I like the simplicity of your chopper. On the commercial machines I have run they put the copper right behind the pinch rollers in the back of the machine. Now their choppers chop the wire into around 3-4 mm long pieces. Because of the design if they don't vary the speed of the chopper to match the wire speed it will jam up into the chopper and usually cause a short. Or the wire will spool out everywhere (It usually does both). Also the cutter head is a special cutter and carbide cut/guide the wire passes thru are expensive. Not to mention the motor that runs the thing. And if you don't have spares. You are in trouble if they need to be replaced and are in the middle of a job. The wire chopper on commercial machines was, for me the most troublesome thing on the machine.
That's effectively what the machine shop I work for does with their commercial (non-diy) EDMs. There is a acrylic box (one per machine) about 3' on each side that the spent wire spools into. Then when it fills up, they dump it into the brass scrap bin.
It makes poor use of space. The guy above me said that theirs is 27 ft^3, and it will probably only accept 10% of the wire you can fit if you chop it. Then you have problems with being able to stuff thin wire into the box as it gets more and more full. Ever hear of "pushing rope"?
You can use ceramic cutting edges, or insulate it by plastic mounting brackets? Makino never did a cutter like Mitsubishi, they squeeze the wire between the pitchrollers so the wire will form a good ring in the trash bucket. Works really good, but you need more than a 10l bucket for that. As edge precision said it's a pain in the ass on most commercial ones, and they are built good, but still need alot.of maintenance.
This is just awesome! I would have let the feed tube go in tangentially on the lid and placed the chopper rotating radially in the bucket though, to leave more headroom for the cut wire. I suppose that would make the bucket too heavy to carry if it ever got that full.
Great build ! I'm sure this question has been answered before but exactly why are you not reusing that wire more than once ? After all, a wire is a wire.
Hi nice job, on my charmilles 510 ( open flush ) it has crimping rollers on the bottom head so as the wire goes through the feed rollers it crimps and then the wire stays flat in the bottom of the machine and after we have run 15k meters of wire i pull out and put in a rig and compress to make a mini bail the scrap people dont like it loose.
I am following this project right from the begining, and a wire edm would be the last important thing for my hobby shop. However, one thing I am worried about is all the pumps and water filtration systems that are needed. Can you make a detailed video on that? Without those in mind, I cannot estimate a cost on how much it would cost me to build such a machine. Thanks! :)
I wonder if you could use a really old-school 3 phase synchronizer setup to make the cutter speed track the wire speed; if not that then perhaps an encoder and a stepper.
A new spool costs about 80 Euros, and has 12.000 meter wire on it. With an average speed of 6 meter/minute you can machine 2000 minutes or 33.3 hours. The wire cost is then 2.4 Euro/hour. This is an average, the wire speed must be higher for some parts.
This chopper would be a nice add- on for a 3d printer extruder so it could print in place carbon or dyneema wire like the anisoprint composer or markforged dual extrusion.
I don't know much about EDM other than how cool it is. I am however surprised that the wire has to run that fast: How much is on a typical spool anyway? I've looked at your videos of the MK2, and it is awesome. Wouldn't mind building one some day.
Actually the chopper will only be electrified if you chose to make the parts out of conductive material, if you use a ceramic cutting edge there will be no back feed into the EDM machine itself.
Thanks for letting me know. I also saw it. I'm looking forward to seeing his wire-EDM build come together. He's acquiring all the key components first. Will probably take quite some time as he is working on so many different cool projects.
making it mostly 3d printed or out of wood (maybe with a metal insert on the face for the cutter to rest against) seems like an easier option if you were to do it again.
Wouldn't it be easier to drill out the hole on the cutter arm and add a machined/3D printed plastic spacer in between the motor shaft and the cutter arm? That way you wouldn't have to redesign really anything, and you gain the ease of controlling the cutter with your cnc controller.
using a file for making the D-shaped hole out of a round hole... must be with the thickening file which adds material rather than removes it. I was told about that kind of tool when I was an apprentice, unfortunately I never managed to find one.
Neat idea and implementation. But, I'm a bit shocked you didn't just isolate those little cutting heads. Just a shim of plastic would have done the trick.
Nice. The chopper on the Charmilles machines I use spit the chopped wire out with some water because it chops it in the lower head. You get wet wire in a bucket 😒
Put a scale under your bucket!... I made the mistake once to wait too long.. i was thinking "oh.. there's only a little bit of brass in the bin".. but.. it is brass.. it is HEAVY.. , i'd suggest, making a mark on the bin, when there's like 10 Kgs in there..you will thank me for that if you forget, and fill the bin completely.. :)
Interesting, the auto-subtitling function of TH-cam doesn't work because it identifies it incorrectly as being Dutch language instead of English. Maybe the language can be set by the content creator when the video is uploaded?
There's more to ToT's style than hands in front of the camera. This complaint makes about as much sense as "all the other newsrooms can't have the anchorman/woman behind a desk looking at the camera, because X news channel used the format first." Even if that bit from ToT was copied, it can be interpreted as an homage to ToT. Imitation is the sincerest form of flattery, and all that.
I don't see the comparison, nor would I think there were an issue if they actually were similar. This style is common on this type of make video. ToT is unique due to his commentary, not camera work.
Hi Tony! Looks like the hand moisturiser is working; much smoother.
LOL
After seeing the first frame I immediately scrolled down to the comments. Thank you for not disappointing me! :)
I like the simplicity of your chopper. On the commercial machines I have run they put the copper right behind the pinch rollers in the back of the machine. Now their choppers chop the wire into around 3-4 mm long pieces. Because of the design if they don't vary the speed of the chopper to match the wire speed it will jam up into the chopper and usually cause a short. Or the wire will spool out everywhere (It usually does both). Also the cutter head is a special cutter and carbide cut/guide the wire passes thru are expensive. Not to mention the motor that runs the thing. And if you don't have spares. You are in trouble if they need to be replaced and are in the middle of a job. The wire chopper on commercial machines was, for me the most troublesome thing on the machine.
Edge Precision what type of machine do you have?
@@tryingtolearnthis If you are referring to the wire EDM. I just recently sold it. It was a Mitsubishi FX20 machine.
Edge Precision oh yeah newer mits machines wire processors are much better and typically only jam when the cutter blades are dull.
I'm probably overlooking something, but if you're having trouble getting the wire on and off the spool, why not just put it in a bucket?
That's effectively what the machine shop I work for does with their commercial (non-diy) EDMs. There is a acrylic box (one per machine) about 3' on each side that the spent wire spools into. Then when it fills up, they dump it into the brass scrap bin.
It makes poor use of space. The guy above me said that theirs is 27 ft^3, and it will probably only accept 10% of the wire you can fit if you chop it. Then you have problems with being able to stuff thin wire into the box as it gets more and more full. Ever hear of "pushing rope"?
@@xenonramone does bot simply take 27ft^3 of brass choppings and go dump it in the scrap bin. it would weigh 6 or more tons.
You can use ceramic cutting edges, or insulate it by plastic mounting brackets?
Makino never did a cutter like Mitsubishi, they squeeze the wire between the pitchrollers so the wire will form a good ring in the trash bucket. Works really good, but you need more than a 10l bucket for that. As edge precision said it's a pain in the ass on most commercial ones, and they are built good, but still need alot.of maintenance.
Same is done by Sodick..
This is just awesome!
I would have let the feed tube go in tangentially on the lid and placed the chopper rotating radially in the bucket though, to leave more headroom for the cut wire.
I suppose that would make the bucket too heavy to carry if it ever got that full.
Great build ! I'm sure this question has been answered before but exactly why are you not reusing that wire more than once ? After all, a wire is a wire.
After a cut, the wire is not the same diameter. when it erodes the material, the wire is eroded too.
Thanks for this video, really enjoy seeing your solutions and hard work paying off.
Hi nice job, on my charmilles 510 ( open flush ) it has crimping rollers on the bottom head so as the wire goes through the feed rollers it crimps and then the wire stays flat in the bottom of the machine and after we have run 15k meters of wire i pull out and put in a rig and compress to make a mini bail the scrap people dont like it loose.
I am following this project right from the begining, and a wire edm would be the last important thing for my hobby shop. However, one thing I am worried about is all the pumps and water filtration systems that are needed. Can you make a detailed video on that? Without those in mind, I cannot estimate a cost on how much it would cost me to build such a machine. Thanks! :)
Bruce Lortz you also need resin filters to change the conductivity of the water. Its not so simple. :)
I will do a video on that too. Also keep an eye on Werner Berry's channel, his video on the water system will probably be more detailed than mine.
a polymer bushing probably would fix the isolation if you ever redid this -- also might be able to just coat the shaft in like kapton tape
Good solution, but makes me wonder about drawing dies and if the wire would be reusable if you could make it uniform again.
I wonder if you could use a really old-school 3 phase synchronizer setup to make the cutter speed track the wire speed; if not that then perhaps an encoder and a stepper.
The style of the shots with the "talking hands" really reminds me of This Old Tony
I wonder, how much does the wire cost per hour? , can you maybe give an example with wire cost?
A new spool costs about 80 Euros, and has 12.000 meter wire on it. With an average speed of 6 meter/minute you can machine 2000 minutes or 33.3 hours. The wire cost is then 2.4 Euro/hour. This is an average, the wire speed must be higher for some parts.
it is simple, easy to find and replace carbide tips, the size of the cut wire is good and does not make much noise, I really like the idea 👏🏻👌🏻
Why did you bother chopping the wire? Surely you could just have it pile up in the bucket if you're just going to recycle it anyway?
This chopper would be a nice add- on for a 3d printer extruder so it could print in place carbon or dyneema wire like the anisoprint composer or markforged dual extrusion.
Couldn't you make the Chopper horizontal so that you utilize more of the bucket?
what is the diameter of the wire going out versus coming in? How do you adjust the wire speed so that a maximal amount of wire is used per cut speed?
How has this worked 4 years on any changes you’d make?
I don't know much about EDM other than how cool it is. I am however surprised that the wire has to run that fast: How much is on a typical spool anyway?
I've looked at your videos of the MK2, and it is awesome. Wouldn't mind building one some day.
Would a pneumatic motor be an option, or are they a lot more expensive?
Actually the chopper will only be electrified if you chose to make the parts out of conductive material, if you use a ceramic cutting edge there will be no back feed into the EDM machine itself.
In case you didn't know. Marco Reps showed his baxedm arc generator in his latest video.
Thanks for letting me know. I also saw it. I'm looking forward to seeing his wire-EDM build come together. He's acquiring all the key components first. Will probably take quite some time as he is working on so many different cool projects.
Have you ever considered building a molibdenum wire edm?
It's less accurate but is way cheaper to run
Is it possible to reuse that wire? I mean not the cut one, but the intact one. If not, why?
It shrinks in diameter after being used for a cut. The arc erodes the stock material and the wire more or less equally.
making it mostly 3d printed or out of wood (maybe with a metal insert on the face for the cutter to rest against) seems like an easier option if you were to do it again.
Great design , very simple
Wouldn't it be easier to drill out the hole on the cutter arm and add a machined/3D printed plastic spacer in between the motor shaft and the cutter arm? That way you wouldn't have to redesign really anything, and you gain the ease of controlling the cutter with your cnc controller.
using a file for making the D-shaped hole out of a round hole... must be with the thickening file which adds material rather than removes it. I was told about that kind of tool when I was an apprentice, unfortunately I never managed to find one.
Awesome project, would you be willing to share the files with me?
Neat idea and implementation.
But, I'm a bit shocked you didn't just isolate those little cutting heads.
Just a shim of plastic would have done the trick.
It would have to be a lot more involved than a shim of plastic. It has a screw running through it.
@@xenonram Nylon screw...
Great job!
someone is a fan of thisoldtony.
Couldn't you just insulate the cutter-motor shaft-blade, and the cutter anvil with insulators so that you could use any grounded cutter power supply?
You don't want any HF EDM current flowing thru any of the motors' bearing in the first place, rite?
This is nice, great job awesome build
Nice. The chopper on the Charmilles machines I use spit the chopped wire out with some water because it chops it in the lower head. You get wet wire in a bucket 😒
Put a scale under your bucket!... I made the mistake once to wait too long.. i was thinking "oh.. there's only a little bit of brass in the bin".. but.. it is brass.. it is HEAVY.. , i'd suggest, making a mark on the bin, when there's like 10 Kgs in there..you will thank me for that if you forget, and fill the bin completely.. :)
could you not just empty the wire into the bucket without the cutter or the spool?
Even at that low of RPM, I'd be a little worried about balance, any offset is bad offset if not balanced properly
Or you could isolate in a plastic cavity one of the carbites!
use a ceramicinsert to cut and it is isolatet.
Subscribed!
Do u have a cad file for this
It's a good idea anyway!
pars tondar
1 second ago
your works and your idea is so great please keep going .
very co
great video, just work little bit on your audio, like cutting out swallowing of saliva :D
я сматываю использованную проволоку и использую второй и третий раз на неточных деталях
可以提供英文字幕嗎？不然不知道內容是什麼🤔？
Interesting, the auto-subtitling function of TH-cam doesn't work because it identifies it incorrectly as being Dutch language instead of English. Maybe the language can be set by the content creator when the video is uploaded?
Yo
Good content, but not cool that you're copying ThisOldTony's presentation style.
There's more to ToT's style than hands in front of the camera. This complaint makes about as much sense as "all the other newsrooms can't have the anchorman/woman behind a desk looking at the camera, because X news channel used the format first." Even if that bit from ToT was copied, it can be interpreted as an homage to ToT. Imitation is the sincerest form of flattery, and all that.
I don't see the comparison, nor would I think there were an issue if they actually were similar. This style is common on this type of make video. ToT is unique due to his commentary, not camera work.