time
• In Sleep Mode, the amount of energy consumed is greatly reduced through the use of an automated pump-shut-off system
• Once the scheduled start time is reached, the system restarts the fluid system thermally, stabilizing the machine for the next days work
Flat power feed terminal• The flat shape makes it easy to index to the next location
• A total of 48 index locations can be used (24 on each side)
Main tension roller• Multiple indexing locations greatly reduces running costs
Large-diameter collection roller• Large collection roller, now with multiple index locations, greatly
reduces running costs
Four positions usable byshifting spacer position
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
21 22
Options
: Standard equipment : Can be field retrofitted : Factory installation only : Not available
ø0.1 (.004"), ø0.15 (.006") Automatic threading *1
XY-axis OPT-drive system specifications
High accuracy, fine wire machining specification *2
Wire processing unit *3
Long stroke taper unit (±60mm) (±2.4")
Long stroke taper unit (±75mm) (±3.0")
Angle Master (S/W)
Angle Master guide kit
AT Master guide kit
Digital-FS power supply
Digital-AE power supply
Fine machining system
Special material machining power supply
Working tank door automatic lock
Automatic elevating work-tank
Dielectric fluid overflow control
Ion exchange resin 10L (0.4cu.ft.) specifications (Organo)
Ion exchange resin 20L (0.7cu.ft.) specifications (Organo)
4-piece filter system
Advanced manual control box (with axis display)
Lighting
Instruction manual (paper edition)
High-accuracy wire-alignment device / Wire-alignment device
Tools (tool box)
Virus infection prevention
Workpiece clamp set
LAN/W *4
DNC (DNC64W S/W)
FTP (S/W)
Option Name NA1200 NA2400
(front door up/down) (3-face elevation)
* Contact your local Mitsubishi Electric sales office or dealer for more information.
<Personal computer><Schedule software>
<Process creation software>
<Coordinate measuring machine> <Robot + WEDM>
DNC
*1 The ø0.1 (.004") and ø0.15 (.006") wires cannot be used with the wire processing unit. (These sizes can be used with the continuous wire feeder after removing the wire processing unit.)*2 Available only with the ø0.05 (.002"), ø0.07 (.003") fine wire automatic feed specifications and UV-axis OPT-drive system specifications set.*3 The wire processing unit cannot be mounted when using high accuracy, fine machining specifications.*4 LAN cable should be used all straight wiring type with shielding connector, category 5 (100BASE-TX correspondence), STP (four shielded twist pair).
The switching type HUB should be used which can ground shielded LAN cable.
Wire-cut EDM automation system• Accumulates workpiece measurement data· Compatible for external set-up using a coordinate
measuring machine· Enables automatic measurement when measuring on an
EDM
• Creates processes offline
• Automatically exchanges workpieces using a robot
Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
Network connection specifications (DNC, FTP Options)
Use EDM’s Explorer and receive data in the common HDD on the EDM side.After that, data I/O operations are required.
Operate on the EDM side and receive data from personal computer.
Operate on the personal computer side and send data to the EDM.
Operate on the personal computer side and send data directly to the EDM's NC data area.
The personal computer’s Explorer and the EDM’s common HDD are used. After that, data I/O operations are required with the EDM.
Commercially available DNC software must be installed on the personal computer side.Refer to DNC Specifications for details on operation.
Data transmission
Data transmission
Data transmission
Standard
Standard
DNC
Data transmissionOperate on the EDM side and and send data directly to the EDM's NC data area.
Data can be received just with data I/O operation.FTP
Data, such as NC programs, machining conditions and variables can be exchanged between a personal computer and EDM.The required options differ according to the models and purpose, and can be confirmed using the following table.One IP address must be prepared for each EDM within the user’s in-house network.
Required Specifications Image drawing SupplementRequired option
Advanced manual control box/standard manual control boxThe advanced manual control box is provided with an LCD display,
and can be used for positioning, zero set and AT operations
High-accuracy wire-alignment device / Wire-alignment deviceUse this device to align the wire to the table
4-piece filter kit4-piece filter specifications reduce filter replacement frequency
Angle Master guide kitMax. 45˚ taper machining possible using dedicated diamond guide
Tools
Lighting
AT Master guide kitBroken wire threading performance is improved when using the AT Enhanced
mode and the (Type Z) guide kit. 0.2, 0.25 (.008, .010”) sizes available.
Workpiece clamp setClamp jigs dedicated for workpiece
Wire processing unitSpent wire is cut at discharge section
UV-axis OPT-drive systemThe OPT-drive system has been adopted for the UV-axis
23 24
�Control unit functions
�Power supply / Control unit specifications
Year, month, date display
Overlap window function
Character string replacement function
Geometric function
Floating decimal point function
Control command
Corner R
Corner chamfer
Linear angle command
30-sec. short-circuit stop
Simultaneous 2-axis wire alignment
Workpiece inclination compensation
Reference block
Single block
Dry run
Automatic return
User macro
Automatic positioning (hole center, edge)
Automatic zero point return
Machining start hole return
Memory operation 1GB
Program edit
Coordinate rotation
Pattern rotation
Program No. designation
Expanded AT function
Graphics (drawing monitor)
Graphics (program check)
Graphics (automatic machining shape drawing)
Graphics (surface display)
Offset
Coordinate reading
Time reading
XY-axis independent scaling
Axis rotation
Automatic 2nd cut
Simple automatic 2nd cut
Block delete
USB flash memory
e-manual (electronic instruction manual)
Repeated positioning
Automatic power failure recovery
Workpiece coordinate system (106 items)
PM control
SL control
3D graphic check
Workpiece alignment
Axis exchange
Mirror image
Circumference calculation
Backlash compensation
Pitch error compensation
Soft limit (inside/outside prohibit)
Wire consumption estimate
Hybrid Pack
CM3 control
OM control
3D viewer (Parasolid data display)
Sleep Mode
Maintenance check
Automatic taper degree calculation
Status recording
Data variable operation
Alarm display
Machining time estimate
Built-in 2D-CAD/CAM
Built-in 3D-CAM
EM control
Update system via Web
3D model compatible PM control (3D-PM)
DAE control
Control unit specifications
Compatible model
Power supply unit specifications
Pow
er s
uppl
y un
itC
ontr
ol u
nit
NA1200 / NA2400
WN4Regenerative transistor pulse type
Completely sealed / Indirect coolingAnti-electrolytic power supply in all modes
50A13 types (RH, RL, KH, KL, HP, CB, MP, HL, MA, LA, LB, LC, LD)
17 types243 types 32 types 10 types 20 types 3 types 5 types 3 types
3 notches (changeable with M code or screen)• Workpiece material: Steel, tungsten, copper, aluminum
• Applicable only for rough-cut conditions• Not usable with CS mode
Built-in600 × 650 × 1765 (23.6 × 25.6 × 69.5)
260 (572)
ModelPower supply circuitCooling methodAnti-electrolytic power supplyMaximum output currentPower supply modeMachine voltage selectionMachining settingOFF timeStabilization circuit AStabilization circuit BStabilization circuit CStabilization circuit EFM circuit (LA, LC, LD)
PM control
AVRUnit dimensions (mm) (in)Unit weight (kg) (lb)
W31NA-2Keyboard, USB flash memory, Ethernet
Touch panel, mouse15" color TFT
Alphanumeric charactersCNC closed loop
Max. 4 axes simultaneouslyX, Y, U, V … 1/0.1µm
50nm (0.000050mm (0.000002"))±99999.999mm
Combined use of increment/absolute valueLinear, circular, and spiral
0.00001 ~ 99.999999 (G code) 0.001 ~ 9999.999 (S code)Automatic selection of machining speed according to gap voltage sensing
Reverse path retrace during a short-circuit±99999.999mm Offset numbers: 1 to 900 (intersection point calculation)
5 types (file, setup, machining support, monitor, maintenance)Interactive screen method
1 to 69991 to 99999999
Nesting level 301 to 99999
Input on screenHigh-speed, medium-speed, low-speed, ultra-slow speed, inching (0.0001mm/0.0005mm/0.0001mm) Positioning function, AT functionXY plane, XY-XZ plane, solid, table scaling, 3D model display, background drawing, automatic machining path drawing
1GBManagement of consumable parts (time display)
SL, CM, EM, OM, PM494 × 175 × 346 (19.4 × 6.9 × 13.6) (excluding keyboard and mouse pad)
20 (44)
ModelNC program input methodPointing deviceDisplayDisplay charactersControl methodNumber of control axesSetting unitMinimum driving unit (mm) (in)Max. command valuePosition command formatInterpolation functionScale magnificationOptimum feed controlPath-retrace controlWire offsetBasic screen menuAutomatic 2nd cutMachining condition (E-pack) storageProgram number commandSub-programSequence numbersManual input positioningManual operation boxGraphicsUser memory capacityMaintenance functionAdaptive controlExternal dimensions (mm) (in)Weight (kg) (lb)
W31 (Advance control unit) Control Unit Functions
* Air (compressed air) is used to operate the automatic wire feeder and work tank door, etc. Air supplied from a normal compressor contains various impurities that could cause operation faults if they get into the pneumatic devices such as the solenoid valve. Install an air filter with drainage discharge mechanism, etc., on the air source (primary source) piping to prevent the impurities from entering the pneumatic devices.
Checklist for Installing MachineDetermining the machining details
Installation Conditions
1) Determine the workpiece
2) Determine the machining site
3) Determine the pre-processing site
4) Determine the post-processing site
Confirmation of foundation work and power supply workIf there is any possibility of radio disturbance, investigate it prior to starting work.
1) Confirmation of floor area
2) Confirmation of environment (constant pressure, dust-proof room, measure for radio disturbance, prevention of external noise)
3) Confirmation of foundation floor
4) Foundation work
5) Primary wiring for power lead-in
6) Grounding work
7) Construction of dielectric fluid (city water) supply/drainage facilities
8) Air piping work
Confirmation of delivery path
1) Traffic restrictions to factory
Road width
Entry road
2) Factory entrance and width of gate in factory m
Factory building entrance dimensions (height × width) m × m
3) Constant-temperature, dust-proof room entrance dimensions (height × width) m × m
Preparation of installation fixtures1) Plan the installation fixtures
2) Prepare or manufacture the fixtures
1) Select the programmers and operators
2) Apply for training seminars
Preparation of consumable parts1) Purchase consumable parts such as the wire electrode
Training of programmers and operators
CautionsThe standard delivery entrance dimensions for delivery in the standard shipping style are given on the product introduction page. If the entrance is smaller than the standard delivery entrance, the machine dimensions may be shipped with different dimensions.Contact a Mitsubishi Electric sales office for details (a separate estimate will be issued).Note that delivery may not be possible in some cases depending on the dimensions. Precautions for Selecting Earth Leakage Breaker
To prevent malfunctions caused by the external noise from control units, etc., a filter is installed on the power supply input. By grounding one end of this filter, an earth leakage current of approx. 30mA to 40mA passes through the filter. A highly sensitive earth leakage breaker (sensitivity current 30mA) could malfunction. Thus, a medium-sensitivity type earth leakage breaker (sensitivity current 100mA to 200mA) is recommended for the EDM. Class C grounding (grounding resistance 10Ω or less) is recommended for the wire-cut EDM. Even if the sensitivity current is 200mA, the contact voltage will be 2V or less, and no problems will occur in preventing electric shock (application of tolerable contact current Class 2, 25V or less).
Harmonic DistortionIf there is harmonic distortion in the power supply, the machine operation could be affected even if the voltage does not fluctuate. In addition, the harmonic current could flow from the wire-cut EDM to the power system and adversely affect peripheral devices. If the effect of the harmonic distortion causes problems, install a harmonic suppression filter or take other measures.
DisposalThe dielectric fluid, dielectric fluid filter, ion exchange resin and wire, etc., are industrial waste. These must be disposed of following national and local laws and ordinances.
1. Installation site Constant-temperature, dust-proof room
· Recommended room temperature 20±1 [°C] (68°F±2)· Usable temperature range 5 to 35 [°C] (44°F to 95°F)Fluctuation of the temperature will directly affect the machine accuracy, so to maintain performance accuracy, select a place with little temperature fluctuation.Install the EDM in a constant-temperature room when performing high-accuracy machining even when using skim cuts.Note that an environment where the temperature fluctuates by 3°C (5°F) or more within 24 hours, or 1°C (2°F) or more within one hour can adversely affect the machining accuracy. Make sure that the machine body is not subject to direct wind from air-conditioners or to direct sunlight.
· Dust-free location is recommended.Grinding dust can adversely affect the machine's linear scales and ball screws, so pay special attention to the installation location to avoid this hazard (separate from grinding machine, or install in separate room, etc.).
· Humidity Within 30 to 75%RH (with no dew condensation)· Temperature range during transportation and storage-25 to 55 [°C] (13°F to 131°F) (when power is not connected)
Tolerable vibration of installation floor· Select an installation floor where vibration or impact will not be conveyed· As a reference, the vibration level should have a max. amplitude of 2µm or less at a 10 to 20 [Hz] frequency
· Consult with the contractor or vibration measuring instrument maker for details on the measuring method
Foundation· The floor should be concrete with a thickness of 400mm (15.7") or more so it can sufficiently withstand the system’s weight
· The installation floor inclination (step) must be 6/1000 (floor inclination 6mm per 1m) (NA2400 Series)
2. Machine heating value• Approx. 8,140W of heat is generated per machine of which 1,512W is heat
generated by the dielectric fluid control unit• Take this into consideration when studying air-conditioning requirements
3. Power supply equipment• Primary wiring
3-phase 200/220VAC±10% 50/60Hz±1Hz• Power capacity
13.5kVA* Use a 14SQ (mm2) or thicker cable for the primary connection.
4. Grounding workWire-cut EDMs must always be grounded to prevent external noise, radio disturbance, and earth leakageClass C grounding (grounding resistance 10Ω or less) as set forth in the Electric Facility Standards is recommended for the EDM
· Class C grounding (isolated) is recommended (Wire-cut EDM dedicated grounding) (Fig. 1)Note) Provide isolated grounding for each machine.
· Common grounding can be used if noise from other devices will not enter through the common grounding; the grounding cable must be connected independently to the grounding location (Fig. 2)
· Use a 14mm2 grounding wire
5. Primary air equipment• Hose diameter : 1/4 hose (hose sleeve outer diameter: ø9.0 (0.35"))• Pressure : 0.5 to 0.7MPa (70 to 100psi)• Flow rate : 75L/min or more (26cu.ft./min.)
6. Shield roomInstall a shield room if a wire-cut EDM affects televisions or other communication facilities in the area. Observe the following points when installing the wire-cut EDM in the shield room.
1. Ground the EDM in the shield room (Fig. 3)2. If the EDM cannot be grounded in the shield room, connect the wire-cut EDM's
grounding cable to the shield room's grounding terminal (through bolt) as shown in Fig. 4
3. Consult with your dealer for details on installing a shield room
Power supply unit
Machine body RSTE
Power supply unit
Machine body
Grounding cable for other device
RSTE
Shield room
Machinebody
Power supplyunit
Shield room
Throughbolt
Within 1m
Machinebody
Power supplyunit
Fig. 1 Fig. 2
Fig. 3 Fig. 4
Check each item, and make sure that no item or order is overlooked.
Check the path inside and outside the factory to avoid any trouble during delivery.
Recommended Wire Electrode
FBH
SBS-HN
HBZ-U (N)
OB-PN
Furukawa Electric
Sumiden Fine Conductors
Hitachi Cable
Oki Electric Cable
* Use of non-recommended wires could result in problems. Always use the recommended wire.
Recommended Sliding Surface Lubricant
Maker
Exxon Mobil
Idemitsu Kosan
Showa Shell
JX Nippon Oil & Energy Corporation
Product name
Mobil DTE26
Super Hydro 68A
Terrace Oil 68
Super Mulpas DX68
Always use the following applicable wire electrodes.
Use the following lubricants on the sliding surface. As of September 2011
Preparation for machine installation
Machine Installation Product Line-up
Machining sam
plesD
rive systems
Pow
er systems
Machining C
ontrolM
achine systems
Control U
nitE
fficiencyO
ptionsPower supply / Control specifications
Machine Installation
Power supply /Control specifications
25 26
Series
K-KL2-0-C0038-C NA1109 Printed in Japan (MDOC)
Wire-cut EDM SYSTEMS
* Not all models are supported for all countries and regions.* Machine specifications differ according to the country and region, so please check with your dealer.* Processing data provided in this brochure is for reference only.
MITSUBISHI WIRE EDM
HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPANNAGOYA WORKS: 1-14, YADA-MINAMI, 5-CHOME, HIGASHI-KU, NAGOYA 461-8670, JAPAN
Revised publication, effective Sep. 2011.Superseding publication K-KL2-0-C0038-B May 2011.Specifications are subject to change without notice.
Wire-cut EDM SystemsNA Series
NA
Series
Recommended