gf machining solutions - agiecharmilles - edm hole drilling - model 300

GF Machining Solutions

DRILL 300AgieCharmilles

2 AgieCharmilles DRILL 300

Swiss design and quality

GF Machining Solutions : all about youWhen all you need is everything, it’s good to know that there is one company that you can count

on to deliver complete solutions and services. From world-class Milling, electrical discharge

machines (EDM) and Laser texturing machine tools through to first-class Automation, Tooling

and software systems — all backed by unrivaled Customer service and support — we, through

our Mikron, Liechti, AgieCharmilles and System 3R technologies help you raise your game and

increase your competitive edge.

The winning solution

High-speed EDM drilling

Fine hole quality

Powerful control

Quick preparation

High degree of autonomy and Automation


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Contents

DRILL 300The winning solution for cooling hole machining of components in aircraft enginesIn today’s aircraft engines, the temperature in the combustion chamber can be close to the melting point of the nickel alloy used. In order to create a film of cooling air on the surface of components to prevent the nickel alloy from melting, cooling holes are needed on the curved surface of com-ponents such as turbine blades, vanes, and shrouds. Machining these cooling holes with high quality and pro ductivity is always the main concern for aircraft engine component manufacturers.


The DRILL 300 is equipped with GF Machining Solutions’ latest

digital generator, allowing the drilling process to be continuously

optimized with every pulse. As a result the machining speed has

been increased significantly compared to conventional EDM drill-

ing.

Technology is chosen according to the desired results. For exam-

ple, by selecting “quality” technology, the electrode wear will auto-

matically be reduced and the heat-affected layer is reduced to a

few microns. Conversely, the operator can select “speed” technol-

ogy to produce holes with the fastest possible erosion rate.

With six-axis configuration, holes with different positions and an-

gles can be freely programmed and machined, allowing for great-

er part flexibility and design. Single setup machining reduces un-

productive time.

By using the automatic electrode/guide changer (AEC/AGC), multiple

holes with different diameters can be machined automatically and

the machine attains longest autonomy.

Due to wide range of optimized technologies for electrically conduc-

tive material like Inconel, steel and hard metal, the DRILL 300 is a

winning solution for cooling hole machining in aerospace as well as

other industrial applications such as cutting tools, automotive, med-

ical and die plates.

The GF Machining Solutions’ answer


With 60 years of experience building Electrical Discharge Machines, GF Machining Solutions has developed a new EDM drilling machine, the DRILL 300. This machine is manufactured in Switzerland to deliver top performance in machining cooling holes for aircraft engine components.


100 mm

60 mm

High-speed EDM drilling

Increasing your productivityThe EDM generator has state-of-the art powerful electronics to increase production output by utilizing efficiently controlled EDM processes that include FPGA technology, digital data recording and fully digitized pulse control. The drilling process is continuously optimized with every pulse, thus the fastest drilling speed is achieved.

Drilling time

Without breaktrough detection

With advanced breaktrough detection

20 mm100 mm

48 s280 s

Depth

Electrode: brass, Ø 1.0 mmWorkpiece: steelSpeed technology

Conventionaldrilling time

28 s170 s

DRILL 300drilling time

DRILL 300up to 40% faster

Conventional EDM drilling

DRILL 300

Steel

Hard metal

Inconel 718

Aluminium

Copper

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0.1 0.15 0.2 0.3 0.4 0.5 0.6 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.00.8

0.1 0.15 0.2 0.3 0.5 1.0 1.5

0.3 1.5

2.0 3.0

Copper

Brass

Carbide

0.8

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1.0

1.5 2.00.8

Fast and reliable breakthroughWithout breakthrough detection, the machining time at break-

through is even longer than the entire hole drilling time when the

flushing process breaks down. With advanced breakthrough detec-

tion on the DRILL 300, the process is monitored in a real time; the

technology is adapted automatically to exit technology; the reliable

process is attained and the breakthrough time is shortened by 50-

70 percent.


Steel

Hard metal

Inconel 718

Aluminium

Copper

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5

5 510

20

510

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40

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20

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60

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80 80

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510

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1010

202020

5 510

3 3 3

40

20

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0.1 0.15 0.2 0.3 0.4 0.5 0.6 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.00.8

0.1 0.15 0.2 0.3 0.5 1.0 1.5

0.3 1.5

2.0 3.0

Copper

Brass

Carbide

0.8

0.3 0.5 1.0

1.0

1.5 2.00.8

Optimal technologiesOne type of technology cannot meet all of your requirements. Ac-

cording to the workpiece material and your stringent metallurgical

requirements, the DRILL 300 has the optimized technologies to fo-

cus on either quality or speed. The quality technology achieves mini-

mum heat-affected layer and better hole integrity, while the speed

technology focuses on short drilling time.


Fine hole quality

The new standard in hole-drilling EDM

Minimum heat-affected layerHeated-affected layer has significant influence on the fatigue life-

time of components and the safety of aircraft engines. The DRILL

300 is designed for achieving the best result in terms of heat-affect-

ed layer and avoiding cracks in the components.

The DRILL 300 digital generator allows the finest pulse duration of

a few microseconds. When quality technology is used, the heat-af-

fected layer can be dramatically reduced to a few microns with a

reasonable machining speed.


with FirstSpark

without FirstSpark

Electrode: brass, Ø 1.0 mmWorkpiece: steel, 20 mm heightQuality technology

Consistent hole dimensionWhen machining cooling holes with conventional EDM drilling, the spatters at the hole entrance are always a problem, especially if there is a small angle between the hole and surface of components. The DRILL 300 has a fine pulse applied with the first spark function, then the technology is automatically adapted to the standard parameters. Therefore, the spatters in the hole entrance are avoidable and a perfect profile is achieved.

In order to optimize the machining of the most complex holes, the DRILL 300 provides the way of programming parameters corresponding to the machining depth. Multi- parameters can be used in the same hole.

With advanced breakthrough detection “Breakthrough Strategy” on the DRILL 300, the hole exit technology is optimized and the exit electrode length is programmable, and backstriking can be prevented. Meanwhile the quality technology also helps attain the

right hole dimensions at the bottom of the hole.


Powerful control

To manage sophisticated hole machining

CNC controlIn order to meet the demands of different applications, the DRILL

300 can be configured with different kinematics: XYZW, XYZWBA,

XYZWAB, XYZWB1C1, XYZWB1, XYZWAB1. With single setup the

holes with different diameters, positions and angles are freely pro-

grammable and machined.

Control unitThe graphical user interface is based on the Windows operating

system and allows real time control of the EDM process. The sys-

tem works with descriptive picture symbols and conversational

screen pages following one after another in a logical way. This al-

lows even new users to understand the EDM principle quickly and

means time to production is very short.


Manual operation – Easy DrillMain functions include all setup cycles, easy and fast program-

ming for single hole machining (one hole on one page) as well

as electrode and guide management.

Work preparationThe machine can import the entire work in the format of XML.

NCC, ISO.NCC and PAT.NCC (compatible with AC CAM DRILL) di-

rectly or prepare the work manually with TEACH function. The

parameters of every machining can be modified with Edition.

The work can be graphically checked.

Work executionThis page activates the work and executing measuring cycles. All

machining, parameters and hole positions are monitored on this

page.


Quick preparation

Single setup machiningWith different kinematics of six axes, holes with different

diameters, positions and angles can be freely program-

mable and machined even with single setup, allowing for

greater part flexibility and design. Single setup machining eliminates the need for additional expensive fixtures and avoids multiple setups to reduce unproductive time.

Reducing the un productive time

Fast setup cyclesThe universal console is equipped with the touchscreen based on

the Windows operating system. The setup cycles probe, edge find-

ing, corner finding, center finding, etc., help to prepare the job in a

convenient way.

Less down timeTo ensure the longest life and reliability of the electronics,

a closed water-air cooling circuit is contained within a dustproof

cabinet, in which the temperature is also monitored and stabilized

with multi-sensors.

With this design, the lifetime of the electronics is guaranteed even

in the most difficult conditions.


High degree of autonomy and Automation

Automatic filtration and conductivity controlWith the 200-liter water tank and a 10-liter resin bottle in a stand-

ard configuration, the water filtration and conductivity are auto-

matically controlled and cycled.

For maximizing productivity

Automatic part changerWith the optional Automation kit, the DRILL 300 can connect to exter-

nal robot to automatically manage part changing.

Automatic electrode/guide changerThe optional linear 16/4 electrode/guide changer and 50/8 rotary

electrode/guide changer are available on the DRILL 300. AEC/AGC

16/4 is affordable solution and AEC/AGC 50/8 is a solution with the

longest autonomy for max productivity.


DRILL 300

DRILL 300

MachineMachine dimensions (L x W x H) mm (in) Without tilting head: 2320 x 1400 x 2180 (91.34 x 55.12 x 85.83)

With tilting head: 2320 x 1900 x 2180 (91.34 x 74.8 x 85.83)Net weight kg (lbs) 2500 (5512) without variants and options

Machining areaElectrode diameter mm

in0.3 ~ 3.0 (option: 0.1, 0.2, 4.0, 5.0, 6.0)0.012 ~ 0.12 (option: 0.004, 0.008, 0.16, 0.20, 0.24)

Max. workpiece dimension mm (in) 1000 x 700 x 500 (39.37 x 27.56 x 19.69)Max. workpiece dimensionwith tilting/rotary axes

mm (in) Ø x L = 350 x 320 (13.78 x 12.60)

Max. workpiece weight kg (lbs) 1000 (2205)Max. workpiece weight with tilting/rotary axes

kg (lbs) 25 (55) including clamping weight

Worktable dimension mm (in) 800 x 600 (31.50 x 23.62)Worktable type 4 bars (2 stationary, 2 adjustable)Distance from table surface to floor mm (in) 850 (33.46)Accessibility Front

AxesTravel X x Y axes mm (in) 600 x 400 (23.62 x 15.75)Travel W x Z axes mm

in450 x 450 (650 optional)17.72 x 17.72 (25.59 optional)

Tilting/rotary axes (option) º ± 100 / 0~360Max. axis motion speed m/min. (ft/min) 4 (13.12)Measuring system for Z, W axes EncoderMeasuring system for X, Y axes Encoder (linear glass scales optional)Lubrication Manual

Dielectric unitDielectric type Industrial water or civil waterDielectric capacity l (us gal) 200 (53)Max. flushing pressure bar (psi) 80 (1160)Filter accuracy µm 5Capacity of deionizing bottle l (us gal) 10 (2.6)Cooling system Water/water heat exchanger

Technical data


DRILL 300

GeneratorGenerator type ISPGMax. mean working current A 60Cooling system inside cabinet Air/water heat exchanger

Numerical controlFlat screen 17” flat touchscreenKeyboard StandardMouse StandardStorage capacity > 230 GB HD, 1024 MB RamInterface port USB and EthernetMeasurement unit Metric/inchCommand format Absolute/incrementalCoordinates system Machine, partMax. number of machining in the program 500Servo controlled axes X, Y, Z, W, A, BImport files XML.NCC, ISO.NCC, PAT.NCCOnboard CAD/CAM AC CAM DRILL as standardFirst spark detection StandardElectrode wear compensation StandardBreakthrough detection StandardOnboard documentation Standard

Electricity supplyThree-phase input voltage V 380 or 400Permissible variations from +10% to -10%Main frequency Hz 50 or 60Power consumption kVA 4.2Nominal current A 6

Cooling water when heat exchanger usedFlow minimum required l/min (gal/min) 20 (5.2)Temperature °C

°F< Tworkshop – 9° C< Tworkshop – 18° F

Compressed airPressure range between bar (psi) 6 to 8 (85 to 113)Flow minimum required m3/h (yd3/h) 5 (6.54)Connection pipe external diameter mm (in) 10 (0.4)

Main optionsAutomatic electrode/guide changer AEC/AGC 16/4, AEC/AGC 50/8Tilting head ° Max. ~ ± 45 Large travel of Z axis mm (in) 650 (25.59)Rotary/tilting table


DRILL 300

DRILL 300 tilting head

1400/55.12’’ 2375/93.5’’

800/31.5’’

Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 ’’

600/23.62’’

40/1.57’’

600/

23.6

2’’

400/

15.7

5

730/28.74’’ 1120/44.09’’

1998/78.66’’

700

27.56’’

1260/49.6’’

598

23.54’’

3393

/133

.58’

’

2280

/89.

76’’

100

3.94

’’

583

22.9

5’’

510

20.0

7’’

2375/93.5’’

800/31.5’’

Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 ’’

600/23.62’’

40/1.57’’

600/

23.6

2’’

400/

15.7

5

730/28.74’’ 1120/44.09’’

2280

/89.

76’’

100

3.94

’’

1900/74.8’’

2248/88.5’’

250

9.84’’

1400/55.11’’

348

13.7’’

3392

/133

.54’

’

583

22.9

5’’

1270

/50’

’

510

20.0

7’’


The DRILL 300 easily drills cooling holes in turbine blades. For this demo blade, 180 through holes and blind holes (Ø 0.5 mm and Ø 1.0 mm) were machined in only 75 minutes, using a single setup with the automatic electrode and guide changer.



EDM (electrical discharge machining)AgieCharmilles wire-cutting, die-sinking

and hole-drilling machines. For over 60 years we have been at the forefront of every EDM de-velopment: designing and refining the EDM process and building machine tools that deliver peerless part accuracies, surface fini-shes, cutting speeds and process reliability. Today, our AgieChar-milles wire-cutting, die-sinking and hole-drilling machines are recognized throughout the world as the best in the business. Our continuous research and development in digital generator techno-logy, control systems and integrated Automation systems are evidence of our commitment to keeping your EDM operations on the leading edge of technology.

MillingMikron high-speed (HSM), high-performance (HPM)

and high-efficiency (HEM) Milling centers. Customers operating in the mold, tool and die and precision component manufacturing sectors stake their reputations on being able to quickly and cost-competitively meet their customers’ demands. That’s why they invest in Mikron machines. Incorpo-rating the latest and most advanced technologies and premium-performance components, Mikron HSM, HPM and HEM machines help you increase your production capabilities and improve your productivity. Designed and built for speed, accuracy and reliability,

the machines, like you, are proven performers.

Liechti Dedicated Aerospace and Energy machining Centers. Aerospace and power generation turbine manufacturers increa-singly turn to Liechti dedicated five- and six-axis machining cen-ters to machine complex, high-precision airfoils on blades, disks, blings, blisks / IBRs and impellers. It’s easy to see why because these machines, with their specific profile machining technology, specialized CAD / CAM software and engineering competence for ultra-dynamic machining in titanium, Inconel, nimonic, titanium-aluminide and high-alloy steels, yield productivity gains as much as 30 percent, thanks to reduced machining times. In the globally competitive aerospace and power generation manufacturing sec-

tor, that’s definitely worth shouting about.

Step-Tec Spindles. At the heart of every Mikron machining center is high-perfor-mance Step-Tec Spindle. Step-Tec Spindles are essential core components of our machining centers. Highly accurate and thermally stable Step-Tec Spindles ensure that our machines can handle everything from heavy-duty roughing to fine-finishing operations.

AutomationSystem 3R Automation, Tooling and software. Productivity is the key to manufacturing success, and automa-ting a manufacturing process is a proven method of increasing its efficiency, effectiveness, quality and reliability. System 3R’s integrated Automation, Tooling and software solutions — simple workpiece pallet and electrode changers and flexible manufac-turing and robot handling systems — increase your competitive advantage.

Customer ServicesOperations Support, Machine Support and Business Support.To help you get the most and the best from your machine tools and equipment, we offer three levels of support. Operations Support covers our range of original wear parts and certified consumables (EDM wires, filters, resins, electrodes etc.) to ensure that your machines are performing at the highest levels. Machine Support maximizes, through our best-in-class technical support, preventive services and quality spare parts, your machine tool uptime. Business Support is designed to help you make a real step-change in your productivity and performance with solutions tailored to your specific needs.

LaserAgieCharmilles Laser texturing machines.Laser texturing is a fully-digitized surface engineering process that has huge potential. The technology enables precise 2D and 3D textures or engravings to be machined accurately and directly onto complex parts or molds to improve and alter their aesthetic appeal, functionality and performance. The process is infinitely repeatable and offers many distinct environmental and economic

advantages over conventional texturing processes.

Laser Additive Manufacturing (AM).GF Machining Solutions has partnered with EOS, the global leader for high-end AM solutions, to integrate this innovative technology and further develop it into its current solutions to fully benefit the mold industry, by focusing on injection efficien-cy : optimized cooling design to reduce cycle time, lower energy consumption, higher quality of plastic parts.


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At a glance

We enable our customers to run their businesses efficiently and effectively by offering innovative Milling, EDM, Laser, Spindle, Automation and Tooling solutions. A comprehensive package of Customer Services completes our proposition.

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gf machining solutions - agiecharmilles - edm hole drilling - model 300

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