|AgieCharmilles GF

|Application of Milling and Electric Discharge Machining

Application of Millingand Electric DischargeMachining

| 03

Introduction on High-Speed and High-Performance Milling

High Speed Cutting (HSC)

The typical application of this technology is the machining of complex three-dimensional

surfaces. As the specific parameter of the process may be considered the workpiece surface

machined per unit of time (cm2/min). NC programmes provide the geometric information eit-

her in form of coordinates or vectors. The data amount to be processed by the machine

control is a function of distance between the coordinates and the programmed machining

feed. Increasing machining feed demands improved calculation speed and intelligence of the

control. High speed spindles are required to match the process. Mainly used cutting tools

are ball nose end mills, flat end mills and toric end mills from solid carbide.

High Performance Cutting (HPC)

In contrast to High Speed Cutting, this technology mainly is used for the machining of two-

dimensional geometries. The cutting depth ap and the stepover ap along with the machining

feed allow calculation of the material removal per unit of time (cm3/min). This process in

particular is suitable when it comes to the removal of large volumes of material or the

machining of difficult to cut materials. High power, high torque spindles are a must. Primarily

used cutting tools are insert type milling heads, specific high performance end mills, drills,

boring heads and special tooling.

The preceding definition is primarily directed towards the extreme facets of both processes.

In reality the limit between High Speed Cutting (HSC) and High Performance Cutting (HPC)

is not static, in fact it overlaps. The analysis of application and environment typically decides

about which process will result in optimum machining performance.

04 |

Introduction on Electric Discharge Machining (EDM)

Two conductive materials (electrode/workpiece) submerged in an insulating liquid, are con-

nected to a source of current which is switched on and off. When the current is switched

on, an electric voltage builds between the two parts. If the parts are brought together to a

certain distance, the voltage is discharged and a spark jumps across. Where it strikes,

the metal is heated up so much that it melts. Innumerable such sparks spray one after the

other (never simultaneously), and gradually shape the desired form in the piece of metal.

Several hundred thousand such sparks must fly per second for efficient EDM.

Two different processes

Die-sinking EDM

In the case of die-sinking EDM, the required shape is formed in the workpiece with a

three-dimensional electrode. By superimposed movements in the main axes X, Y, Z, C, varied

shapes, indentations and cavities are created, such as cannot be achieved by any other

machining system.

Wire-cut EDM

In the case of wire-cut EDM, the metal is cut with a special metal wire electrode. The wire

travels along a pre-programmed path. By differing movements of the upper and lower wire

guides, angled or conical surfaces can be produced to the highest accuracy and with the

finest surface finish.

Powerful technology

The performance of modern EDM equipment is extremely high: high cutting speeds, highly

efficient automation, interlinking and storage of very long and recurring machining cycles.

And thanks to electronic monitoring and fully automated correction of the EDM process, no

supervision is required.

06 |

Electric Discharge Machines (EDM)

High-Speed and High-Performance Milling Centers

HSM Spindle Technology

Tooling / Automation

Consumables

AgieCharmilles GF

Brands and Products

Contact

www.agiecharmilles.com

| 07

AgieCharmilles GF

AgieCharmilles GF is the world’s leading provider of machines and system solutions to the

tool and mold making industry and to manufacturers of precision parts. It is the GF

Machine Tools Group of its majority shareholder Georg Fischer. AgieCharmilles GF’s pro-

ducts range from electric discharge machines (EDM) and high-speed (HSM) and high-

performance milling (HPM) centers through tooling, services, spare parts, wear parts and

consumables to automation solutions. EDM and HSM are the two key technologies in tool

and mold making. They are indispensable in the manufacturing of molds and press tools

for the series production of plastic, metal and glass parts and for the machining of high-

quality precision components. As a globally active group, AgieCharmilles GF maintains a

presence at 50 sites worldwide through its own organization.

AgieCharmilles GF views focusing on customers' needs as an integral factor in success.

The Group has longstanding trust-based relationships with many of its customers, often

stretching back to the founding of the customer's business. The values the market most

frequently attributes to AgieCharmilles GF are high quality, precision, reliability and out-

standing professionalism in service and technical support. AgieCharmilles GF owes its

growth in a difficult market environment and its installed base of over 100,000 units

worldwide to this customer-centric approach.

08 |

AUTOMOT

Production of complex components as well as cavities and tools for

the production of plastic parts, castings, forgings and stampings.A

uto

mo

tive

| 09

O-IVE

Iterations into the early

stages of the produc-

tion cycle. Lifecycle-

management and cost

pressure demand

flexibility and integrated

processes leave no

room for error. Partner-

ship demands trust,

reliability and coopera-

tion.

10 |

MOTSPOR

Mo

tors

po

rtProduction of high-value components.

| 11

TOR-RTNew regulations, individual requirements, local characteristics,

consecutive product improvements, exotic and partially new

materials result in an eternal prototype stage. In-time delivery,

despite the need for flexibility and calculated risk, makes winners.

12 |

AERONTIC & ASPACEA

ero

na

uti

c &

Ae

ros

pa

ceProduction of complex, high-value components in

high-temperature resistant alloys, titanium, aluminium

and other materials.

| 13

NAU-AERO-

E

Costly tests and authoriza-

tion procedures, regulations

and difficult to machine

materials are the challenges.

Superior performance,

innovation and security are

equally important,

while the factor of eco-

nomic viability is

increasingly gaining

importance.

14 |

MEDICALIMPLANTSTRUMEN& APPLIAM

ed

ica

l Im

pla

nts

, In

stru

-m

en

ts a

nd

ap

pli

an

ces

Production of implants, instruments and components from corrosion-

resistant alloys, titanium or conventional materials.

| 15

L TS, IN-NTS

ANCES

Special demands for the biological compatibility of the materials used for implants as

well as the medical surroundings in general are impact production procedures and processes.

To go to new ways means high investments to transact, but new trends require new

approaches.

16 |

ELECTICS & MATRON

Ele

ctro

nic

s &

Me

cha

tro

nic

s

Excessively short product life cycles require flexibility, short

production times and leave no room for manual rework.

Controlled processes and automation are indispensable. New

technologies make innovative approaches possible and are

prerequisite for competitiveness.

| 17

RON-MECH-

NICS

Molds and tools for the mass production of plastic parts, castings, and stampings.

Production of chassis components and elements for high-value electric appliances.

18 |

HOUSHOLD

Ho

us

eh

old

Plastic injection molding, alu-

minium die casting, punching

tools as well as blow molds for

one-way packages, one-way

articles, mass ware and design

articles.

| 19

SE-D

Appliances and utensils for daily household use are diverse.

Exclusive design and customer requirements require

continuous research into new manufacturing approaches.

The expenditure for the production of seemingly ordinary

goods often is enormous, ensuring precision in details

where no one would suspect it.

A RELIAPARTNEA PASSIEXCELLE

ABLER WITH ON FOR ENCE

22 |

LEISU& SPOL

eis

ure

& S

po

rtProduction of parts from alumi-

nium, plastic, steel alloys or

other materials. Injection molds,

aluminium casting dies and

punching dies.

| 23

URE ORTS

New fashion trends in sport

and leisure generally are

interconnected with new

design. The one who reaches

the market first reaps higher

margins. Shorter time to

market and flexibility pay off.

24 |

GENERMACHG

en

era

l M

ach

inin

gProduction of parts for a multiplicity from applications

and in a large variety of materials.

| 25

RALINING

Lead time is the essential criteria in this sector. Flexibility and

short set-up times for individual parts and small batch production

are as important as autonomy and reliability with larger series.

26 |

LUXUGOODL

ux

ury

Go

od

sProduction of accurate parts or

for the luxury goods segment,

including designer pieces from

stainless steel, brass, titanium

or precious metal. Molds and dies

for the mass production of com-

ponents for trend and fashion

items.

| 27

URYDSExotic materials and intricate details, perfection in the detail and high customer

expectations result in a particular situation. These unique requests require

suitable concepts and specific know-how.

28 |

POWERGENERTION

Po

we

r G

en

era

tio

nMachining of high value components in temperature resistant

alloys; dies for the manufacture of semi-finished products.

| 29

RRA- Complex geometries and

extreme material char-

acteristics necessitate

special production pro-

cesses and concepts. The

advancement of tools,

machines and processes

provide potential for ra-

tionalization, their per-

formance decides on

the feasibility.

30 |

AUTOMAT

Au

tom

ati

on

Improvement in productivity, increase of flex-

ibility despite fluctuations in demand,

changing production priorities and the need

for the shorter lead time.

| 31

O-ION

The integration of production facilities into existing networks

and processes requires careful planning and implementation.

Multiple machine concepts and the combination of production

and control processes in production cells present new

ways of reacting to the challenges of a globalized market.

32 |

SERVICE ACADEMCOMPETECENTRES

Se

rvic

es

Aca

de

my

&C

om

pe

ten

ce C

en

ters

AgieCharmilles GF attaches great value to the superior

skills and continuing education of its staff. Personnel from

the areas of after-sales service and application must

demonstrate ability to understand and resolve our cus-

tomers’ problems. Through on-site support, training and

one-on-one advice, our staff provides optimal customer

support.

| 33

Y &ENCES

1200

1000

800

600

400

200

0 2002

526

2003

764

Jan-Jun 2005

485

2004

1039

The technological progress of machine tools and manufac-

turing processes requires a continuous learning process.

Fundamental and advanced know-how are taught in training

courses, while project-oriented workshops allow resolution

of individual issues. Know-how and the exchange of expe-

rience help to secure a technological lead and are an

important complementary service to the machine tool.

Trained participants within Service Academy

34 |

http://www.agiecharmilles.com/en/addresses.htmlM

ain

Lo

cati

on

s

Headquarters

Agie Charmilles Holding Ltd

Bundesplatz 1

CH-6300 Zug, Switzerland

Tel. +41 (0)41 711 13 76

Fax +41 (0)41 711 13 71

E-Mail info@agiecharmilles.com

Agie Charmilles Management

Agie Charmilles Management Ltd

Case postale 373

Rue du Pré-de-la-Fontaine 8-10

CH-1217 Meyrin 1 / Geneva, Switzerland

Tel. +41 (0)22 783 34 69

Fax +41 (0)22 783 32 68

E-Mail info@agiecharmilles.com

Agie Charmilles Management Ltd

Amsler-Laffon-Strasse 9

CH-8201 Schaffhausen, Switzerland

Tel. +41 (0)52 631 26 21

Fax +41 (0)52 631 28 68

E-Mail info@agiecharmilles.com

| 35

Agie Charmilles Management Ltd

Via dei Pioppi 2

CH-6616 Losone, Switzerland

Tel. +41 (0)91 806 91 11

Fax +41 (0)91 806 95 15

E-Mail info@agiecharmilles.com

North and South America

USA, Brazil

Europe

Germany, France, Italy, Netherlands /

Benelux, Poland, Sweden, Switzerland,

Spain, Czech Republic, Turkey, United

Kingdom

Asia

China, Japan, Korea, Malaysia, Singapore,

Taiwan, Thailand

Publishing details

Published by

Agie Charmilles Management Ltd

Concept & Text

New Applications & Technologies

Design concept & Layout

4th floor design, Switzerland

Printing

Tipografia Poncioni SA, Switzerland

|AgieCharmilles GF

|2006

Agie Charmilles Management SAVia dei Pioppi 2, CH-6616 Losone

Tel. +41 (0)91 806 91 11Fax +41 (0)91 806 95 15www.agiecharmilles.com

Adding Quality

to People’s Lives