Swiss company GF Machining Solutions has launched a new range of wire EDM machines called CUT X at its Losone factory. These machines aim to challenge traditional EDM technology. They come in two models: the CUT X 350 and the CUT X 500. The CUT X 350 can work with parts up to 800 x 550 x 250 mm, while the CUT X 500 handles larger parts up to 1,050 x 700 x 250 mm.
Both machines offer high precision thanks to a new thermal management system and improved mechanical design. This system keeps the workspace temperature steady by using sealed cabinets and doors that trap cold air and control airflow. By isolating heat sources from the machine’s mechanics, the machines perform consistently even when external temperatures change.
The CNC control gathers data from temperature and humidity sensors placed inside and outside the work area. This data feeds into an artificial intelligence (AI) algorithm that predicts thermal changes and adjusts the positioning of the machine’s axes (X, Y, U, and V) accordingly. This AI adjustment maintains accuracy during long cuts and varying temperature conditions.
Another feature of these EDM machines is the ability to switch between open and closed wire guides on the same machine. Open guides suit straight cuts or taper angles under 3 degrees and handle different wire sizes without needing replacement. Closed guides deliver higher accuracy, faster cutting, and better surface finishes for taper cuts up to 30 degrees. The wire guides use interchangeable cartridges that operators can swap in less than 15 minutes.
The machines also include new upper and lower heads made with additive manufacturing. These heads reduce the gap between the wire guides and the workpiece, improving cutting accuracy. They also increase fluid flow for better flushing, which helps speed up the cutting process.
Operators control the machines via the UNIQUA human-machine interface (HMI), which features a 19-inch vertical touchscreen, a full keyboard, and a mouse. The interface supports legacy files from older EDM models and includes a graphic tool for programming both on and off the machine. It is compatible with major CAD/CAM software.
The CUT X machines offer flexible production with an automatic wire changer (AWC) that holds two identical wire circuits. This system allows operators to use a thick wire for fast rough cutting and a thinner wire for precise finishing cuts. It can also use two wires of the same size, with or without coating, to balance speed and surface finish.
To avoid wire breakage, the machines use Spark Track technology and an Intelligent Spark Protection System (ISPS). These monitor the spark position in real time and adjust the spark energy when needed to protect the wire and maintain cutting speed.
The machines feature 90-degree corner doors that open automatically. These doors provide easy access for operators and enable robotic loading and unloading. Additional automation includes a Z-axis touch probe that measures the workpiece’s top surface and aligns the wire accordingly. An automatic slug removal system moves waste pieces into a dedicated bin.
Wire handling is fully automated with features like automatic wire threading, an integrated wire chopper to reduce downtime, and a double-wire spool combined with AWC technology. These systems allow the machines to run continuously with minimal human intervention.
