Wire-cut EDM Systems

Grand Tubular

New generation makes it‘s mark in a continuously updated lineage.

1972 1980

1990

2000

2012

DWC50S-LT1 DWC50H-DNC2 DWC100H-CNC2 DWC90-CNC1 DWC110N-CNC1 DWC90FSK-CNC1 DWC90G DWC90H DWC90PH DWC110PH DWC90C

PX05 FX10 DWC90PA CX20 SX20 DWC400HA DWC110SA DWC110SZ DWC90SB DWC90HA

FX20K QA20 RA90AT FA20 FA20P PA20 FA30V PA05S FA20S FA10PS

NA2400 BA8 FA20S Advance FA50V

Mitsubishi Electric Wire-Cut EDMs

2 3

MV SeriesMV Series

Functions and Features Fully equipped with useful functions for the manufacturing workplace, featuringrefined style, high performance, energy savings, simple operation and vast expertise

Total Digital ControlDigital technology optimizes all enhanced functions required by Wire-cut EDMs

Improved productivity Easy operation Energy savings,low running cost

• Faster machining is realized with improved power-supply performance (Ra 0.45μm with 3 cuts) (Ra 0.28μm with 4 cuts)

• A wide range of application technologies is supplied with the machine.

Machining time comparison forRa 0.45μm with 3 cuts

• Search function for machining conditions has been improved.

• Job scheduling adjustments use the schedule call back, extra job insertion and ME-pack* feature

* ME-pack is a package of machining processes including offset, machining speed and adaptive control settings

Innovative automatic wire threading

• New annealing system greatly improves wire threading even under bad conditions

• Wire break point insertion is greatly improved for thick workpieces

• Wire threading mode can be selected to match the workpiece shape (i.e., jet stream on, jet stream off and submerged break point insertion)

Improved machining accuracy

• Equipped with a Tubular Shaft Motor• Mitsubishi Electric‘s optical drive system uses fiber-optic

communications between the control unit, servo amplifier and Tubular Shaft Motor to improve machining accuracy

Grand TubularMV1200R

4 5

Grand TubularMV2400R

Servo amplifier

ADVANCE control unit

Tubular shaft motorwith linear glass scale feedback

Tubular shaft motorwith linear glass scale feedback

Conventionalmodel

MV-R

Wire electrode:Ø 0.20 mm/BS

Workpiece:Steel 1.2379,t60 mm

Machining condition search screen

Set-up screenReduced 17% ±

• Power consumption reduced up to 69%Conventional

model

MV-R

Conventionalmodel

MV-R

Conventionalmodel

MV-R

Conventionalmodel

MV-R

• Filter cost reduced up to 45% (Automatic changing filtration flow rate)

• Wire consumption reduced up to 46%

• Ion exchange resin cost reduced up to 25%

± Reduced 69%

± Reduced 45%

± Reduced 46%

± Reduced 25%

Machine design

Casting machine design• The classic Meehanite casting machine design provides

a solid construction for long-term precision, as well as to handle heavy workpieces.

Drive positioning

• The Tubular direct drives are assembled in the center of the moving weight for smooth movement. The glass scales are located within the immediate vicinity of the working area for best precision.

Hardened table and all stainless-steelstructure

• Equipped with a hardened table• The working tank and dielectric reservoir

are made of stainless-steel• Resistant to deterioration by dielectric fluid and sludge

Tubular Shaft Motor• Power consumption is reduced by utilizing a full 360°

magnetic flux as the effective driving force• Highly accurate axis movement is possible without any

backlash• Non contact power transmission ensures stable and

accurate axis movement for many years• Twelve years warranty on the drive system for positioning

accuracy

6 7

Utilizes all magnetic fluxas an effective driving force

Shaft Magnet Coil Coil

Magnet

Magneticflux

Improved machining accuracy Next-generation drive system and refined power-supply control technology

Corner machining control (CM3 control: Corner Master3)

• Improves machining accuracy at extremely small in-corners and out-corners

• Realizes highly accurate shape machining even for complicated geometries with several types and sizes of corners

• Corner accuracy is automatically optimised according to simple priority settings given by the operator

Optical Drive System• High-speed fiber-optic communications and a tubular shaft

motor synergistically improve machining accuracy• Servo amplifier and control unit developed by Mitsubishi

Electric contribute to system optimization

Die-shaped machining samples Comparison of corner accuracies

Comparison of straightness accuracy during finish machining

Fully-automatic rough machining control (PM control: Power Master)

• Generator settings are selected automatically by Power Master function – best results possible without expert knowledge

• Automatically recognizes varying machining conditions and makes adjustments for the optimum generator settings 3D-PM

• Analyzes 3D data, recognizes shape characteristics and anticipates optimum generator settings according to varying shape characteristics

• Eliminates transition lines which appear easily in stepped machining areas

Examples of PM machining applications

8 9

Shape control power supply (Digital-AE II )

• Wire straightness is digitally controlled with the world‘s only electrical-discharge position control

• Total machining time is reduced by improving straightness accuracy during rough, finishing and fine finishing processes

Workpiece: SteelNo. of cuts: 5Electrode material: ø0.25mm

100mmt

200mmt

Straightness accuracy (both sides) ɥm

Digital AE IIConventional model

Conventional technology• Machining conditions are

opitmized• Number of cuts are increased• Upper/lower dimension

difference is compensated mechanically (taper angle)

Digital-AE IIDischarge rate relative toworkpiece thickness ismonitored byelectrical-discharge positioncontrol

Stepped shapemachining

Stepped shapemachining

Cross-cavity shapemachining

Conventional corner control CM3

In-corner60°

(R 0.2 mm)

In-corner90°

(R 0.15 mm)

Shape error: 2 to 3 ɥm Shape error: 1 ɥm

Servo amplifier

Tubular shaft motor withlinear glass scale feedback

Tubular shaft motor withlinear glass scale feedback

ADVANCE control unit

Shap

e co

ntro

lpo

wer

sup

ply

Innovative automatic wire threading Advanced technology for greatly improved productivity

Wire electrode annealing structure• Improved wire annealing system and tension control unit

enhance wire threading (producing a curl ratio of 10% or less), which straightens the natural curl caused by spooling

• The greatly lengthened distance of annealed wire improves automatic wire threading for thick workpieces

*A curl ratio of less than 3% applied for the conventional model (FA Series)

Improved automatic wire threading

• New annealing system greatly improves wire threading with a curl ratio of less than 10%

• Wire break point insertion is greatly improved for thick workpieces

• Wire threading mode can be selected to match the workpiece shape (i.e., jet stream on, jet stream off and submerged break point insertion)

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 the 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

10 11

Tension control

Anneal structure

Improved productivity

High-speed machining has been enhanced by newlyimproved power-supply performance for multi-pass type jobs

Table insulation• Insulated worktable ensures improved surface finishing• Stable machining realized even when using short-pulse

and low-voltage machining conditions

High-speed digital control

• Spark detection speed (up to twice as fast as conventional models) provides improved discharge efficiency and suppresses wire breakage simultaneously while improving machining speed

Hardened table

Ceramic

Casting

D-FS – Perfect Surface• The digitally controlled fine finishing generator (D-FS)

is already well-known from Mitsubishi Electric‘s high-end NA series and now it‘s an option with the MV-R. It can achieve surface finishes that are less than 0.12 μm Ra.

12 13

0 100(%)

0 100(%)

Workpiece thickness mm

Mac

hine

d su

rface

d ro

ughn

ess

Machining time comparison for Ra0.45ɥm with 3 cuts

Machining time comparison for Ra0.28ɥm with 4 cuts

Conventionalmodel

MV-R

Conventionalmodel

MV-R

Machining samples

Machining samples

Surface roughness

Surface roughness

Wire electrode: ø0.2/BSWorkpiece: Steel (1.2379), t60mm

Wire electrode: ø0.2/BSWorkpiece: Steel (1.2379), t20mm

Reduced 17% ±

Reduced 17% ±

Easy operation User-friendly features ensure easy operation

Easy 3-dimensional Workpiece Set Up• By measuring the workpiece flatness with a dial indicator,

the wire tilt can be automatically compensated to match the angle of the part. This reduces further set-up time

• This function works either with a manual dial gauge or automatically with a touch sensor (option).

Easy selection of machining technology

• Interactive operation easily creates NC data with machining condition

• Job scheduling adjustment uses the schedule call back, extra job insertion and ME-pack feature

* ME-pack is a package of machining processes including offset, machining speed and adaptive control setting

Precise positioning

• Highly accurate workpiece set-up is possible with the water flow on or when a workpiece is submerged

Advanced 3D data for machine control

• Reads and displays 3D CAD data (Parasolid format *1) with a built-in 3D CAM

• Generates 3D model contours with a built-in 3D CAM• Creates NC data, including machining conditions,

with a built-in 2D CAM• Automatic ME-pack insertion into the 2D CAM path• Analyzes cutting conditions for improved machining

performance with a 3D-PM*1 Parasolid is a registered trademark of UGS PLM Solutions Co., Ltd.

14 15

Energy saving, low running cost Realizing low costs and environment-friendly operation

Running costs• Total running costs are reduced up to 42%, which is

accounted mainly by filter, ion exchange resin and power consumption

New energy-saving Sleep Mode

• The new energy-saving mode can be scheduled according to the current job ending time and start time the next day

• In Sleep Mode, the amount of energy consumed is greatly reduced as the result of using an automated pump-shut-off system

• The dielectric fluid circulation starts automatically, depending on the scheduled start of work time. This way, the working temperature of the machine will be reached just in time for start of work next day

Power consumption reduced up to 69%

Filter cost reduced up to 45%

Filter cost is reduced by changing thefiltration flow rate between the rough cutand finishing processes

Wire comsumption reduced up to 46%

Increased power-supply efficiency reducesthe wear on the wire allowing the wire spoolingrate to be reduced by PFC

Compared to conventional Mitsubishi Electric Wire-cut EDM (FA Series), compared to the same machining amounts

Wire electrode : ø0.2/BSWorkpiece : Steel(1.2379), t60mm)Surface roughness : Rz3.5μm/Ra0.45μm

Wire consumption reduced up to 46%

• Increased power-supply efficiency reduces the wear on the wire allowing the wire spooling rate to be reduced

Multiple use wear parts(e.g. Power Feed Contact)• 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)• Multiple indexing locations greatly reduce running cost

16 17

Saves electricity bysupplying only the minimumrequired amount of power

Supplies power andsupplies dielectric fluidto the bottom of the table

Supplies dielectricfluid to the bottomof the table

Temperature adjustedso machine can be use immediately

22:00End of work(Fluid system

shut-down time)

6:00Wake-up

(Fluid system start-up time)

8:00Start of work

EDM work Sleep Mode Recovery Temperatureadjustment EDM work

24 index locations on each side

Conventionalmodel

MV-R ± Reduced 69%

± Reduced 45%

± Reduced 46%

Generation 2002

Generation 2007

Generation 2012

Wire electrode Filter Ion exchange resin Power Consumption others

Conventionalmodel

MV-R

Conventionalmodel

MV-R

0 20 40 60 80 100(%)

0 20 40 60 80 100(%)

0 20 40 60 80 100(%)

The new Advance CNC control

Easy Screen• The workpiece set-up takes place as usual via screen

views that are simple and logical in their succession. A “short version” offers the Easy Set Up function, which provides all essential set-up possibilities in one screen view. It could not be any easier to get started...

Ergonomic Design

• In addition to the 15" touch screen, the machine is also equipped with fixed function keys as well as a PC keyboard and mouse. These features enable simple and precise operation even when the CAM functions are utilized

3D PowerMaster• The Advance Control reads the 3D CAD data for information

regarding height run and interruptions in the workpiece. When the Advance Control is processing in the 3D Power Master mode, it anticipates height differences and cavities in the workpiece and reacts accordingly. The possibility of the workpiece being damaged with marks and lines is avoided by this anticipatory eroding process, which at the same time optimises the performance and cutting speed

E-Manual / Alarm / Maintenance Support

• The Advance Control comes with complete machine documentation, including numerous search and help functions. Directly from within the respective processing screen, you can call up the corresponding explanations from the machine‘s operating manual, maintenance guidelines for the corresponding machine components, and additional notes regarding alarm signals

Advance-Control • User-Friendly • Quick • 3D funcionality

18 19

Large step

Blind hole

Upper/lowernozzles are seated Machining

direction

ADVANCE PLUS control ADVANCE PLUS control expands the capabilities of electrical-discharge machining

Improved corner accuracy• ODS provides high accuracy even when

cutting a U-V independent tapered shape• Machining accuracy is improved in very small inside &

outside corner radii

Improved machining speed• New V350V power-supply control realizes high-speed

machining• Optimized control of power-supply during intermediate

and finishing processes reduces total machining time

Machiningspeed

Corneraccuracy

Circularaccuracy

Energysavings

Security

Energy savings• Energy consumption is reduced according to the

current job ending time and the next days starting time (Sleep Mode)

Improved circular accuracy

• Compensation accuracy improved by new AFC III servo control

X

X

X

X X

X

McAfee® is a registered trademark of McAfee, Inc. in the United State and other countries

Machining time reduced up to 17%

Corner accuracy ±1μm

<Top surface of arbitrary shape up and down/Bottom surface of circle command>

Corner machining controlusing CM3

Wire electrode: ø0.2/BSWorkpiece: Steel(SKD11), t30mm

Power consumption reduced up to 69%

* Compared to conventional Mitsubishi Electric Wire-cut EDM (FA Series)

Anti-virus protection

20 21

Wire electrode : ø0.2/BSWorkpiece : Steel(SKD11), t60mm

* Compared to conventional Mitsubishi Electric Wire-cut EDM (FA Series)

Circular accuracy within 2μm

Security• Anti-virus protection is provided as standard equipment

by one of the world leaders in security control• Pattern file can be used semi-permanently without renewal

Conventionalmodel

MV-R ± Reduced 69%

Conventionalmodel

MV-R Reduced 17% ±

Special materials: PCD / CBN cutting

Programming software ProfDia

• The software ProfDia has been developed specially for the generation of measuring and processing programs for rotational tools. Calibration data from the machine (position measurement via sensing elements) is automatically taken into the processing programs

Positioning Spindle (B-axis)• Servo-controlled B-axis, completely integrated in machine

CNC control. Allows indexing and multi-sided machining in one clamping as well as simultaneous machining. Max. workpiece weight: 50kg Max. rotation: 20 rpm

Circular milling tool

• In addition to the workpiece form, “exotic” materials also place high demands on a Wire EDM system. The MV-R Grand Tubular overcomes these challenges without difficulty. The V350 generator unit quickly cuts PCD and CBN while achieving exceptional surface qualities. Not to mention, it is all accomplished with the reliability Mitsubishi Electric is known for. The tool package option increases the possibilities of processing cutting tools in numerous automation levels up to and including fully automated serial production.

Processing of special materials • Production of cutting Tools

22 23

Additional axes and spindles

Rotating / Positioning spindle (B-axis)

• Servo-controlled B-axis, completely integrated in machine CNC control. Allows indexing and simultaneous processing as well as high-speed rotation (EDM grinding). Max. workpiece weight: 30kg Max. rotation: 1,000 rpm

Positioning spindle (B-axis)

• Servo-controlled B-axis, completely integrated in machine CNC control. Allows indexing and multi-sided machining in one clamping as well as simultaneous machining. Max. workpiece weight: 30kg Max. rotation: 25 rpm

Micro rotating / positioning spindle (B-axis)

• Fully integrated rotating / positioning spindle for smallest highly precise parts, e.g.: Production of ejector punches with diameter ≥ 0.05 mm, conical thread implementation in medical technology, Wire EDM turning and grinding, simultaneous machining. Max. rotation: 3,000 rpm Clamping interface e.g. compatible with ER 16

Articulation axis• Fully CNC-integrated A-B hollow axis for processing of

highly accurate conic shapes. Multi-axis machining to the center of the workpiece and multi-sided machining in one setup, implementation of high-precise conic polygons. Max. workpiece weight 5 kg (with optional counter support up to 25 kg)

Simultaneous machining, indexing operation, high-speed rotation – everything is possible

24 25

Automation solutions

Melfa RV12SL

• Easy programming and highest precision guarantee highest flexibility. Also for continuous production of parts, this is the ultimate solution. Mitsubishi robot RV-12SL Handling weight: 12 kg Coverage (radius): 1385 mm Repeatable accuracy: ± 0.05 mm

Multi-purpose automation cell

• Mitsubishi Electric supplies automation solutions for many purposes, e.g. for automatic mould and die processing

MasterCell• The cell software, MasterCell, controls numerous wire

eroding machines in connection with flexible automated solutions from Mitsubishi Electric and optimizes your serial production processes

Customised solution for mass production

• Even customised automation solutions for individual mass production processes can be realised smoothly from one hand

26 27

Product Line-up

MV1200R(manual vertical front door)

MV2400R(automatic vertical front door)

4-axis Tubular Shaft Motor (XYUV)Four-sided hardened table

MV1200R

MV2400R

Grand Tubular

28 29

20kg Wire station

Wire collectionbox

Generator

Dielectricfluid unit +temperaturecontrol unit

Machine

Operation panel(Monitor)

*1 is min. 500 an *2 is min. 700, when the 20kg wire spool unit is mounted

*is min. 670, when the 20kg wire spool unit is mounted

20kg Wire station(option)

Wire collection box

E.KO-Ioniser

Dielectricfluid unit +temperaturecontrol unit

Machine

Operation panel (Monitor)

Additional information Weight of machine body: 2700 kgWeight of power supply unit: 240 kgHeight of machine: 2015 mm

Requested minimum measurement forentrance door/gate (WxH): 1910 x 2015 mm1: Power supply

3 phases 400 V / AC, PE ± 10%, 50/60 Hz, 20 kVA Primary fuse 32 A slow

A transformer with the following measures belongs to the machine: WxDxH (0.8m x 0.35m x 0.8m) Weight: 199 kg

The transformer must be placed in a distance of max. 5m from the machine. The maximum cable length and the cross section must be considered for this. The data can be taken from the transformer documents (cable not included in the scope of delivery). The transformer must be connected to the power supply by an electrician provided by the customer, complying with the different regulatios of each region/country.

2: Water supply: Single filling of the system with water, no regular water connection is necessary.

3: Pneumatic connection: 5-7 kgf/cm³ » 500-700 kpa Air volume minimum: 75 l /min 3/8" hose connection

4: Network connection5: E.KO-Ioniser dimensions: WxDxH (370 x 660 x 1150 mm)6: The erosion system should be set up to preferably consolidated

concrete floors on a suitable hard industrial ground.

110

110

320

540

640

300

400

110 110

Additional information Weight of machine body: 3500 kgWeight of tank without filling: 350 kgWeight of power supply unit: 240 kgHight of machine: 2150 mmRequested minimum measurement forentrance door/gate (WxH): 2022 x 2150 mm1: Power supply

3 phases 400 V / AC, PE ± 10%, 50/60 Hz, 20 kVA Primary fuse 32 A slow

A transformer with the following measures belongs to the machine: WxDxH (0.8m x 0.35m x 0.8m) Weight: 199 kg

The transformer must be placed in a distance of max. 5m from the machine. The maximum cable length and the cross section must be considered for this. The data can be taken from the transformer documents (cable not included in the scope of delivery). The transformer must be connected to the power supply by an electrician provided by the customer, complying with the different regulatios of each region/country.

2: Water supply: Single filling of the system with water, no regular water connection is necessary.

3: Pneumatic connection: 5-7 kgf/cm³ » 500-700 kpa Air volume minimum: 75 l /min 3/8" hose connection

4: Network connection5: E.KO-Ioniser dimension: WxDxH (370 x 660 x 1150 mm)6: The erosion system should be set up to preferably consolidated

concrete floors on a suitable hard industrial ground.

420

640

840

400

600

110 110

110

110

Model MV1200R MV2400RMachine Travel path (X/Y/Z) mm 400 x 300 x 220 600 x 400 x 310 Travel path (U/V) mm 120 x 120 150 x 150 Taper angle (workpiece height) ° 15 (200 mm) 15 (260 mm) Max. workpiece dimensions (W x D x H) mm 810 x 700 x 215 1050 x 820 x 305 Max. workpiece weight kg 500 1500 Table dimensions (W x D) mm 640 x 540 840 x 640 Table layout 4-sided hardened table Possible wire diameters mm 0.1 – 0.3 Wire spool reception kg 10 Automatic wire threading Yes Wire chopper Yes Overall machine dimensions (W x D x H) mm 2025 x 2760 x 2015 2687 x 3030 x 2150 Machine weight kg 2700 3500Filter unit Tank capacity l 550 860 Filter particle size μm 3 Filter elements 2 Temperature control Unit cooler Weight (dry) kg Included to machine 350 weightGenerator Power unit Regenerative transistor pulse type Cooling method Completely sealed / indirect cooling Max. output current A 50 Dimensions (W x D x H) mm 600 x 650 x 1765 Weight kg 240Control Input method Keyboard, USB memory stick, Ethernet TFT colour monitor 15" touchscreen Control method CNC closed loop Min. instruction step X, Y, Z, U, V μm 0.1 Min. driving unit μm 0.05 Max. instruction value mm +/-99999.999Equipment Wire station 20kg Option (retrofittable) Optical drive system with linear scales XYUV Yes Digital AE II power supply Yes Fine machining system Yes Digital fine finishing generator (< Ra 0.12 μ) Option (not retrofittable) Manual vertical front door Yes --- Automatic vertical front door --- Yes 4-filter system --- Option (retrofittable) Ethernet Yes DNC/FTP Yes Anti-Virus protection Yes Sleep mode Yes mcAnywhere Control Option (retrofittable) mcAnywhere Contact Option (retrofittable) mcAnywhere Service Option (retrofittable) External signal output Option (retrofittable) Additional axis/rotation Option (retrofittable) Tool package Option (retrofittable) Automation solutions Option (retrofittable)

MV1200ROne-piece 4-sided table hardened stainless steel

MV2400R One-piece 4-sided table hardened stainless steel

Technical-Data

<Table drawing>

<Table drawing>

50-M8tapped holes

72-M8tapped holes

Travel

Trav

el

Travel

Trav

el

30 31

MITSUBISHI ELECTRIC EUROPE B.V. · German Branch · Mechatronics MachineryGothaer Str. 8 · DE-40880 Ratingen · Fon +49 (0)2102-486-6120 · Fax +49 (0)2102-486-7090

edm.sales@meg.mee.com · www.mitsubishi-edm.deMat. 255702

Official Technology and application partner of Mitsubishi Electric