Cost effective Wire EDM recommendation?

So here I am, I learned to utilize wire work for mold design, but we're not able to control workflow as if it were in house (surprise!)
We're gonna need a wire sometime. Another problem is the "sipping from a firehose effect"...(How do I start?)

I'm knowledgeable on other machine tools(sinkers, mills, grinders, lathe, deckel, etc), this is a new one however...
If you guys could give me some tips and pointers I would really appreciate it!

Thanks alot in advance guys!
Regards,
-Frito

P.S. If you don't mind, I'm going to maintain this OP to keep my current thoughts on top.

Needs:

1. Accurate
   
   I need it to be accurate to <.0001", and simply maintainable to keep it there.
2. Relatively short learning curve for someone familiar with sinkers
3. XY +VU
   
   Needs to be able to do tapers/undercuts
4. Space efficient
   
   We have limited real estate in the shop. That said, accuracy and value may outweigh size
5. Simple wire change a plus
   
   Down to .003-.004 wire reliably preferable (not prone to breakage).

My understanding at this point is that a 90's Agie would be my best bet, but not tech supported from GFAC.

I don't know where parts could be had other than ebay

Is the control a pain?

Post processor needed?

I also understand that a Brother was really good in it's time, but died with some Swiss government thing...
I've heard that Mits makes a good one (POCO had a sinker in their classroom 12yrs ago when I went down there for learning about the graphite side)

Current questions:
CAM needed for production?
Is G-coding these a pain?

What about g-coding for tapers/4axis?

Talk to Larry McNamee at edmsupport.com. he can assist you with all the details of the 90's Agie wires, he has parts and an excellent service tech to support those machines.


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Quote:

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Originally Posted by mdynac

Talk to Larry McNamee at edmsupport.com. he can assist you with all the details of the 90's Agie wires, he has parts and an excellent service tech to support those machines.


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Thanks alot for the speedy reply!
I really appreciate it.
-Frito

I have run Mitsubishi machines and we have been quite happy.

I don't know if maintenance is "simple" for any wire machine, especially an older one if you go that route.

At least my experience is that for an older machine, going from .008" wire to .004" wire triples the cost, and auto threading goes out the window. I seem to remember it taking me up to an hour to thread my first couple of jobs on our then 20 year old machine...luckily there haven't been too many of them.

For wire machines you can get by with Bobcad for CAM...it's nice to have Esprit with it's built-in settings and such but not absolutely necessary. Tapers at least with Mits are easy to add into your G code as an "A" value once you set the proper Z values for the head height and where the pivot points are on the guides.

@sybilsurf,
Thanks for the insight on .004 vs .008 wire.
AND with the coding simplicity. I already use GibbsCAM, which offers a wire module upgrade, but it may be cost effective to get a seat of Bobcad just for the wire.

Branching into new machine tools is always alot like sipping from a firehose... You know you need the water, but there's soooo much going on, it'll rip your lips off.
...It's a love+hate thing. (chair)

-Frito