MITSUBISHI WIRE EDMdl.mitsubishielectric.co.jp/dl/fa/document/catalog/edm/k... · 2011-12-22 · Wire-cut EDM SYSTEMS * Not all models are supported for all countries and regions

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



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”)


• Highly accurate pitch machining is possible using the OPT-drive system and X/Y independent construction method


NA1200OPT-drive system

ø0.2(.008")/BS

STEEL (PD613)

20mm(0.8'')


• 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.


NA2400OPT-drive system

ø0.2(.008")/BS

STEEL (PD613)

20mm(0.8'')


• 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


NA1200Digital-FS

ø0.2(.008”)/BS

Tungsten carbide (G8)

70mm(2.8”)


• 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


NA1200Digital-FS

ø0.2(.008")/BS

STEEL (SKD11)

50mm(2.0'')


• 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


NA2400Digital-V power supply

ø0.3(.012")/BS

STEEL (SKD11)

300mm(11.8'')


• 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


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



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


Brass


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



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



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



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



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



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



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



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



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



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

Documents

MITSUBISHI WIRE EDMdl.mitsubishielectric.co.jp/dl/fa/document/catalog/edm/k... · 2011-12-22 · Wire-cut EDM SYSTEMS * Not all models are supported for all countries and regions