Radar987,
I am the EDM Product Manager at Makino, and the (x2) machines you have identified are both capable of producing the work you have outlined. I believe you will have difficulty in telling the two models apart from an accuracy standpoint, especially since your parts are very small. Both machines utilize a similar structure and design, but the U32j machine is the higher-level model. Below are a few differences between the U3 and U32j machines...
U3:
- Standard with 0.010" wire (0.004", 0.006", 0.008, and 0.012" Guides are optional)
- Standard configuration can achieve surface finishes in Steel to 8~10uinRa (Optional Crystal Fine Finish Circuit can achieve surface finish to 3~4uinRa)
- Utilizes a Stationary Work Table design (this improves accuracy, as the machine is always moving the same mass regardless of work piece weight and fluid fill height)
- The water reservoir is built into the base casting of the machine to minimize floor space, and this design also improves thermal stability
- The machine uses a pneumatic Rise/Fall Front Door for Work Tank access, and Work Tank allows you to access the underside of the work piece from underneath the table
- Standard with HyperCut settings (this is a special Makino technology that achieves a fine 16uinRa surface finish with 3 Pass Machining)
- Standard with the Pro-Tech circuit (this is an active anti-oxidation/anti-rust system that protects the entire work piece and work tank)
- Utilizes 0.05um Glass Scale Feedback
- Machine Specifications state a Dynamic Shape Precision of 5 microns (0.0002”), which is a combination of feature size and location over the full stroke of the machine (all parts moving & working together)
U32j:
- Standard with 0.010" wire (0.002”, 0.003”, 0.004", 0.006", 0.008, and 0.012" Guides are optional)
- Standard configuration includes the Crystal Circuit, which can achieve surface finish to 3~4uinRa
- Utilizes a Stationary Work Table design (this improves accuracy, as the machine is always moving the same mass regardless of work piece weight and fluid fill height)
- The water reservoir is built into the base casting of the machine to minimize floor space, and this design also improves thermal stability
- The machine uses a mechanical 3-Sided Rise/Fall Work Tank that is fully programmable, and Work Tank allows you to access the underside of the work piece from underneath the table
- The machine is designed for greater thermal stability, and includes additional active cooling of the entire machine structure and a higher accuracy Chiller Unit
- The machine mechanical construction alignment accuracy is held to a finer tolerance
- Standard with HyperCut settings (this is a special Makino technology that achieves a fine 16uinRa surface finish with 3 Pass Machining)
- Standard with the Pro-Tech circuit (this is an active anti-oxidation/anti-rust system that protects the entire work piece and work tank)
- Utilizes 0.05um Glass Scale Feedback
- Machine Specifications state a Dynamic Shape Precision of 3 microns (0.0001”), which is a combination of feature size and location over the full stroke of the machine (all parts moving & working together)
Summary:
- The U32j is capable of operating with smaller diameter wire
- The enhanced accuracy of the U32j will be difficult to see and measure considering the small size of your parts (higher accuracy pitch positioning over the full stroke of the machine is not needed for your application)
- The U32j Out-of-the-Box settings are designed for high accuracy, whereas the U3 favors the Speed size of the spectrum (this just means that you might have to adjust offsets a bit more on the U3)
- The U32j and U3 (with optional Crystal Circuit) can achieve the same surface finish
Questions:
- A smaller diameter wire will produce a small inside corner radii, but what are your part requirements?
- Running 0.002” wire is more difficult (especially wire threading) than running the traditional industry norm of 0.010” wire. When running 0.002” wire, Makino recommends using pure tungsten wire for best performance.
- Life expectancy of Wire EDM is long…because there are little mechanical forces in EDM, and most machines are replaced due to performance and electronic obsolescence.
- Wire EDM machines do require TLC, and structured pro-active maintenance is a key operating factor for reliability.
- Wire EDM’s do have consumable components that require replacement over time (Wire Guides, Filters, Di-Ionization Resin, Rollers, etc.), and the amount of parts and intervals on replacement vary GREATLY between the different machine tool OEMs and also the type of application and accuracy requirements being performed.
- From the type of work you have described, the maintenance and life of the consumable components should be minimal, but the life of a typical Wire Guide is 2,000 to 3,000 machining hours.
- The long-term cost of Wire EDM operations (includes costs of wire, wire guides, filters, rollers, resin, etc.) should be in the range of $5 to $6 per hour
- The installation of the machine on a polished concrete floor in a clean office-type environment is EXCELLECT!
- Please let me know if you would like to have a direct discussion to talk in greater detail…I can be reached at 248-921-2474
- Here are some additional helpful links:
Makino Webinar on Wire EDM Maintenance:
The true operational impact of wire edm maintenance. | Makino
EDM Today article on Machine Installation:
EDM_Today_Winter_2018
- Brian