Taiwan Breaches Tech Barrier to CNC Wire-Cut EDM Market

Harsh competition from mainland China and Southeast Asia is forcing Taiwan's manufacturers of conventional and computerized electric discharge machines (EDMs) to develop higher value-added products, including computerized numerically controlled (CNC) wire-cut EDMs, over the past few years. The effort is part of an overall industry strategy to compete on performance rather than chase lower-cost rivals to a profit-thin future.

According to one industry insider, Taiwan controls up to 70% of the world's conventional EDM market. To rev up production of high value-added products, some domestic manufacturers in this line have been trying with mixed results to secure core technology for producing high-end wire-cut machines.

To help resolve the technology bottlenecks faced by local EDM producers, the government-backed Industrial Technology Research Institute has been developing and transferring to the private sector core technologies for the production of CNC wire-cut machines. The new technology is helping some local firms to compete with larger rivals in Japan and Europe.

According to customs statistics compiled by the Taiwan Machine Tool Foundation (TMTF), exports of Taiwan-made EDMs amounted to US$60.309 million in the first five months of this year, up 29% from the corresponding period of last year,

Hong Kong and mainland China together formed the largest export outlet for the products in the first five months of this year. The U.S. stood at second place, followed by Turkey, Thailand, Holland, South Korea, United Kingdom, Vietnam, Italy, Malaysia, Germany, Japan, Singapore, Indonesia, India, Brazil, and Canada.

The outlook for Taiwan's EDM manufacturing industry is promising as many manufacturers in this line have seen substantial growth in demand. TMTF chief executive Wang Cheng-ching expects domestic EDM manufacturers to enjoy an order surge from both domestic and foreign markets, including mainland China, Southeast Asia, Southwestern Asia, the U.S. and East Europe, in the months ahead.

Catching Up with the Leading Brands

Accutex Technologies Co., Ltd. Was founded in 2001, but the young company has already grown exponentially to become one of Taiwan's leading technology oriented manufacturers of high precision, high quality wire-cut EDMs. Accutex claims says its machines can compete with the world's leading brands, such as Agei, Charmilles, Mitsubishi, Sodic, Fanuc, Makino, Seibu, and ONA, on functions, accuracy, surface roughness, and automation.

The company's machines use the electrolysis-free (EF) power-machining method, which can reduce wire consumption by 10% up to 15% and boost life span of the press molds by as much as six times.

Although the company is still in its early years, its officials say that their research and development team has more than a decade of experience in developing EDMs. Thanks to their dedication, Accutex's machines are equal in quality to those made by top Japanese suppliers, the company says.

The company has developed nine models, including five flushing and four submerged types, with working sizes of 350 x 250 x 220mm to 1, 100 x 650 x 500mm.

The officials claim that their EF power-machining system, which is used as their standard discharging unit, achieves an average surface roughness of 0.004 to 0.005 meters after completing the third cutting process. If even better surface roughness is required, buyers can choose the option of using micro-sparking technology to achieve an average roughness of under 0.0013 meters.

Accutex president Chang Jui-chen says that his firm is dedicated to the development of cutting-edge technology, and to the maintenance of its reputation for superior technology in the global arena. "Our strong R&D department will support the continuous development of more sophisticated production technologies in the field of wire-cut EDMs, " he emphasizes. "In the months to come, we'll make an all-out effort to develop a super high speed EDM that will reduce surface roughness to 0.001 meter or better. We are also developing a super high precision machine with ceramic insulation, which I expect to increase the value of our products by more than 30%.

The president goes on to say that Accutex has adopted a unique wire-feeding and annealing system that keeps threading time under the industry minimum of eight seconds. The system boasts a 90% success rate in break-point threading and has start point holes as small as 0.4mm.

Accutex has built up a solid foundation for the sale of its products in Taiwan, mainland China, South Korea, and North America, and within the next few years it expects to tap the European market. The company believes that its revenues will continue growing in 2005 as demand from these markets rises.

Branded Quality

Jiann Sheng Machinery & Electric Industrial Co., Ltd., founded in 1982, specializes in the development and production of EDMs and wire-cut EDMs.

Jiann Sheng uses 'JS' brand on most of its EDM output, with some products supplied on an ODM (original design manufacturer) basis for both domestic and foreign manufacturers.

The company earned its ISO-9002 and CE mark approval in 1997, demonstrating its capability in terms of both product quality and corporate management. In addition, the company's products have been granted the "It's Very Well Made In Taiwan" award by the Ministry of Economic Affairs (MOEA).

With strong development capability and expertise in high precision EDMs, Jiann Sheng has a very wide range of product lines, including conventional EDMs, CNC EDMs, wire-cut EDMs, and drilling EDMs. Unit prices of the company's product lines range from US$15, 000 to US$78, 000.

Andy Liang, general manager of the company, says his company is one of the few manufacturers in Taiwan able to produce a complete range of EDMs. Thanks to its long-term efforts to develop innovative products, the company is now developing a series of advanced EDMs to further fill out its product lines.

The company says it can develop high-performance EDMs to cope with the need of the 3C (consumer electronics, communications, computer) industry.

The company's CNC-EA700L EDM features a 900 x 600mm worktable and 1, 400 x 800 x 500mm work tank. The unit has a 300mm spindle travel and 200kg electrode loading weight.

Its W-A50-series wire-cut EDM adopts C1-class precision ballscrews and linear guideways driven by AC servomotor to ensure highly accurate positioning. The machine is made of high-grade heat-treated Meehanite cast iron, which can prevent the machine from heat deformation during long periods of operation. The W-A35 series has an optional automated threading mechanism.

Jiann Sheng's EDMs are widely welcomed by many specialized manufacturers in various industries. The company's major export outlets are mainland China, South Korea, the Philippines, Vietnam, Malaysia, Indonesia, Thailand, India, Germany, France, Spain, Portugal, Belgium, Britain, Australia, Austria, Sweden, Denmark, the U.S., Canada, and New Zealand.

Growing Fast

Ho Chen Mechanic Electric Industry Co., Ltd. Is one of Taiwan's newest producers in this line, though its management team brings extensive industry experience.

Company sales manager Chen Chih-hsiung says his company is dedicated to offering a full range of EDMs. The company currently supplies CNC, Z-axis programmable, and conventional EDMs. Wire-cut models will be added to its product line in April next year.

At present, the company's most popular item is the H210+E100 CNC EDM, which features a 2, 000 x 1000mm worktable and a 2, 000 x 1, 000 x 600mm in X, Y, and Z-axis travel. The machine can processes workpieces in dimensions up to 2, 900 x 1, 500 x 700mm.

Made of high-quality cast iron tempered to relieve stress, the machine structure was designed using advanced computer-aided design system to ensure deformation-free performance and high accuracy machining after years of operation. The table surface is hardened by high-frequency heat treatment for maximum wear resistance. Precision ballscrews on the X-axis and Y-axis can smooth transmission and deliver high-accuracy traverse.

Ho Chen's EDMs are equipped with an industrial-grade computer controller with a 15-inch user interface for easy operation. The controller can store up to 100 sets of machining files, with each set containing 10-step automatic machining sequences. The entire machining cycle, from coarse machining to fine finishing, is fully monitored and displayed.

Chen says his firm's products have been sold domestically and exported to mainland China, Malaysia and South Korea. "We are preparing to develop the U.S. and European markets next year when our wire-cut EDMs are introduced, " says Chen.

The company uses "Ho Chen" brand in its products, but OEM (original equipment manufacturer) and ODM orders are also welcomed. The company says it can develop new models according to customer designs. For instance, the company has just received an order from a Malaysian customer seeking a CNC EDM with a 3, 000 x 1000mm worktable. The order will be filled in March next year.

Currently the company uses a self-developed personal computer (PC)-based control system running MS-DOS system. The company plans to develop a Windows-based control to facilitate sales to the U.S. and European market next year.

On the Cutting Edge

Joemars Machinery & Electric Industrial Co., Ltd. Was founded in July 1989 by Chen Shun-yuan to manufacture high-quality automated EDMs backed by comprehensive after-sale services.

Thanks to its long-term efforts to develop cutting-edge manufacturing techniques in the EDM arena, the company has won many awards, including the "It's Very Well Made in Taiwan" award presented by the MOEA. The ISO9001:2000-certified company says its products are approved by such standards as CE and EMC.

The company boasts it has edged ahead of rivals in the EDM field in the area of quality, thanks to its strict inspection system. A majority of its output is exported, and sales have been surging ahead at a double-digit pace over the past several years.

At present, the company focuses on the production of CNC and sophisticated conventional machines, including wire-cut EDM, CNC/ZNC EDMs, small-hole drilling EDMs, and broken tap removers.

The company's HD-series three-axis fully automated CNC EDM adopts a Heidenhain TNC416 controller. The machine uses the most advanced 'L.W.F.' circuits to decrease electrode wear, especially at the sharp corners. X, Y, and Z axes can move simultaneously for machining high-precision, sophisticated molds. The CNC power supply unit is designed with module boxes to allow easy maintenance and service.

Recently the company introduced a new series of auto wire-threading EMD dubbed AWT series. The new series provides wire-threading functions for fully automated wire-cutting process.

The company's AWT455S-model CNC EDM features 750 x 650 x 255mm in maximum workpiece dimension, and 450 x 300 x 250mm in X-, Y-, and Z-axis travel.

The company says it has sold products to more than 43 nations, including mainland China and Hong Kong, the United Kingdom, the United States, Thailand, South Korea, Singapore, Malaysia, Italy, France, the Netherlands, South Africa, and Egypt.

Joemars established a subsidiary named Changzhou Joemars Industrial Automation Co., Ltd. In mainland China in 1997 in order to tap the huge market there.