Programming a part on the MV2400S

Supplying the demanding Formula One (F1) industry is not something that every sub-contract manufacturer can achieve, but Hampshire-based Premier Precision Tooling (PPT) has been working with F1 teams and the supply chain for more than 20 years. To service this fast-paced and highly demanding sector for two decades is a challenge the company relishes — something that is simplified and streamlined by the application of Mitsubishi EDM machines supplied by the Wellesbourne-based Engineering Technology Group (ETG).

As one of the UK’s leading providers of sub-contract EDM services, PPT also works with customers in the wider motorsport, aerospace, marine, oil and gas, medical and toolmaking sectors. To deliver first-class quality, precision and service levels, the company has invested in a variety of Mitsubishi wire and spark erosion machines down the years with a plant list that includes the MV1200S, MV1200R, MV2400S and MV4800S wire erosion machines, the Mitsubishi EA12S and EA12D spark erosion machines and a Mitsubishi ED24 EDM hole drilling machine.

Adding to this comprehensive list, the ISO:9001 company installed two new MV2400S wire erosion machines in November 2022. Discussing why the company has committed to Mitsubishi machine tools, Chris Arnold, one of the three directors at PPT, said: “The company opened for business in 1997 and we had our first Mitsubishi EDM machine from the start. We started with the Mitsubishi CX20 wire EDM and this was followed by a second machine before we grew our business and moved to the second- and third-generation Mitsubishi FX20 and FA20 wire machines.”

Huge leap forward
“Up until 2010, we bought a number of these machines as the quality, reliability and service was exceptional and that year we bought our first machine of the fourth generation, the MV1200S which proved to be a huge leap forward in terms of technology.”

The Waterlooville company operates several machining centres with a comprehensive plant list in the inspection department — but it is the Mitsubishi EDM machines that are centre stage at Premier Precision Tooling.

The eight-employee business manufactures anything from prototypes and small batches through to production runs upwards of 2,000-off on its EDM machines. This can include anything from shims, tools, jigs and fixtures, and gearbox components for the F1 market through to splines and keyways for aerospace engine parts. With the facility to machine multiple parts in a single set-up from materials as diverse as copper, aluminium and titanium through to carbide, steel and a host of other materials.

Mr Arnold added: “75% of our workload is wire EDM, another 15% is spark erosion and we have a small percentage of milling; it is a mix that is uncommon in most machine shops — but it is where our expertise lies. Our Mitsubishi machines will run unmanned overnight and when we are busy, the machines will run 24/7 with just two operators working across seven wire EDM machines. This is the advantage of investing in high-end technology from a supplier like Mitsubishi.”

‘Staggering shift in technology’
Looking at the first MV1200S machine that arrived in 2010, Mr Arnold said: “Compared to its predecessors, the machine was a staggering shift in technology. The MV Series took us from a 32-bit architecture to a Windows platform, the generators were far more powerful and the cutting speeds were much faster, making the machine more economical for our business. So much so, that we bought a second machine only a few months later. From that point, we have gradually replaced all our second- and third-generation machines with the MV Series.”

Mr Arnold added: “The two new MV2400S machines have replaced two older Mitsubishi BA24 machines that were both 15 years old. The older machines still performed very well, but their ability to run reliably unmanned was not particularly high due to the age of the technology and the precision of the automatic wire rethreading feature. With the new MV2400S machines, we can now run unmanned for an entire weekend in some instances. On our larger MV4800S, we can load a 20kg wire spool and run for 55hr without intervention.”

A component being processed on the MV2400S

Mr Arnold explained: “The new MV machines are at least 25% faster than the previous BA24 series and the auto wire re-feed is 100% precise and reliable for prolonged unmanned running, which was an issue with the previous machines. As a company that can run 24/7 when we are busy, maximum uptime is of critical importance to our business.

“Equally important is the economical benefits of the new technology. With energy and consumable costs climbing, every business has to be conscious of this. With the new installations, the machines are at least 15% more energy efficient, as the more powerful generators can cut faster with less power required. Additionally, the machines are using less wire while they are cutting faster. For example, a 10kg reel of wire can last for 30hr and cost anywhere between £130 and £150 — if we can reduce the wire consumption by 15% and run faster, this is a significant cost saving.”

He added: “The touchscreen control and intuitive software functions are also making a huge difference to our programming times, and we are only scratching the surface. The programs are easy to create and edit. As a company that has had Mitsubishi machines for more than 20 years, we can be somewhat set in our ways. However, we are continually learning new features and functions and realising the benefits we can reap from the machines.”

Mr Arnold concluded: “Additionally, we have known the team from ETG for over 20 years and they are there to offer us support and guidance as we evolve to the next generation of technology. We would not go anywhere else for our EDM technology and we will continue to equip our business with the latest technology as we move forward.”