new ideas in edm winter 2001 - · pdf filepower tools, formerly skil corporation is the sole...
TRANSCRIPT
Inside This Issue:
A Message from Harry Moser..................2
What to expect in 2002
Roboform & Do-Rite.....4
Charmilles’ Roboform 40Greatly Increases Do-Rite’sEfficiency
Charmilles Website GoesInto Over DRIVE ...........7
WIN 2 TICKETS TO THEDAYTONA 500!
New Links at charmillesus.com..........8
FAQ, ACTSPARK, careersand used machines
Charmilles’ First Ever Webcast.......................10
The Roboform 390/690launched online
Kansas American Tool .............................12
Tall orders filled byCharmilles
EMO 2001 ..................14
What was new inHannover, Germany
www.charmillesus.com
Winter 2001
Online Product Launch Makes Machine Tool History
Customer Response FormHow is Charmilles doing?
Can we help you with any concerns related to Charmilles?If we can be of assistance, please fill out the form below and mail, fax, or e-mail to:
Charmilles Technologies
Attention: Quality Manager
560 Bond Street
Lincolnshire, IL 60069-4224
E-mail: [email protected]
Fax: 847-913-5340
Machine Model Number: ____________________________
Serial Number: ____________________________________
Description of concern or customer need: Date: __________________
At your company, whom should we contact? _____________________________________________________________
Company name ___________________________________________________________________________________
Phone number ( ____ ) _____________________________________________________________________________
Your name _______________________________________________________________________________________
CHT 12883 11/01 8M
www.charmillesus.com
Winter 2001
2
www.charmillesus.com
2002: Continued Contraction or Recovery?
4. WTC also is driving some large U.S.companies to shorten their supplychain lengths, sourcing key compo-nents and tools locally for fear ofrepeated disruptions to global just-in-time deliveries.
Some of the initial economic reportsfrom October suggest that the economydid not contract as much as expectedfollowing September 11 . Charmilles’experience confirms this observation.Specifically, September and Octobermachine orders were higher than ourmonthly average year-to-date. Also,consumable sales (wire, filters, etc.,) areon target to be up about 10% in 2001over 2002, suggesting that shops are,on average, still making sparks,although with substantially reducedbacklogs. As a result, we haveincreased our machine orders from thefactories and hired two additional serv-ice engineers, bringing ourU.S./Canadian total to 65.
My conclusion is that, if there are notrepeated major terrorist attacks, ourbusinesses will recover, likely starting inthe second quarter of 2002. In themeantime, focus on the strong end mar-kets such as medical, power generationand defense. Share the holidays withfamilies and friends and then comeback ready for the recovery in 2002!
Harry MoserPresident, CharmillesTechnologies
2001 is about over and thankfully so.Four seeds for a strong 2002 recoveryhave been sown in the problems of2000 and 2001 .
1. The Fed raised interest rates 6 timesin 1999 and 2000, latest May 16,2000. Since the economy’s responseto the interest rate cuts takes 6-24months, the depressing effect of mostof the rate increases is still being felt,counterbalancing much of the stimu-lative effect of the ten 2001 ratereductions. In 2002, the rate reduc-tions will clearly dominate.
2. The 2001 tax cut and the new pro-gram of government spending andadditional tax cuts will add strongadditional stimulus.
3. Due to the terrorists’ focus on theU.S., international investors maytrend away from U.S. financial mar-kets in favor of Euro basedinvestments. The result should be areduction in the dollar’s valueagainst most international currencies.The Fed and Treasury have, for toolong, focused on a strong dollar tostabilize financial markets andreduce U.S. inflation. Any manufac-turer could have told them that therisk of inflation in manufacturedproducts is minimal, given the hugeamounts of excess world capacityaimed at supplying the U.S. market.
Do-Rite Die & Engineering hasbeen in business for nearlyhalf-a-century. Forty-nine yearsago, John Szymanski beganthe business. Do-Rite, primarilya die maker for aluminumparts, moved to its presentlocation in South ChicagoHeights, Illinois in 1969.
“We just finished a job that in theold days would have taken us 20weeks,” says Al Szymanski,President of Do-Rite. “We did it in12 weeks without putting exces-sive overtime into it.”
“What they wanted to do,” saysRico Ostini, the salesperson at
Tristate Machinery inWheeling, IL that sold theRoboforms to Do-Rite, “wasto be able to make thesame mold they did 10years ago and quote it forless money today than theydid 10 years ago. Theyneeded to have some‘lights out’ operation. Theyhave fewer employees now
than they’ve had in the past butthe output has stayed the same oreven increased.”
The table on the Roboform is bigenough to accommodate multiplecavity inserts in the tank whichmakes the operation super-effi-cient when the machine is runningunattended on nights and weekends.
Do-Rite has had the twoCharmilles’ Roboforms for fiveyears now. Al says that thebiggest problem the machineshave helped resolve is inconsisten-cies in burn time that would lead
4
Charmilles’ Roboform Greatly Increases Do-Rite’s Efficiency
www.charmillesus.com
to unpredictability of Do-Rite’sdelivery time.
“One guy might have taken 10hours to burn one job andanother guymight takeone weekfor thesame job,”Al says.“Now, withthe orbitingand CNCit’s moreconsistent.”TheProgramExpert sys-temgenerates an easy and consistentprogram, guaranteeing the exactfinish and size of the cavity.
In orbiting, the electrode moveswithin the cavity like a spoon stir-ring coffee. Only one electrode isnecessary to rough and finish thejob, alleviating the need for sepa-rate electrodes. Orbiting creates aflow of the dielectric to flush outany excess particles. Hence, theburn is much more stable and effi-cient, not to mention quicker, too.
The current generation is theRoboform 54P. The sinker-EDMfeatures a fast, highly adaptivegenerator, two-door tank design,
CNCA mold for S-B Power Tools machined by Do-Rite.Do-Rite has had a long relationship with SB, bothwith the traditional Skil ‘WormDrive’ saw (pic-tured here) and the new Bosch saws (pictured on page 6).
Over the years, it has built up aloyal clientele of customers,including S-B Power Tools. S-BPower Tools, formerly SkilCorporation is the sole producerof Skil-brand and Bosch-brandcircular Saws, and has relied onDo-Rite’s craftsmanship for 40years.
But with the arrival of the latesttechnology, including twoCharmilles’ Roboforms, Do-Rite’sprocesses have gone to a wholenew level.
and linear glass scales. It comesequipped with an easy-to-usecontrol and a large capacity toolchanger.
Do-Rite sits at the end of a streetof machining companies acrossfrom a neighborhood of homes.12 employees work at this facility.Al and his brother Ed, the com-pany’s vice president, greet theirvisitor and usher him to a well-kept front office that is equippedwith two large work desks. Soon,they are headed back to the veryclean production area. It’s abright fall day and sunlight isstreaming in through the windows.
Al walks over to a worktable andpicks up a ‘fin’ job recently doneat Do-Rite. The finished piece iscalled a ‘heat-sink.’ Al picks upthe piece that has five blades onit and says, “in the old technology,
we would have made separateblades for each one of these. Itwould have been a nightmare.”Al points to a Mikron machiningcenter, a VCP 600 and says,“This machine cut the electrodesin one day. We take it to theEDM and it burns all night. Thewhole thing took three days ver-sus two weeks.”
“It’s a very professionally-runbusiness,” says Donal R. Fifeabout Do-Rite’s operations. Fifeis a senior Diecast engineer atthe S-B Power Tool Company,Do-Rite’s largest customer. “Theydo a good job of investing inthe right pieces of high-techequipment. They don’t go over-board because they don’t wantto burden themselves with toomuch of the high-tech stuff thatreally doesn’t have the payback.
They do a good job of selectingjust the right machines to shortenthe delivery time and make bettertools but at the same time holdthe overhead down.” Fife alsolikes the fact that Do-Rite main-tains a healthy balance betweenthe older and youngerCraftsmen/Machine Operators.
Fife works out of S-B’s HeberSprings facility, which is a largeArkansas employer involved in thehigh speed, high volume manufac-ture of circular saws. One of thesaws produced is S-B’s bench-mark ‘WormDrive saw,’ the firstline of saws that the original SkilCorporation produced. TheWormDrive saw is a very powerfulsaw, used primarily in construc-tion. There are five castings on the
5New Ideas In EDM
www.charmillesus.com
" "
… continues on page 6
S-B Power ToolsWormDrive saws:
WormDrivesaw, forwhich Do-Rite makes thedies: the motorhousing, gear housing, upperguard, lower guard, and bearingplate.
Another characteristic of theRoboform that appeals to Do-Riteis that it provides better finishes sothere is less hand time involvedafter the burn is done. Al estimatesthat the reduction in burn timeamounts to 50%. Ed also likesCharmilles’ ‘Program-Expert,’which writes the bulk of the pro-gram. ‘Program-Expert’ allowseven inexperienced oper-ators to use the Roboformat full capacity.The operator tells‘Program-Expert’what he wants tostart at and what he’d like the fin-ish to look like and the softwaretakes it from there.
Ed likes the convenience of the‘Program-Expert.’ “Charmilles sup-plied us with common programsthat we would be using through-out most of our burning cycles sowe really haven’t had to write anyspecial program cycles,” he said.“We just modify them to a differ-
ent cutting depth tothe ones they gave us so
it’s been a very easymachine to run. The machine
gives you the optimum burn andorbit settings. You just tell it whatyou want to start at and what youwant your finish to look like and itfigures everything out for you.”
The increasedefficiency hasled to newcustomers forDo-Rite.
Al says,"Because ofthe equipment I now have, I canturn jobs over quickly. This allowsme to do smaller jobs for peoplein the area that I wasn’t able todo in the past. Before with manualequipment, that type of work wasdifficult to do. Financially, it endedup being a favor more than any-thing and it took us away from ourother jobs.
"Now, we’re at least able tobreak-even. Those little jobs, if youadd them up at the end of theyear, they’re quite a considerableamount. It can be enough to paythe Christmas bonus, for instance."
Al rejects the notion that high-speed milling can replace EDM
functions. “That’s not always true,”he says, “because you just can’tget to some areas with a cutterthat you would have to use. So insome cases yes, there are appli-cations where a high-speed millwill do it and other applicationswhere the high-speed mill mightdo 75% of it. Then you have tomake a decision as to which wayyou’re going to go. So if I have todo any EDMing at all, I might justgo ahead and EDM the wholething.
“We then use the high-speed millto make a complex electrode withall details so the two technologies
are complementary. When youEDM you don’t have to deal withthe chips you have from themilling process so unattendedmachining is much more realisticwith the Roboform EDM.”
An increased workload at Do-Ritehasn’t required more man-hoursdue to the unattended capabilitiesof the Charmilles’ machines.“Unattended machining is our sec-ond shift,” Al admits. “Many timesa customer wants us to workanother shift and we don’t have to— we just keep the machines run-ning. It’s easier on us as ownersbecause we don’t have to be heresupervising people. We can be athome.”
6
Charmilles’ Roboform 40 Greatly Increases
Do-Rite’s Efficiency
www.charmillesus.com
Program-Expert allows even
inexperienced operators to use the
Roboform at full capacity.
The Bosch 1677M
The Bosch 1678
Program Expert
7New Ideas In EDM
www.charmillesus.com
Charmilles’ web site has beenundergoing some changes, not theleast of which is the addition of anew racing section. This new sectionwill contain information onCharmilles involvement with PenskeRacing, as well as photos and race reports.
Some background…
Charmilles and Penske Racing are now swapping know-how in Nascar Winston Cup racingwith the addition of a Robofil 330F wire EDM at PENSKE-JASPER Engine Company inConcord, North Carolina.
Using EDM, Penske Racing engineers and designers are discov-ering ways to produce components that are more accurate,more reliable and more economical than ever before. Manyspecialized components that could not be purchased “off theshelf” are now readily available.
From engine components, suspension parts, transmission gearsto a simple bracket, EDM can often help to eliminate special fix-tures, operate unattended and speed up part delivery time.
Daytona 500 Race Package Contest
Charmilles Technologies will award three Daytona 500 all-inclu-sive race packages as part of its involvement with Penske racing.
Three winners will each receive:
• Two grandstand seat tickets
• “Behind the Scenes with Penske Racing” (winners will spendSaturday in the garage area with the Penske Racing team)
• Garage & pit tour on Sunday before the race
• Hotel accommodations (three nights) in Orlando
• Airfare to and from Orlando
CharmillesWeb SiteGoes IntoOverDRIVE…
CharmillesWeb SiteGoes IntoOverDRIVE…
To register, please visithttp://www.charmillesus.com.
DAYTONA
At www.charmillesus.com, we’realways growing and improving.Look what we’ve been up to …
FAQ
under $75,000, the full CNC diesinking SE seriesfeatures a mechanical design with a short C frameand a DC motor and encoder drive.
C-Axis and linear tool changers are standard features on the SE series.
Learn more about ACTSPARK athttp://www.charmillesus.com/prod/actspark.cfm.
Careers
There’s no better place to work in the EDM worldthan Charmilles (at least we think so). Charmilles isalways looking for the best of the best to be a part
8
Visit our new Frequently Asked Questions (FAQ) section for information on common issues and chal-lenges. If you don’t see your question addressed,submit it to our technical experts for a promptanswer—who knows, your question may be featuredin a future FAQ section!http://www.charmillesus.com/faq.cfm
ACTSPARK
ACTSPARK is a new line of affordable, entry-levelEDM for the U.S. market. Charmilles will sell andsupport the ACTSPARK machines starting Oct. 2001 .
ACTSPARK’s product offerings include a full range ofCNC basic die-sinking EDMs. The SP1 and SP3,priced at under $39,000, offer a compact design ina small footprint and are easy to operate. Priced
www.charmillesus.com
See What’s New Athttp://www.charmillesus.com
See What’s New Athttp://www.charmillesus.com
of our team. Job postings areavailable at http://www.charmille-sus.com/comp/jobs.cfm. We’relooking forward to meeting you!
Used Machines
The newly improved usedmachine section now features list-ings of available Charmillescertified, used machines. The list isupdated monthly, so, if you are inthe market for a used Charmillesmachine, please visithttp://www.charmillesus.com/prod/listings.cfm.
9New Ideas In EDM
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illesus.co
m/p
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s.cfm
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You Can See Your Ad in New Ideas In EDMCall Steph Meyers at DGS Group • 317-479-3155
extension 121
On December 11, 2001,Charmilles Technologies mademachine tool history with itsfirst online product launch ofseveral new EDM machines.Charmilles introduced new machines,including the Robofil 390/690, duringa live webcast viewed by distributors,customers and industry press.
Over 55 distributors established central viewing centers for their cus-tomers to view the event. Together,the distributors gathered over 230participants worldwide.
“We are excited about this new technology,” said Gisbert Ledvon,marketing manager for Charmilles. “It maximizes the latest in technology,and allows more of our customersand distributors to participate withoutthe often difficult logistics of travel.”
Guests were introduced to themachines via live audio and anonline video presentation. Followingthe presentation, guests participatedin a live Question and Answer session.
Take a look at some of the new prod-ucts featured during the webcast…
Robofil 390/690
The cost-effec-tive Robofil390/690 is theresult of closecollaboration ofcustomersaround the
world. With its state-of-the-artWindows-based CT-Millennium
numerical control, the 390/690 sup-ports the most advanced telecomtechnologies. By combining the bene-fits of both flushing and localsubmerged machining, the 390/690delivers instant cutting action withoutthe need to fill or drain the worktank. Its mechanical enclosed cabindesign delivers precision, ruggednessand reliability. The 390/690 is idealfor a wide variety of stamping tools,mechanical engineering applicationsas well as plastic injection moldinserts.
Robofil 2030SI-TW
The Robofil2030SI-TW isthe first wireEDM machinewith an auto-matic wirechanger. It also
achieves dramatic time savings anddelivers flexibility when machiningparts for which two different wiresare required. The new 2030SI-TWfeatures a fully automated dual-wiresystem which accommodates twowires of different diameters whileboosting overall machining productivity.
Roboform 85
Like the Roboform35P, the Roboform85 delivers theperformance our customers wantwith a dedication
solution, automatic drop door and a
linear tool changer available for upto 7 positions to accommodate elec-trodes up to 16.73” in length. It alsooffers X, Y, Z travel of31 .5”x23.62”x19.68”, and can handlemaximum workpiece dimensions upto 63”x43.3”x17”.
QCRw
The QCRw rep-resents 100%Charmilles tech-nology, making it
possible to handle large clampingframes having dimensions equivalentto the table of the machine.
Designed to be able to pre-adjust theworkpieces away from the machine,the QCRw allows transfer loads of upto 200lbs. The QCRw is available onthe Robofil 240/440 machine.
ACTSPARK
ACTSPARK is anew line of affordable, entry-level EDM.ACTSPARK’sproduct offeringsinclude a full
range of CNC die-sinking EDMs. TheSP1 and SP3 offer a compact designin a small foot print and are pricedat under $39,000. The SE series fea-tures a mechanical design with ashort C frame and a DC motor andencoder drive and is priced at under$75,000.
To view the archived presentationand review the Q & A, please visithttp://www.charmillesus.com/launcharchive.
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In the Spotlight: Charmilles’First Online Product Launch
www.charmillesus.com
15.75”
agreement for five machines fromMaplan and they were on their way.
Today, 15 employees work at thecompany. Estimated 2001 sales willbe about $1 .5 million. KansasAmerican Tooling has developed anice niche — tooling for rigid PVCplastic fence and decking materials.The tooling goes to plastic extrusioncompanies that specialize in thisindustry. In a fence, all of the partsand posts are plastic. Doering esti-mates that in a standard line ofplastic fence there are probablymore than a dozen profiles.
Kansas American Toolingseems to be riding thecrest of a burgeoningmarket. Doering says,
“The plastic fence business right nowis where plastic sidings for homeswas 25 years ago. It is still somewhatin its infancy but it’s a very fast grow-ing market at this point in time.Everyone puts a deck on a newhouse and you don’t want to stain
KansasAmerican
Tooling’s firstexposure towire EDMscame as a result of a specific prob-lem. The McPherson, Kansascompany that makes tooling for theplastic extrusion industry, had takenon a job for a customer but discov-ered that it didn’t have a machinebig enough to cut the part.
“We needed to wire cut some 12-inch thick parts and the old machinethat we had, that we’ve now gottenrid of, only had eight-inch heightcapability,” says Harlan Doering, avice president at Kansas AmericanTooling. “To make the parts weneeded to make, we had to have abigger machine.”
That machine was Charmilles’ Robofil310. Within a year, they had pur-chased another Charmilles machine— the Robofil 300. The height capa-bility of both of these machines is15.75 inches.
“We build a fully-streamlined flowpath in our extrusion dies and youcan’t do that without a wire-EDMmachine,” Doering says. “The abilityto cut greater angles than most othermachines can do is probably the first
thing that sold us on Charmilles.”
Today, the Robofil 310 has beenrecast as the Robofil 310P. It is stillthe ideal choice to accommodatetall workpieces up to 15.75 incheshigh. An integrated anticollisionsystem on all five axes, provide foreffective protection from damageof all parts during manual or unat-tended operation. With astandard 35-pound wire spool, theRobofil 310P features automaticthreading for extended machining.
The numerical control, the CAM-CT, is especially designed for
EDM wire cutting and is easy to use.It enables prompt programming oftwo-axis contours.
The Robofil 300 also fits the need oftoolmakers who need to machine tallworkpieces. Yet, the 300 is able tomaintain a very compact structure,mounted on a single base.Charmilles has developed anexclusive process for themovement of the machiningheads on the Robofil 300. Thisprovides U V travel equal to XY travel.
Kenton Gearhart and BobPoole founded Kansas AmericanTooling in 1994. The business waspart of American Maplan at one timebefore Gearhart and Poole sepa-rated from Maplan and createdKansas American Tooling. The twofounders executed a lease-purchase
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Kansas American Tooling GetsTall Jobs Done with Charmilles
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and clean itall the time so you put up a
deck that has maintenance-free plas-tic as a decking board. They also lastfor many years.”
There are three types of tooling thatKansas American Tooling manufac-tures for this market — dies, templatesystems, and sizing calibrators.Doering walks through these applica-tions. “We have a die that hangs onthe extruder,” he says, “and then wehave what we call ‘dry-sleeve cali-brators.’ These are used to set theproduct in shape with water coolingand vacuum to hold the product outto the tool and hold it in shape. Andthen it would go into a water tankthat utilizes a set of templates tomaintain shape. That can be any-where from 20 to 60 feet longdepending on the speed of the prod-uct and the wall thickness in terms ofbeing able to cool it at the rate thata customer might desire.”
Doering says that hehas been happy
withCharmilles’
full mainte-nanceprogramand itsservicecommit-
ment.That’s an
important partof any business
relationship Doering says,because good service is the biggestdriver to insuring repeat business.
“One of the key things that we do asa company,” Doering continues, “isthat we not only build the tooling butwe go out and actually start the tool-ing up at the customer’s facility andfine tune the tooling at the customer’s
facility. Generally, we spend a weekthere for each profile that we pro-duce to make sure that the toolingworks like it needs to and that thecustomer understands how to oper-ate the equipment and how to takecare of the equipment.”
13New Ideas In EDMNew Ideas In EDM
www.charmillesus.com
With 2,263exhibitors from 39
different nations andover 200,000 visiting
trade professionals, thisyear’s EMO (Exposition
mondiale de la MachineOutil) was the biggest
machine tool show ever.Held on the world’s largest
fair space, in Hannover,Germany, EMO 2001 covered
over five million square feet andspread over 26 exhibition halls.
During the show, Charmilleslaunched several new productsand exhibited a new variety ofwire EDMs, such as the Robofil390/690, and automation solu-tions starting with the QCRi serieson the Roboform diesinkingmachines and the QCRw robotseries for the Robofil 240/440 wiremachines.
“EMO 2001 was a great oppor-tunity to show once again how wepush the limits of EDM,” statedGisbert Ledvon, MarketingManager Charmilles-US.
One way Charmilles didthis was by producing acell phone mold by millingthe electrodes on an HSMfrom Mikron Bostomatic
HannoverEMO
then using the electrodes in theRoboform machine to EDM thecavities. The pallet then was trans-ferred to the Robofil 440 QCRwRobot. The Robofil 440 was thenused to cut lifter pin pockets to fin-ish the mold. All of the parts wereloaded with robots into theRoboform and Robofil machinesand the whole process was auto-
mated. When the part was donethe Millennium CNC on theRobofil sent an e-message to acell phone to tell the operator thatthe job was complete.
EMO 2001 gave Charmilles thechance to show customers andjournalists from all over the world where the future of EDM is going.
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www.charmillesus.com
2001 Snapshot
Robofil 440
Roboform 55QCRi
GEORG FISCHER Manufacturing TechnologyGF
560 Bond St.Lincolnshire, IL 60069
www.charmillesus.com
Tel: (888) CTC 1EDM
AGIE CHARMILLES Group
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Use this space to obtain product information
on Charmilles EDMs:
Please send me detailed information on the Charmilles EDMs I’ve indicated
below:
Wire EDMs
Check all boxes that apply to your interests:
❏ Submerged cutting type ❏ Non-submerged cutting type
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CHT 12883 11/01 8M
GEORG FISCHER Manufacturing TechnologyGF
560 Bond St.Lincolnshire, IL 60069
www.charmillesus.com
Tel: (888) CTC 1EDM
AGIE CHARMILLES Group