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THE GF AgieCharmilles CUSTOMER NEWSPAPER

4-5

2-3

6-7

12-19

10-11

20-21

22-23

8-9

AIRE EROSION

LEITNER AG

RAWELA

EMO MILANO 2009

GB PRECISION

W-TECHNOLOGY

KSF

PRONTOR

FORMPLAST

24-25

26-27 BOMO

Michael HauserCEo GF AgieCharmilles

ENGLISHEdItIoN

04

Automotive • Motorsport • Aeronautic • Education • Electronics • Household • Machinery Power Generation • Molding • Mecatronics • Luxury • Research • Medical Instruments General Machining • Leisure • Aerospace • Sports • Medical Appliances • Automotive Motorsport • Aeronautic • Education • Medical Implants • Electronics • Household Machinery • Power Generation • Molding • Mecatronics • Luxury • Research • Medical Instruments • General Machining • Leisure • Aerospace • Sports • Medical Appliances

dEAR REAdERS,

the year 2009 is for the machine-tool industry the key year with challenges as we have never known them before. It may also go down in the history of the machine-tool industry as the year when the economy made the difference between success and failure.

At the same time, each crisis brings new chances. those acting countercyclically trust that a downturn is followed by recovery and, subsequently, an upturn. For many of our customers, who are daily con-fronted with new challenges, this is not different. they want us to respond to them with possibly innovative and con-vincing solutions. And, because they are entrepreneurs, they think and act accordingly. Now they invest in machinery and equipment and simultaneously optimize processes in order to emerge on the market stronger when the recovery comes.

For you, we are exactly the right partner: GF Agie-Charmilles supports you in your efforts by offering you specially tailored technology with a wide range of prod-ucts. We train your employees and help you to get more out of your GF AgieCharmilles products in order to win out over your competitors.

Visit us at EMo Milano 2009 in Hall 7, Booth #F13/E20.

We are look forward to seeing you!

Sincerely yours,

UNIQUELY POSITIONED TO HELP YOU ACHIEVE MORE More technology, more precision, more automation, more productivity and more satisfaction are at the heart of GF AgieCharmilles’ commitment to helping custom-ers achieve more success, and our exhibition space at EMO Milan 2009 is the place to «Experience more» of the solutions we have developed specifi cally to enable your success today, tomorrow and beyond.

LASER TECHNOLOGY AT GF AGIECHARMILLES

You want to differentiate yourself in a highly-competitive marketplace, gain new customers and reap the benefi ts of an excellent price/perfor-mance ratio?

Join us at the EMO in Milano or at the International Technology Show in Germany and see how you can take your competitive edge with our laser technology to the next level by doing a part like this.

Michael Hauser, CEo GF AgieCharmilles

HSM AND EDM, WHEN PRECISION IN MOLD MAKING IS REQUIREDFormplast Purkert, s.r.o. focuses on the design and manu-facture of injection molds, as well as the injection molding of demanding technical parts and the mounting of assemblies. In the company’s own tool and mold making department, the Czech undertaking prefers to use Milling and EDM equipment from GF AgieCharmilles.

FROM DESIGN OFFICE TO COMPLETE PROVIDER

The Czech company based in Jablonné nad Orlicí in Moravia was founded in 1992 as a design office by its present proprie-tor, Ing. Zdeněk Purkert. Soon Formplast was manufactur-ing tools itself, manufactur-ing plastic parts with its own automatic injection molding machines. With the mounting of assemblies, the company took the step to become a com-

With «SolidWorks», «Catia V5», «Powermill», «Surfcam» and «Moldflow MPA 7.0», Formplast has all the impor-tant CAD programs for technical mold making at its disposal.

For graphite machining jobs Formplast puts its trust in the MIKRON HSM 500. The MIKRON VCP 600 is employed for hard milling.

plete solutions provider. Today Formplast employs 150, 40 of whom manufacture tools and 95 produce injection molded parts. The main customers for the high precision, technical plastic parts are the automobile and electri-cal engineering industries. With six EDM and two HSM machines from GF AgieCharmilles, Form-plast is capitalizing on reliability and Swiss precision.

GF AgieCharmilles | results todAy | 04

AUTOMOTIVE | FORMPLAST 2

www.formplast.cz

FORMPLAST

Jatečni 541

561 64 Jablonné nad orlicí

Czech Republic

tel. +420-465 649 018

+420-465 467 404

Fax +420-465 467 400

Contact

Ing. Zdeněk Purkert,

Managing director and Proprietor

[email protected]

Machines from GF AgieCharmilles

- 1 MIKRoN VCP 600

- 1 MIKRoN HSM 500

- 2 Fo 550

- 1 Fo 350

- 1 Fo 31 P

- 1 FI 440 SLP

- 1 FI 290

Clamping system

System 3R

Programming

Powermill

SolidWorks

Catia 5.0

Surfcam

Measuring, testing

Coordinate measuring machine

from Wenzel

optical measuring machine

Scope Check from Werth

«With its reliability, preci-sion and ease of operation, the MIKRoN VCP 600 is an important component in our tightly calculated production sequences.»

said Ing. Zdeněk Purkert, Proprietor and

Managing Director of Formplast s.r.o.

The mold insert of the injection mold-ing tool for the production of reflectors with the reflecting surfaces which have been milled with the MIKRON VCP 600.

PRECISION REQUIRE-MENTS DEFINE THE MACHINING PROCESS

A typical order for Formplast is the production of a reflector for automobiles. Beginning with the basic dimensions from the cus-tomer for the finished part, the development and the CAD design are made, accompanied by Moldflow analyses. In this phase, Formplast determines the thick-ness of the sides and defines stays for reinforcing the reflector. In the next step, the machining processes are determined in ac-cordance with economic viability and precision requirements. Given the need for a left and right reflector, the injection molding tool is made by Formplast as a two-cavity mold. Steel 1.2343 is the material used and Moldmax is used for details. The require-ment is a surface finish of Ra 0.1 µm and a tolerance of ± 0.02 mm, which is to be achieved over the whole mold. The MIKRON VCP 600 complemented by EDM is ideal for this process.

RELIABLE MACHINES MAKE ORDERS PRE- DICTABLE

With the MIKRON VCP 600, equipped with a spindle from Step-Tec with an HSK 40 spindle cone for rotational speeds of up to 42,000 rpm, first of all the coarse form of the mold insert is milled. The mold insert is hard-ened for a long tool life and then clamped on the MIKRON VCP 600 again for finishing milling. Path after path is milled reliably until the required roughness is nearly achieved. The mold insert then polished to a reflective fin-ish. «Our MIKRON VCP 600 has 12,000 hours of operation with-out repair on its meter. That’s what I call reliability,» comments proprietor Ing. Zdeněk Purkert. He continues, «So we can plan orders exactly and utilise our machines’ capacity sensibly.» Because hardly is the injection mold ready, production of the re-flectors begins on the automatic injection molding machines. Willing hands then fix the mold-

ings to a mobile frame, which, as soon as it is completely loaded, is then moved into a coating machine. There the reflectors are coated statically with aluminium powder. The subsequent final assembly is the final production step. A sequence that is nearly in synchronous rhythm with the mold making at Formplast so that no downtimes occur. Given its reliability, the MIKRON VCP 600 is a decisive guarantor for this.

A conveyor belt transports the reflec-tors directly from the automatic injection molding machines to where they are fixed to mobile frames and then pushed into the coating equipment.


AUTOMOTIVE | FORMPLAST 3

ED MACHINES PRECISION IN SPACE

Aire Erosion Ltd., a contract EDM company using machines from GF AgieCharmilles, specializes in the manufacture of complex molds made from difficult to machine materi-als. Based in Leeds in Northern England, Aire Erosion is a supplier in great demand by the high-tech sectors of the aerospace, medical, power generation, gas and oil field and automotive industries in the United Kingdom.

ExCELLENT PRODUCTION FOR ExCLUSIVE USE

When Steve Batt borrowed money to found Aire Erosion Ltd. in 1989, a success story was born, which continues to the present day, boasting annual growth rates of 30%. As of 2008, Aire employs five wire and three die-sinking machines, as well as two drilling machines, all exclu-sively GF AgieCharmilles equip-ment. «With these machines, I can offer the entire machining spectrum of electrical discharge machining,» says Steve Batt. «Combined with almost 30 years

of EDM experience, our know-how about exotic materials as well as the exceptional preci-sion of our machines, we have become the preferred partner of customers from blue-chip indus-tries.» Thus for a new aerospace project, with which Aire Erosion Ltd., from among three competi-tors worldwide, was entrusted with the order to manufacture a Bearing Active Preload System (BAPS). These systems, used in spaceship mechanisms, must have a long operating life, uniformly low torques, as well as a corresponding rigidity and bearing capacity. In addition, the

BAPS must absorb the vibra-tions occurring during the start into space with exactly defined preload forces. This explains the design, which seems highly com-plicated with the finest webs and exactly calculated dimensions of the openings and forming.


AERONAUTICS | AIRE EROSION 4

www.ezedm.com

AIRE EROSION LTD.

Bobbin House, Viaduct Street

Leeds LS28 6RR

United Kingdom

Phone +44-(0)113 256 0466

Fax +44-(0)113 255 9700

Contact

Stephen Batt, Managing director

[email protected]


- 1 FI 440 CC

- 2 FI 440 SLP

- 1 FI 240 CC

- 1 FI 230 F

- 1 Fo 550

- 1 Fo 550 S

- 1 Fo 350

- 2 Sd 1

Clamping system

Erowa

Programming

Easycam

Measuring, testing


from Kodak

«thanks to efficient shift operation, we achieve 2000 operating hours a month with our EdM machines - A performance record which also clearly speaks in favour of the manufac-turer GF AgieCharmilles.» said Stephen Batt, Managing Director

of Aire Erosion Ltd.

Stephen Batt, Managing Director of Aire Erosion Ltd., with an ED machined component for the oil field industry.

Aire Erosion Ltd. uses twelve different electrodes to machine the openings in the bearing active preload system. EDM C 3 material is used, which guarantees the lowest wear with its composition of 60% graphite and 40% copper. After the ED wire cutting, the remaining openings are made on the FO 350 die-sinking ma-chine, in part as undercuts, in that the electrode is screwed in for machining via the C-axis.

WIRE EDM CUTTING DEFINES THE BASIC PRECISION

For this order, Aire Erosion uses a ring made of titanium turned externally, which is provided with all the start holes for the wire cutting. This begins the EDM specialists’ work. The titanium ring is clamped edgeways with indexing on the FI 440 CC ED wire-cutting machine. The brass wire is threaded in at top and bottom through the starting holes on the ring so that two openings can be cut simulta-neously. By indexing in exactly

DIE-SINKING EDM COMPLETES THE COM-PLEx PRODUCTION

The next step is the production of electrodes, which Aire Erosion Ltd. does using wire EDM. All in all, twelve electrodes made of EDM C 3 are employed per bearing active preload system. This material, with a composi-tion of 60% graphite and 40% copper, is relatively expensive. However, it offers optimal wear-ing behavior and thus longer periods of use. An opening is also cut into all the electrodes making standardised fixing to the electrode holder possible. The bearing active preload system is now clamped to the FO 350 die-sinking machine, and the electrode magazine is loaded

with the electrodes. All the re-maining openings are machined in automatic operation, in part as undercuts, in that the electrode is screwed in for machining via the C-axis. After a total of 68 hours, the machining of the bearing active preload system is completed, with half of the time being taken up with wire cutting, the other with die-sinking ± 5 µm is achieved at mechanically criti-cal points, such as the thin webs, and all the machined surfaces show a surface quality of Ra 0.2 µm - performance lev-els that must be consistently achieved on all twenty bearing active preload systems Aire Erosion produces annually.

defined angles, all the openings are cut with one full cut and five trim cuts to achieve a final finish of Ra 0.2 µm. This is no simple undertaking with titanium, but one which Aire Erosion masters without problem thanks to the GF AgieCharmilles Clean Cut technology on the FI 440 CC. The surface coating influenced by the cut is thus minimized to a depth of 3 to 6 µm, no oxidation occurs and up to 66% of the impurities in the metal are eliminated. This ensures that the bearing active preload system can withstand the extreme conditions in airless space at zero gravity.

Details on the bearing active preload system make clear the high demand made by manufacturing with wire EDM cutting and die-sinking – difficulties increased by the titanium material itself, which requires special EDM technologies.


AERONAUTICS | AIRE EROSION 5

5-AxIS MILLING FOR FREEDOM OF SHAPE WHEN MANUFACTU-RING SURGICAL INSTRUMENTS

Leitner AG successfully uses high-speed milling machines from GF Agie-Charmilles for the manufacture of surgi-cal instruments. The instruments made of exotic materials in many cases are manufactured completely by the Swiss company and supplied to renowned med-ical technology firms all over the world.

GREAT MANUFACTURING DEPTH RECEIVES MANU-FACTURING COMPETENCE

Leitner AG was founded over 30 years ago and, under its present managing director and proprietor Daniel Müller, has specialized in the manufacture of surgical instruments. Mr Müller took a post graduate course in medical technical studies, and is thus the interdisciplinary interface between surgical requirements and manufacturing engineer-ing feasibility for his customers. Through complete production and with 35 highly specialized

Bore gauges for surgical implants are milled five-axially on the MIKRON HSM 400U as re-chucking is not possible because of the lack of reference straight lines.

The pallet changer of the MIKRON HSM 400U is loaded with up to sixteen workpieces which are then automatically worked off as finished bore gauges.

skilled employees, Leitner AG maintains the competence for quality and production for which it uses six heavy-duty, high-speed milling centres from GF Agie-Charmilles. Drilling, turning, mill-ing, laser welding and labelling, as well as polishing and abrasive blasting round off the machining procedures. Two surgical instru-ments provide insight into how Leitner AG effectively uses milling machines from GF AgieCharmilles.


MEDICAL INSTRUMENTS | LEITNER AG 6

www.leitner-ag.ch

LEITNER AG

Hauptstrasse 93

CH-2563 Ipsach

Switzerland

Phone +41-(0)32-331 30 77

Fax +41-(0)32-331 31 19

Contact

daniel Müller, Med. tech. NdS/HtI

Berne, Managing director

and Proprietor

[email protected]


- 3 MIKRoN HSM 400U

- 2 MIKRoN UCP 600 Vario

- 1 MIKRoN UCP 600

- 1 AC Classic 2S

Clamping system

Erowa

Programming

Mastercam

Surfcam

Certification

ISo 9001

ISo 13485

FIVE SIMULTANEOUS AxES FOR HSM MILLING WITH-OUT RE-CHUCKING

Leitner AG receives CAD data from customers for the manu-facture of bore gauges for surgical implants from which it creates the milling programs with Mastercam and Surfcam. Given the geometric character-istics of bore gauges – only flat die surfaces, re-chucking is not possible because of the lack of reference straight lines – Leitner AG uses a MIKRON HSM 400U. Thanks to its five simultaneous axes, this high-speed milling machine makes it possible to completely machine the bore gauges from 1.4301 steel and achieve a surface quality of N 6, a dimensional accuracy of 50 µm and a position accuracy of 30 µm over the whole workpiece. The machining takes place for the most part autonomously as the integrated pallet changer can be loaded with up to sixteen workpieces, which are then automatically exchanged and machined. «This dimensional and position accuracy on work-pieces, with practically only flat die surfaces to be achieved, is the most astonishing thing about the MIKRON HSM 400U for me,» comments Daniel Müller related to this order.

POWERFUL FEED WITH CFC MACHINING jOBS

The second machining example demonstrates the great variety of materials that are machined at Leitner AG. A surgical target clip made of carbon-fibre reinforced plastic (CFC) is to be milled at full speed. Surgical target devices are used for determining the exact position when screwing bones. The material used is CFC as it has the property of being radiolucent for x-rays and thus not visible on the monitor for the surgeon during the operation. Leitner AG uses a MIKRON UCP 600 Vario for the production, as this heavy-duty machining centre

with its sturdy construction and high own rigidity guarantee a reliable and efficient process for the machining of the tough material CFC. When machining the contour of the target clip, a vector regulation for full torque in the lowest area applies the power of the Step-Tec spindle optimally to the workpiece. «With the MIKRON UCP 600 Vario we were able to optimise the machining parameters for the material CFC without any prob-lem,» Daniel Müller explains the milling of carbon-fibre reinforced plastic for the first time.

The surgical target clips made of carbon-fibre reinforced plastic (CFC) are milled at full speed on the MIKRON UCP 600 Vario.

With its sturdy construction and great own rigidity, the MIKRON UCP 600 Vario is the ideal high-speed milling machine for machining the tough material CFC.

A surface quality of N 6 is achieved on the surgical bore gauge and the dimensional and position accuracy over the whole workpiece are in the five-hundredth range.


MEDICAL INSTRUMENTS| LEITNER AG 7

MANUFACTURE COMPLEx FORMS SIMPLY WITH EDMAn excellent price and performance ratio, quick delivery as well as constantly high quality and reliability are characteristics of Rawela, s.r.o. in Lanškroun. The Czech company belongs to the German Weidmüller Group, and designs and makes tools for customers in the whole of Europe.

Wire EDM and die-sinking are the pre-cision manufacturing methods with which the finest webs, narrow slits or complex forms, such as in the case of an injection molding tool for terminal blocks, can be realized.


MOLDING | RAWELA 8

RAWELA

Žichlínek 162

563 01 Landškroun

Czech Republic

tel. +420-465 321 240

Fax +420-465 325 003

Contact

Jiří Kolá, Head of tool Making

Jaroslav Langer,

Head of Injection Molding

[email protected]


- 1 FI 2030 SI with robot

- 1 FI 2030 SI

- 1 FI 200

- 2 AC Progress V2

- 2 AC 100d

- 1 Fo 350 S

- 1 Fo 350

- 1 Fo 200

Clamping system

Erowa

Programming

Catia 5.0

Peps

Measuring, testing


from Mitutoyo

Profile projector

Roughness measuring device

«We know from Weidmüller that with machines from GF AgieCharmilles we are manufacturing with a guar-anteed future. And with its new branch in Brno, GF Agie- Charmilles is, so to speak, just round the corner.»

said Jiří Kolá,

Head of Took Making at Rawela

Constant quality checks and meticulous work are the best guarantee for Rawela for the supply of optimal products, such as these terminal blocks.

TOGETHER OVER 40 YEARS OF TOOL-MAKING ExPERTISE

Rawela s.r.o. was founded in in 1994 as a Czech-German tool-making business. Since the company’s inception, it has been based in the new indus-trial estate in Žichlínek near Lanškroun, not far from the Polish border. Together with Weidmüller, Rawela can look back over 40 years of know-how in the manufacture of injection molding and punching tools. «Building up on this,» says Jiří Kolá, Rawela Works Manager, «our tools are constantly being improved in that the latest pro-duction methods are applied.» Rawela designs and constructs 60 completely new tools per year, and in addition there are approx. 40 tools, which are modified and improved. A six-way injection molding tool for the production of terminal blocks shows Rawela’s method of procedure with one of these new tools.

THE INTERPLAY OF MANUFACTURING PROCESSES IS DECISIVE

For the six-way injection mold-ing tool, Rawela selected 1.2767 steel, which was vacuum-hard-ened after milling the external die and the large areas. After surface grinding, all the starting holes for the wire EDM process were cre-ated. The next step was the cut-ting of the ejectors and inserts, as well as the manufacture of the copper electrodes with wire EDM and Milling. Ten copper elec-trodes were used on the FO 350S die-sinking machine with which the basic forms were ED ma-chined. A further ten electrodes were used when die-sinking the slide, all of which were exchanged automatically by means of an attached robot. After assembly, the six-way injection molding tool, with which then 300,000 terminal blocks made of PA 66 were pro-duced monthly, weighed 300 kg.

PRECISION ON THE WORKPIECE BRINGS PRECISION ON THE FINISHED PART

A surface quality of VDI 22 had to be reached on the form-giving parts and a tolerance accuracy of ± 0.1 µm over the complete six-way injection molding tool. These daily recurring precision requirements and, not least, also the good experience of the par-ent company in Germany, were the crucial factors why Rawela invested in ED machines from GF AgieCharmilles. So the FI 2030 SI ED wire-cutting machine and the FO 350 S ED die-sinking machine, both of which offered the best prerequisites for optimal results with their high repetitive and positioning accuracy, were used for machining the mold inserts of the six-way injection molding machines.

All the routine procedures, such as electrode or workpiece changing, are automated to the greatest extent at Rawela. GF AgieCharmilles has supplied personalised solutions for this, which meets Rawela’s requirements exactly.


MOLDING | RAWELA 9

ECONOMIC MILLING IN TOOL AND MOLD-MAKING

With over 30 years of experience in tool-making for household articles, food and drink in-dustry, as well as for pharmaceuti-cal and cosmetic products, GB Pre-cision Engineering has developed an exceptional reputa-tion in the market-place. The English company uses GF AgieCharmilles Milling and EDM equipment to achieve precision on the workpiece, as well as eco-nomic machining.

SUCCESS WITH CONTINU-OUS INVESTMENT

An outer suburb of Birmingham is the base of GB Precision Engi-neering, where seven employees develop, design and manufacture tools and components. Asked about the company’s philosophy, the managing director, Paul Turner, responds, «Investments in people and machines are money well spent, paying off with excellent results for the cus-tomer.»

The end result of this philosophy includes two milling and three electrical discharge machines from GF AgieCharmilles in use in GB Precision Engineering’s workshop. A mold insert job lot for an injection molding die for the production of beverage bottle caps reveals the ways in which GB Precision Engineering uses its MIKRON VCE 1000 Pro milling machine effectively.


MOLDING | GB PRECISION 10

www.gbprecision.co.uk

GB PRECISIONENGINEERING

1 Port Hope Road

Sparkbrook

Birmingham B11 1JS

United Kingdom

tel. +44 (0)121 766 7008

Fax +44 (0)121 773 2824

Contact

Paul turner, Managing director

[email protected]


- MIKRoN VCE 1000 Pro with a

double pallet changer

- 1 Bostomatic 32 GS

- 2 At Hyperspark 2

- 1 AC Progress 2 with Workpal

Clamping system

dynafix Macro and Junior from

System 3R

Programmierung

Mastercam

Peps from Camtek

Measuring, testing

Profile projector

Co-ordinate measuring

machine from Mitutoyo

Microscope

«the MIKRoN VCE 1000 Pro is used by us univer-sally. From the finest detail to coarse roughing jobs. A machining centre with a convincing price/perform-ance ratio.»

said Paul Turner, Managing Director

GB Precision Engineering

Workshop drawings and mold inserts show the forced vent apertures, which were drilled and milled with the MIKRON VCE 1000 Pro.

The holes, which serve as the forced vent apertures during the injection mold-ing process, are to be seen clearly after the drilling process on the MIKRON VCE 1000 Pro.

The MIKRON VCE 1000 Pro is the ma-chining center GB Precision Engineering uses to execute difficult jobs.

THE FORM DETERMINES THE MACHINING PROCE-DURE

For these mold inserts, GB Precision Engineering selected blanks made of 440 C steel, which were machined in nine steps. First, the outside con-tour with the projecting edging is turned. Next, all the holes are drilled with a 0.7 mm drill diagonally from the upper end to the inside on the MIKRON VCE 1000 Pro. A 3 mm ball nose cut-ter is automatically exchanged to create the contoured surface. Using the MIKRON VCE 1000 Pro means that GB Precision Engi-

VERSATILE ENOUGH FOR ALL CONTRACT jOBS

«With regard to its performance profile, the MIKRON VCE 1000 Pro is the ideal machining centre for our application spectrum,» managing director Paul Turner observes, underlining this ma-chine’s standing in his company. And indeed, the VCE Pro series offers a large number of capa-bilities and functions, which are unique in this class:- A good view of the workpiece from three sides- Shorter downtimes through lateral tool changers

neering can leave the flat surface from turning and machine that would normally be a turned feature on the machine without having to add another operation. At least there is a further change of tool and then the interior of the mold insert is milled with an 8 mm milling cutter. After these machining steps, the mold in-serts are hardened by an outside company. Back at GB Precision Engineering, narrow slits are made by means of die-sinking EDM on the AT Hyperspark 2. The mold inserts are then moved to the MIKRON VCE 1000 Pro once again for milling for the concluding machining tasks.

- Reliable machining with tool probe TS 27- The Heidenhain control «speaks» the workshop’s language- Digital drive technology for optimal control dynamics- Robust mechanism for excellent damping

The above properties are highly regarded by GB Precision Engineering in everyday work because they enhance manufac-turing reliability and the preci-sion on the workpiece.


MOLDING | GB PRECISION 11

GF AGIECHARMILLES: NEW TECHNOLOGY SET FOR DEBUT AT EMO MILANGF AgieCharmilles, already well-known as the world’s leading supplier of machines, automation solutions and services to the tool and mold-making industry, will unveil a completely new technology at EMO Milano 2009, scheduled Oct. 5-10, in Exhibition Area Fieramilano, Strada Statale del Sempione 28, Milan. The centerpiece of GF AgieCharmilles’ exhibition at EMO 2009 is its invitation for visitors to «Experience more» of the products and solutions that have long made GF AgieCharmilles a preferred partner.

at EMO Milan 2009 a selection of EDM, Milling and Automation Solutions that take precision and effi ciency in production to new heights.

Specifi cally, GF AgieCharmilles’ EMO Milan 2009 presence will feature three milling machines (MIKRON HPM 800U, MIKRON HPM 600 HD, MIKRON HSM/XSM 400/400U LP), four electro ero-sion machines (FORM 2000 HP, FORM 1000, CUT 1000 OilTech,

CUT 30), a smart machine corner demonstrating modular solu-tions bringing together the best of GF AgieCharmilles’ tech-nologies, an area spotlighting Step-Tec motor spindles. In addi-tion – a nice hospitality area – where visitors can meet with GF AgieCharmilles representatives to discuss the range of available technologies and solutions best suited to their individual busi-nesses, will be open.

From 9:30 a.m. to 6 p.m. daily, visitors to GF AgieCharmilles’ exhibition space in Hall 7, Booth # F13/E20, will «Experience more» of the company’s wide range of products and solutions, including the new laser technol-ogy that will be demonstrated at EMO, as well as innovative approaches to electric discharge machining, milling, customer services, automation, and motor spindles. Underpinning it all is GF AgieCharmilles’ commitment to enabling customers’ success across a wide range of industrial segments: injection molding, tool and die, aeronautics and aerospace, motor sports, and the production of medical and dental implants, instruments and ap-pliances.

Supporting this wide array of success-enabling technolo-gies, automation solutions and support is the service and Swiss reliability for which GF Agie-Charmilles is known. As custom-ers increasingly look for better value in terms of product func-tionality, design and reliability, GF AgieCharmilles demonstrates

EMO 2009Hall 7 Booth # F13/E20

EMO | MILANO 2009 12

EMO MILAN 2009:EAGERLY AWAITEDINTERNATIONAL EVENT

Focusing on metal forming and metal cutting machine tools, machines for welding, thermal and surface treatments, robots, automation hardware and soft-ware, assembling, tools, parts, accessories, metrology, quality control, and safety and environ-mental protection systems, EMO Milan 2009 provides an ideal backdrop for GF AgieCharmilles’ unique offering. The exhibition is sponsored by CECIMO, a Euro-pean consortium of machine tool organizations, and held every six years in Milan. EMO Milan

A modern and welcoming space featuring a variety of innovations in EDM and Milling, as well as the unveiling of a new technology, make the GF Agie-Charmilles exhibition the place to be at EMO Milan 2009.

«Experience more» is the promise of GF AgieCharmilles’ exhibition space at EMO Milan 2009. Visitors are invited to experience more performance, greater reliability and a wide range of machines, services and automation possibilities.

GF AGIECHARMILLESTO HOST SHOWIN SCHORNDORF

As a special follow up for those customers and colleagues un-able to visit EMO Milan 2009, GF AgieCharmilles goes a step further this year by hosting its fi rst International Technology Show (ITS) at its new World Ap-plication Center in Schorndorf, Germany. The event, scheduled Oct. 23-30, will spotlight 15 GF AgieCharmilles products in a state-of-the-art, 1,400-square-meter showroom.

2009 represents a universe of know-how and is widely regard-ed as one of the most eagerly awaited events of each decade by the worldwide manufacturing industry.

With a net exhibition area of about 100,000 square meters, EMO Milan 2009 will feature more than 1,250 companies representing at least 35 coun-tries. In 2003, EMO Milan drew a crowd of about 155,000 people to the capital of Lombardy to explore exhibitions covering all segments of the industry, from metal forming and metal cutting to components, tools, robots and automation.


CUSTOMER SERVICES:A CONTINUUM OFSUPPORT

Preventive maintenance, training opportunities, original parts and certified consumables, a customer helpline and the renowned Privilege Club form the core of GF AgieCharmilles’ Customer Services Business, proudly offering the most comprehensive service package in the industry. As part of GF AgieCharmilles’ exhibition at EMO Milano 2009, representatives of the Customer Services Business will showcase a broad range of services designed to help customers experience more success throughout the lives of their businesses.

As a world leader in electric discharge machining (EDM) and high-speed and high-per-formance milling (HSM/HPM), it should come as no surprise that GF AgieCharmilles offers a superlative range of services designed to enable customers’ success. With more than 700 engineers worldwide, more than 10,000 combined years of market experience and the world’s best structured sales and service organization, GF AgieCharmilles is uniquely positioned to make its customers more competitive with a continuum of support from a single, reliable source.

ORIGINAL PARTS, CERTIFIED CONSUMABLES ExTEND EQUIPMENT LIFE

By using GF AgieCharmilles original parts and certified consumables, you extend the life of your equipment and build your business with the confidence that your equipment is operating at peak precision and performance.

Only GF AgieCharmilles can guarantee the various tolerances demanded by GF AgieCharmilles products. By using our original

parts and certified consumables, all specifically designed and manufactured to meet our high standards and your daily needs, you keep your production levels highly predictable and protect your equipment from damage.GF AgieCharmilles original parts did not happen overnight; they are the result of painstaking research and rigorous testing of our machines’ components to gauge their performance and meet highly-demanding produc-tion specifications both internally and with subcontractors. Our exacting quality management process includes close analysis of failures, allowing us to quickly implement corrective measures when necessary.

Wire, resin, filters and dielectric fluids all play important roles in the smooth operation of your GF AgieCharmilles equipment; that is why we select only those man-ufacturers who adhere strictly to our demanding standards and who produce high-quality consumables.

Ninety-five percent of all GF AgieCharmilles parts are avail-able for next-day delivery, once again confirming the company’s

industry leadership and commit-ment to the smooth operation of your business.

HELPLINE PLACES OUR ExPERTS AT YOUR FINGERTIPS

Our experts, each completely dedicated to providing unparal-leled service, are on call daily to answer your questions. They draw on a legacy of experience and knowledge to provide solu-tions customized to your needs.

Our goal is to continuously and seamlessly provide you with ways to retain your competitive advan-tage. Seventy-percent of equip-ment problems can be resolved by telephone; our helpline team exists to ensure your success.

PREVENTIVE MAINTENANCE MEANS LESS DOWN TIME

Whether the economic environ-ment is booming or receding, GF AgieCharmilles’ preventive main-tenance agreement ensures less machine down time and greater productivity, factors which together mean more success for your business. A simple precautionary meas-ure, the preventive maintenance agreement can result in as much as seventy-percent less unpro-ductive machine time as well as greater machine reliability, assurance that machine opera-tion continues at optimal levels, longer equipment service life, and enhanced equipment per-formance.

GF AgieCharmilles preventive maintenance protects custom-ers’ investment by positioning customers to get the most value from their machines.

TRAINING ENHANCES COMPETITIVE EDGE, MAxIMIZES POTENTIAL

Years ago, learning by doing might have been enough to maintain optimal equipment performance, but in today’s ex-tremely competitive global busi-ness environment, maintaining performance means maintaining a competitive edge. That is where GF AgieCharmilles training can play a key role in the success of your business.

Effective training enhances your competitive edge by improv-ing your production quality and enabling you to meet the grow-ing, changing demands of your customers. As a world leader in spark machining and milling,

GF AgieCharmilles has devel-oped a unique training concept to help you achieve – and main-tain – excellence.

PRIVILEGE CLUB SHOWS OUR LOYALTY TO CUSTOMERS

Every GF AgieCharmilles cus-tomer is a member of the Privi-lege Club which demonstrates our loyalty to our customers and offers access to exclusive advantages. By earning Privi-lege Points, our customers can receive value-added services at special prices and save money with each purchase.

The Privilege Club is already available in many regions like Italy, France, Germany, North America and many more will follow.

Benefits with real-world busi-ness value are at the center of GF AgieCharmilles’ Customer Services Business, and there is no better time than EMO Milan 2009 to find out just how our service offering can help you maximize your equipment investment.




SMART MACHINE:DISTINCT ADVANTAGES FOR MILLING AND EDM

GF AgieCharmilles’ smart machine technology brings new in-telligence to Milling and EDM processes with a range of Smart Modules that support the machine operator and improve over-all performance and productivity. The distinct advantages of smart technology will be spotlighted in a special smart ma-chine corner in GF AgieCharmilles’ booth at EMO Milan 2009.

Three-dimensional setup on AC VERTEX machine.

Econowatt screen on FI 240 CC.

SMART MODULES OPTIMIZE MILLING, SUPPORT OPERATOR

To make smart machining possi-ble on the milling side, GF Agie-Charmilles established compre-hensive communication between its machines and their operators so that the operator receives the precise information necessary to assess the milling process. In addition, GF AgieCharmilles smart machine technology sup-ports the operator in optimizing the milling process, considerably improving performance. Based on that precise information and the operator’s assessment, the machine optimizes the milling process, improving both safety and quality, all in an unmanned operation.

The result is a whole host of benefits to your milling opera-tion: greater accuracy in shorter machining times; improvements to workpiece surface quality as well as surface and shape ac-curacy; recognition and execution of critical machining strategies; greater process safety; higher availability of the machine; better operating comfort; and consid-erable increases in reliability in unmanned operations.

New for GF AgieCharmilles smart machining technology is the PC diagnostic and reporting software, machine monitoring system (MMS), which promptly recognizes possible disturbances on the milling machine and sup-ports preventive maintenance.

The diagnostic messages are au-tomatically transmitted by email via Ethernet; by LSV2 protocol for direct alarm feeding into the software; or by SMS with RNS (Remote Notification System). The MMS software supervises, announces and visualizes op-eration conditions of GF Agie-Charmilles milling machines and logs all events. It is the perfect support in the rapid recognition and efficient avoidance of poten-tial component crashes.

As a result, the machine user does not have to actively com-pare data to notice a mainte-nance deficit because MMS looks for such deficits. With MMS, the operator observes the machine in real time. Component modules are diagnostic, maintenance, process and efficiency.

Other features of GF Agie-Charmilles’ smart machine technology: the system counts operation hours with an eye to preventive maintenance for your machine components; opera-tional data counter and statistical evaluation to improve maintain-ability of your machine; diagnosis and tracking of machine errors; monitoring of the machine’s operating conditions; and receive email or a text message if an error occurs during the milling process.

EDM NOW COMPLETES GF AGIECHARMILLES’ SMART MODULE WORLD

The intelligence and expertise of GF AgieCharmilles smart nodule technology is now available as an option or separate module on the company’s EDM machines, rep-resenting a distinct advantage to customers worldwide and moving GF AgieCharmilles ahead of most of its competitors.

Availability of GF AgieCharmilles EDM smart modules supports the machine operator through-out the EDM process and is a revolutionary step in optimization of EDM machining. GF Agie-Charmilles already is known for its wealth of achievements in this field, including: Integrated Collision Protection (ICP) which protects the machine in handling potentially-fatal errors; «expert

systems» that assist facilitation of machine use under optimal conditions; availability of GF AgieCharmilles expertise for machining with large angles, particularly in molding applica-tions; and the transfer of data and machining results with the most sophisticated means, including SMS.

Smart Modules are evidence of GF AgieCharmilles’ keen awareness of customers’ need for increased productivity and their heightened awareness of the environmental importance of energy conservation.

Econowatt (ECO) establishes GF AgieCharmilles’ leadership in energy savings and environ-mental preservation. ECO allows you to stop and restore optimum conditions for the EDM machines with the Stop and Start option,

allowing significant energy sav-ings. Further, the Advanced Setup (ASET) function makes the opera-tor aware of the exact position of parts in the machine; different alignment cycles acquire and au-tomatically correct the reference. Alignment of the upper surface of a piece may, depending on the machine and required tolerance, be achieved with standard or very high precision probes.

The Job Management System (JMS) offers great advantages for the multi job which can be fully controlled through the list of preparations parameterized independently. Autonomous management of each job even offers the possibility of introduc-ing an urgent job into the list at any time and allows for necessary suspensions and safeguarding machining parameters related to the piece at hand.

Precision Protection Productivity


LASER: ExPERIENCEOUR LASER TECHNOLOGYA new GF AgieCharmilles technology offers customers an opportunity to take their competitive edge in Milling and EDM to the next level. Laser technology presents a wide spectrum of intriguing possibilities for customers who want to differentiate themselves in a highly-competitive marketplace, gain new customers and reap the benefits of an excellent price/performance ratio.

A STEP AHEAD OF THE COMPETITION

The newest applied science from GF AgieCharmilles dovetails perfectly with customers’ search for new application fields, allows them to extend their product range and differentiates their market presence from that of their competitors. EMO Milan 2009 is the first step toward acquiring the necessary knowl-edge to make the best use of GF AgieCharmilles’ new technology – before your competitors do.

The history of industrial devel-opment shows that there are certain rare windows of opportu-nity when critical decisions must be made. The decision to invest in a new technology at a certain point in time should not be made lightly. GF AgieCharmilles – an established technology leader – is positioned with a track record for enabling its customers’ success, as well as the products, services and emerging technolo-gies to help take your business to the next competitive level.

WE ENABLE GREATER SUCCESS

It is common knowledge that every machining technique has unique advantages and limita-tions, but GF AgieCharmilles is convinced that its new technology will enable customers to achieve sustained success.

In launching its new Laser tech-nology, GF AgieCharmilles brings together the best of EDM and Milling expertise for the benefit of customers. EMO Milan 2009 is the place to learn how our Laser technology can be used profitably in conjunction with your existing or new GF AgieCharmilles EDM and Milling machines.

Revolutionizes 3D electrode texturing.

Roll engraving and texturing.

Distinct surfaces like loudspeaker grids.

Plastic cap molds.

New opportunities for thermo forming technique.

Three-dimensional mold texturing.

At EMO Milan 2009, GF Agie-Charmilles will debut its Laser technology, which is ripe for ap-plication within a completely new product range. Visitors to EMO Milan 2009 will be the first to see how the new technology extends GF AgieCharmilles’ already impressive portfolio of EDM and Milling products.

ENTRY LEVEL TO HIGH END: IT’S ALL HERE

Wherever you are in the life of your business – just starting out, growing and looking for ways to increase your market presence, or well-established and using the most high-end EDM and Milling machines – GF Agie-Charmilles’ Laser technology is available in a complete product range, from entry-level to high-end models.

Intrigued? Meet us at EMO Milan 2009 – and be prepared to expe-rience more. Can’t wait to learn more? Have a look here for more information: http://www.gfac.com/index.php?id=13803





MILLING: POSITIONINGCUSTOMERS FOR MORE SUCCESSFor machining operations large or small, fully, partially or not yet automated, GF AgieCharmilles Milling products position customers to experience more success than their competitors.

providing excellent results under regular workshop conditions, as well as a solution to industries dependent on the recuperation of even the smallest chips of high-value materials like gold and other precious metals. The con-struction deliberately separates the chip from the lubricant. Sev-eral chip management options, including a wash down system to keep the work space free of chip deposits, are available.

For the reduction of unproduc-tive – and costly – down time, GF AgieCharmilles offers a range of automation solutions for the HSM/XSM LP series, from a well-established pallet magazine with System 3R and Erowa interface to single part handling with an industrial robot supported by a vision system. Optional automa-tion systems allow for highly-efficient use of the machine as well as alignment of production to specific needs and situations – putting customers in the driver’s seat when it comes to flexibility.

The MIKRON HSM/XSM LP series takes precision chipping to a new level. Precise compliance of the tool path in high feeds defines the surface quality of the concave and convex surfaces, so the mill-ing texture on the workpiece is among the most critical consid-erations in high-speed milling (HSM). The MIKRON HSM/XSM 400/400U LP represent a new benchmark, with geometrical stability ensured by continuous control of every cooling circuit. Because each linear axis has its own cooling circuit, the heat is re-moved entirely from the machine and not distributed within the machine.

Outstanding accuracy is achieved through digital cleaning of the tool cutting edge before milling. This revolutionary approach en-hances dramatically the reliability of accurate machining.

In total, the HSM/XSM LP series stands as a new benchmark in milling and a testament to GF AgieCharmilles’ commitment to making its customers more suc-cessful.

HSM/xSM LP SERIES: A BRIGHT IDEA BECOMES REALITY

Versatility and attention to both accuracy and surface finish make GF AgieCharmilles HSM/XSM LP (Linear Performance) series with approved linear motor technology the ideal solution for a wide range of machining operations, whether the focus is prototypes, molding, or fully-automated small series production.

Two years after GF AgieCharmilles premiered a prototype of its MIKRON XSM technology at EMO Hannover 2007, the idea has become a mature product line that will debut at EMO Milan 2009, with the MIKRON HSM/XSM 400/400U LP, which have dem-onstrated their reliability during beta testing with customers.

To achieve the superior perform-ance and reliability expected of a mature product line, GF AgieCharmilles relied heavily on feedback from customers using the MIKRON HSM/XSM 400/400U LP series under demanding condi-tions. As a result, while the exter-nal appearance of the series is unchanged, most internal compo-nents were completely redesigned, yielding an extremely powerful and solid HSC machine. For the customer, these improvements mean extraordinary value across a wide range of applications.

The new OPTICOOL 42,000 min-1 motor spindle by Step-Tec, with its high- torque of 8.8 Nm (S6, 40 percent) – double the torque of the previous spindle model – yields economical axial and radial cutting depth during the milling process, efficiently addresses the high chip removal requirements for today’s milling from solid. At the same time, the OPTICOOL concept of the spindle nose cool-ing system permits a previously unknown degree of precision on the workpiece during long processing times with a single tool, and the oil/air system con-tinuously lubricates the spindle’s ceramic hybrid ball bearings. Efficient chip management is another feature of the series,


The MIKRON HSM/XSM LP series fea-tures linear motor technology on all axes.

The MIKRON HSM/XSM LP series pushes technology to the limit with a perfect sym-biosis of dynamics and precision.

Visitors to our EMO Milan 2009 exhibit will get a taste of GF AgieCharmilles’ leading-edge applied science, including intel-

ligent tool measurement, linear motor technology, multi-axis machining, and expanded pal-letization options, all engineered

with an eye to each customers’ needs for more machine value and greater productivity.


MIKRON HPM 600 HD, 1200 HDOFFER A WORLDOF ADAPTABILITY

When performance counts, customers count on GF Agie-Charmilles to support them as their businesses grow and change, as evidenced by the MIKRON HPM 600 HD and 1200 HD high-performance machining centers. The HPM HD series is impressively adaptable: non-automated machine tools today, GF AgieCharmilles pallet chang-ers tomorrow, and industrial robots to take your operation into the future.

The spectrum of requirements fulfi lled by the series is both vast and specifi c. Prototype construc-

PALLET CHANGING GETS EASIER WITH MIKRON HPM 600U AND 800U

GF AgieCharmilles makes pallet changing a snap for the MIKRON HPM 600U and 800U, now avail-able with a two-pallet changer or seven-, nine- or 12-pallet magazine. Customers will get a close up look at the MIKRON HPM 800U with a seven-pallet magazine at EMO Milan 2009.

The pallet changing system expedites machine operations without limiting ergonomics in the work room and load-ing station. But that is not the only exciting characteristic of the MIKRON HPM 600U and 800U, designed for the universal production of high-quality parts with three, four or fi ve axes. The series also features state-of-the art motor spindles, directly driven rotary and swiveling axes and stable construction which, together, are the ideal founda-tion for economical and accurate machining in modern tool and mold making as well as the pro-duction of high-quality parts.

The high-performance machin-ing centers boast a unique ma-chine base concept containing strong driving elements of the X,

must be avoided. The solution is highly effi cient removal of chips from the machining area. Several chip management options are available.

How can the MIKRON HPM HD range be adapted to meet chang-

Y and Z axes, allowing optimal automated loading of workpieces via the pallet changer, and a tool changer that can accom-modate 30, 60,115, 165 or up to 210 tools.

The MIKRON HPM 600U and 800U line is a stable, extremely compact basic machine fea-turing a large work area. The maximum X-Y working range of the MIKRON HPM 800 U is 800 millimeters x 800 millimeters. At the Z axis, the machine offers

Work areaLongitudinal X mm Lateral Y mm Vertical Z mm Working spindle (40% ED, S6)15’000 rpm, ISO-SK40 kW / Nm 20’000 rpm, HSK-A63 kW / Nm Feed rateFeed rate / Rapid traverse (X, Y) m / min Feed rate / Rapid traverse (Z) m / min Work tableClamping surface mm Max table load kg

MIKRONHPM 600 HD

600600500

39/8439/84

40 30

800x600500

MIKRONHPM 1200 HD

1200600500

39/8439/84

40 30

1400x6001200

thanks to modular design and engineering.

In addition, low-vibration move-ment control on all axes allows for not only output intensive rough machining but for dynami-cally precise path guidance dur-ing surface fi nishing.

a clearance of 800 millimeters from table surface to the spindle nose. The maximized work area enables the machining of cylindrical workpieces of up to 800 millimeters in diameter. The dimensions of the rotary swivel table make it possible to machine workpieces up to 600 millimeters tall, using 100 millimeter-long tools.

The MIKRON HPM 800U takes versatil-ity to a new level, allowing mixed use and pallets loaded up to 500 kilograms each.

Shown here is the loading station for two-pallet version of the MIKRON HPM 800U. The pallets can be rotated 360 de-grees, so the work pieces are accessible from all sides.

The loading of pallets with a crane is much easier with the big magazine door of the MIKRON HPM 800U. Oscillating workpieces can be placed securely.

The MIKRON HPM 800U changes the pallets through the machine, resulting in unlimited work room and loading station ergonomics.

Top view of Delphin clamping chucks

tion, mold making, fully automat-ed small series production, out-put intensive high-performance cutting (HPC) milling operations, and dynamic surface fi nishing are just a few of the applications to which the MIKRON HPM 600 HD and MIKRON 1200 HD are perfectly suited.

The HPM 600 HD is the small-est machine in the range, and its larger sister machine, the HPM 1200 HD, offers increased X working range. Both have a Y working range of 600 millimeters and a Z working range of 500 millimeters for trouble-free ma-chining of large workpieces.Since chip volumes generated by HPC milling can take on consid-erable dimensions, even small amounts of chip accumulation

ing needs? The basic machine with its 30-piece tool magazine is a reliable production asset with-out automation but a world of automation possibilities opens up with the 60-piece tool magazine, readying the machine for easy automation with pallet changers and automation interface. There are several automation alterna-tives available–from the estab-lished Mikron solution in-house pallet magazine to robot assem-bly by well-known manufactur-ers. Also a novelty is the acces-sibility of a Delphin table. This innovation makes the HPM series even more fl exible and functional than it already is. The addition of an industrial robot is easily ac-commodated by retrofi tting or as a special solution, depending on the customer’s particular needs,

250 mm

250 mm




FORM 2000 HP: A graphite electrode with very thin walls is a typical example of a highly demanding application where, thank to iQ technology, machining can be performed with wear-free erosion of the electrode for highest accuracy and effi ciency.

EDM:HIGH PERFORMANCEAND HIGH PRECISION

High performance, high precision and deep understanding of EDM customers’ needs GF AgieCharmilles hallmark, and these values are mirrored in three new product ranges to be featured at EMO Milan 2009.

In the EDM spotlight at GF Agie-Charmilles exhibition space will be the FORM 2000 HP and FORM 3000 HP, the FORM 1000, the CUT 1000 OilTech and the CUT 20 P and CUT 30 P.

FORM 2000 HP/3000 HP:HIGHEST PRECISIONAND PRODUCTIVITY

High precision is the hallmark of GF AgieCharmilles’ new FORM 2000 HP and FORM 3000 HP, die-sinking machines that take over where the FORM 2000 and FORM 3000 left off. Engineered to meet the most exacting standards of accuracy and high-est productivity demands, the FORM 2000 HP and FORM 3000 HP offer modular automation, high removal rates, innovative iQ technology for minimum elec-trode wear in electric discharge machining and exceptional posi-tioning accuracy to meet the very strict requirements of technical mold making.

The FORM 2000 HP and FORM 3000 HP features a new, so-phisticated and unique Thermo Control system which compen-sates for temperature variations, offering unmatched precision under workshop conditions. Temperature stabilization is achieved by cooling the X, Y and Z glass scales with stable temperature dielectric, acting as a constant reference for the temperature compensation sys-tem. As a result, each individual machine axis is optimized for its specifi ed size.

With µm-exact precision on the workpiece, both ED die-sinking models meet the high demands of technical mold making and highly demanding applications. Typical applications include multi-functional plastic parts, like webs, jaws, apertures and cavities which make possible the installation and secure mounting of electrical components. The necessary precision is achieved by ED machining with µm-exact axis positions. Properties that make maximum productivity and maximum precision possible include: modular, integrable electrode and pallet changer; improved travel paths of 400 x 300 mm the X, Y and Z axes on the FORM 2000 HP, and travel paths of 600 x 400 x 500 mm on the FORM 3000 HP; and an ISPG generator for high removal rates in all application fi elds.

In addition, the series features GF AgieCharmilles’ own iQ innovative quality technology as an integrated feature. This outstanding and unique feature makes wear-free ED machining possible with graphite elec-trodes, vastly reducing electrode costs and providing for higher form accuracy. At EMO Milan 2009, GF AgieCharmilles will debut some astounding improve-ments to this already outstand-ing technology.

Another impressive innovation on the FORM 2000 HP and FORM 3000 HP is the introduction of Smart Modules, allowing the operator to take advantage of the series’ powerful features to max-

In the EDM spotlight at GF Agie-Charmilles exhibition space will be the FORM 2000 HP and FORM 3000 HP, the FORM 1000, the CUT 1000 OilTech and the CUT 20 P and CUT 30 P.

FORM 2000 HP/3000 HP:FORM 2000 HP/3000 HP:HIGHEST PRECISIONHIGHEST PRECISIONAND PRODUCTIVITYAND PRODUCTIVITY

High precision is the hallmark of GF AgieCharmilles’ new FORM 2000 HP and FORM 3000 HP, die-sinking machines that take over where the FORM 2000 and FORM 3000 left off. Engineered to meet the most exacting standards of accuracy and high-est productivity demands, the FORM 2000 HP and FORM 3000 HP offer modular automation, high removal rates, innovative iQ technology for minimum elec-trode wear in electric discharge machining and exceptional posi-

imize effi ciency and economics. An example is Econowatt, which enables consistent savings of electrical power by optimizing the use of power-consuming re-sources. Other smart machines enable consistent savings on the number of electrodes required to machine multi cavities, or connection of the machine with an external server for remote monitoring.


Finest roughness down to Ra µm and perfect surface quality are the require-ments for this extrusion die made of carbide.

Perfect contour accuracy, small wire down to 20µm diameters and small inter-nal radii are required for this element of a punching tool made of carbide and micro shapes.

GF AgieCharmilles’ CUT 20 P and CUT 30 P features AC Easy CAM, a user-friendly system that allows for the easy execution of even complex contours.

FORM 1000 REPRESENTS LEAP IN ACCURACY

With the FORM 1000, GF Agie-Charmilles – already a tech-nology leader – offers a leap in accuracy by building on the experience, know-how and performance established by the FORM 2000/3000.

Equipped with the ultra-modern, high-performance ISPG gen-erator that allows for a high degree of compatibility between high-precision applications and already is standard on the FORM 2000/3000 HP, the FORM 1000 is ideal for a wide range of uses and especially for micro applica-tions.

The FORM 1000, with the new module generator integrated in the work area for best efficiency in erosion, makes it possible to machine tool with a smaller surface (1mm2) and a roughness of Ra 0.05 microns on the final piece. Thanks to new iQ tech-nologies for nominal electrode wear, the extraordinary perform-ance of the FORM 1000 opens up new application horizons in fields like watchmaking, medical instruments and implants, mi-croelectronics and high-precision molding.

A mechanical structure with in-novative patented monobloc cast-ing for separate main axes, dual measuring system on all axes, and strict separation of the heat

CUT 1000 OILTECH SETS THE STAGE FOR MACHINING IN OIL

GF AgieCharmilles’ new CUT 1000 OilTech, a variant of the well-known CUT 1000, allows for the use of oil as a dielectric and boasts a new generator to cover the requirement of specific appli-cation fields. Its design, thermal behavior and control system are consistently identical to the CUT 1000.

The CUT 1000 OilTech was spe-cifically developed to accommo-date oil as a dielectric fluid. The new machine will no doubt inter-est the watch industry because it

CUT 20 P, CUT 30 P: ATTRACTIVE PRICE, USER-FRIENDLY INTERFACE

The evolutions embodied in GF AgieCharmilles’ CUT 20 P and CUT 30 P make the production of standard molds and general mechanics parts more efficient, with a complete package and an excellent quality/price ratio.Characterized by a high level of reliability, GF AgieCharmilles products are especially appealing to customers who are sensitive to rising costs. For these custom-ers the CUT 20 P and CUT 30 P are ideal: they are available at an attractive price and with a com-plete package that allows them to quickly become productive.The technologies developed for the CUT 20 P and CUT 30 P makes possible the production of parts under less-than-suitable

conditions, because the ma-chines’ design takes workpiece variances into consideration, detecting differences in material thickness and adapting automat-ically to changing conditions to ensure continuous production.As with all GF AgieCharmilles machines, the CUT 20 P and CUT 30P are equipped with quality glass scales, excellent ergonomics, an extremely ac-cessible workpiece area and a user-friendly interface. The user interface facilitates direct and intuitive dialogue. Data input takes place in a structured way with pictures and symbols guid-ing even inexperienced opera-tors to fast and effective results. The series’ technology package ensures optimal performance in cutting speed as well as good surface quality.

source and electro erosion create the FORM 1000’s exceptional characteristics: travel paths X, Y and Z of 220 x 160 x 250 mm; maximum piece size of 550 x 330 mm; positioning accuracy of ± 1µm on the whole axis travel; and excellent surface quality (RA of 0.05 µm).

The FORM 1000’s modular tool changer has a capacity of 300 tools, allowing for the execution of work involving a multitude of electrodes, and the machine is equipped with the powerful VISION 5 control, with new features tailed to micro erosion applications. Other prominent features of the VISION 5 control are the ability to directly import of workpiece and electrode data, and integrated work manage-ment and data entry mode, identical to a PC – allowing you to perfectly match the needs of your modern workshop.

will yield finely machined parts, ready for assembly, with no vis-ible corrosion. Another example is the manufacture of carbide stamping tools for the micro-electronics industry: surface finish and cutting-edge quality will be perfected with no affected layer or micro cracking, resulting in longer tool life.

To meet the high requirements of machining with oil dielectric, the CUT 1000 OilTech has a com-pletely new generator, enabling surface finishes of Ra 0.05 and perfect surface quality of finished parts. The small wire/workpiece distance allows extremely small radii and the highest profile

accuracy. The high machin-ing performance of the CUT 1000 OilTech is also improved by its unique AC DUO, allowing machining with two wire diam-eters for maximum efficiency and economy. The range of possible wire diameters, 0.20 mm to 0.02 mm, perfect covers the require-ments of the application fields for which the CUT 1000 OilTech is designed. The CUT 1000 and CUT 1000 OilTech are the only ED wire-cutting machines in the world which not only cut but also thread with 0.02 mm wire.

The CUT 20 P and CUT 30 P series is completed by a com-puter-aided design/computer-aided manufacturing (CAD/CAM) programming system, AC Easy CAM), onboard in the standard configuration. Created in collabo-ration with FIKUS MetalCam, AC Easy CAM allows even EDM beginners to get up to speed in hardly any time at all. In addi-tion, AC Easy CAM provides for the execution of even complex contours and is designed to as-sociate directly with technologies and strategies specific to the customer’s applications.

0.1 mm

High positioning and high accuracy of the shapes and the details are required (surface Ra <0.1µm). Steel component: tool insert for producing packaging (clips) clamping.

Examples of applications for the FORM 1000 in the micro sector.




MILLING IN THE MICRON RANGEWith two milling machines from GF AgieCharmilles, W-Technology handles nearly 50 percent of the production of its components precise to the µm. The Czech company is a manufacturer of clamping devices and supplies cus-tomers worldwide.

ADVANCED IN THE MARKET FOR CLAMPING DEVICES

In Bruntál, a small town in Mora-via, Milan Volf founded W-Tech-nology in 1990. From modest beginnings, the Czech company has today gained a small but respectable share of the market share among the large clamp-ing device manufacturers. With six employees, W-Technology produces some 20,000 parts an-nually from its range of prod-ucts covering 250 components.

W-Technology carries out all the production steps itself with modern machine equipment at its disposal. Apart from surface grinding and turning, the ma-chines from GF AgieCharmilles are: FI 440 CC wire EDM, FO 35 die-sinker, as well as MIKRON VCP 600 and MIKRON HSM 400 milling machines. The example Square 15 shows how W-Tech-nology uses milling.


GENERAL MACHINING | W-TECHNOLOGY 20

www.w-technology.cz

W-TECHNOLOGY

Polní 8

792 01 Bruntàl

Czech Republic

Phone +420-554 773 300-7

Fax +420-554 773 308-9

Contact

Milan Volf, Managing director

and Proprietor

[email protected]


- 1 MIKRoN VCP 600

- 1 MIKRoN HSM 400 with

sevenfold pallet-changer

- 1 Fo 35 P

- 1 FI 440 CC

- 1 Hd 30

Programming

Visual Mill

Bobcut

Measuring, testing

Microscope

Roughness measuring device

«We decided on Milling machines from GF Agie-Charmilles in order to be able to manufacture with a guaranteed future. A small company with six employ-ees must handle invest-ments carefully.»

said Milan Volf, Managing Director

and proprietor of W-Technology.

W-Technology deals with nearly half of all production parts with the two milling machines MIKRON VCP 600 and HSM 400.

Two further clamps from the range of over 250 components from W-Technology.

PRODUCTION DEMANDS INTERDISCIPLINARY MANUFACTURING

Before a new part is produced, it must first be developed, then the design is created with drawings and CAD models, from which W-Technology derives the machin-ing steps for a pilot run. When the part is ready for production, such as in the example Square 15, the process begins with turning at full speed. After the outside contour and thread have thus been machined, the Square 15 are clamped in fours on a pallet. The retainer of the Square 15 is rough milled with coated milling tools on the MIKRON VCP 600. The next step is vacuum hardening done outside the company.

PARALLELISM, SURFACE AND PRECISION ARE DECISIVE

Back at W-Technology, the Square 15 is completed and clamped to the pallet again in fours. Thanks to the pallet-changer, the MIKRON HSM 400 can be loaded with a total of sev-en pallets so that unsupervised night and weekend operation can be executed. The Square 15 parts now obtain their final quality on the MIKRON HSM 400: a surface quality of Ra 0.1 µm and a con-tour tolerance of ± 2 µm. Quality features which were an impor-tant argument for the purchase of the MIKRON HSM 400. The fi-nal working step is a 100 percent check, which is documented. The total machining time consists of 40% turning, 50% milling as well as 10% other works, which proves the high status of milling at W-Technology.

When a Square 15 has been finished, each one is provided with a protective film against chemical and physical influences.

Every finished Square 15 goes through a 100 percent check, which is documented.


GENERAL MACHINING | W-TECHNOLOGY 21

HALVING THE MICRON WITH WIRE EDM Small runs for medical technology, watches, machine building and special machine building, as well as inserts for cutting tools are the core business of KSF Feinwerktechnik. With six wire EDM machines from GF AgieCharmilles, the young Pforz-heim-based company produces preci-sion parts in the micron range in job contract work.

SUCCESSFUL BUSINESS MODEL WITH HIGH-PRECI-SION WIRE EDM

The company KSF Feinwerk-technik was founded in 2002 by its present managing direc-tors Andreas Krüger and Jens Schulze. The company is based in Huchenfeld near Pforzheim, the «Gold City» in the south of Germany, which historically has always maintained an affinity for precision mechanics. In KSF’s fully air-conditioned facility, the four members of the staff manu-facture high-precision parts, which push the limits of feasibility of wire EDM again and again. The finest surface finishes, narrow-

est slits, smallest inside radii or highest fitting accuracy are superlatives which certainly apply in the case of KSF, and which the company skilfully combines with profitability. Three examples show the masterly use of wire EDM from GF AgieCharmilles: A punch and die for a blanking die, an eye operation instrument as well as a fixing aid for the manufacture of emitter slats.

A member of KSF staff prepares the starting drill holes for the subsequent ED wire-cutting jobs. The smallest threading opening for the AC Vertex 1 ED wire-cutting machines is the wire diameter plus 50 µm.

The AC Excellence 2SF+F ED wire-cutting machine is set up for the next machining job.


MEDICAL INSTRUMENTS | KSF 22

www.ks-feinwerktechnik.de

KSF FEINWERKTECHNIK GDBRAndreas Krüger + Jens Schulze

Huchenfelder Hauptstrasse 80

75181 Pforzheim

Germany

tel. +49-(0)7231-280 92 9-0

Fax +49-(0)7231-280 92 9-9

Contact

Andreas Krüger, Managing director

Jens Schulze, Managing director

[email protected]


- 2 AC Vertex 1

- 1 AC Excellence 2SF+F

- 1 AC Excellence 3

- 1 AC Challenge 3

- 1 AC Evolution 2SF

Clamping system

Mecatool from System 3R

Programming

Peps 5.3.13

Mecanic Meca 02

CAd ME 10

2d CoCreate drafting

3d CoCreate one Space Modeling

(Solid designer)

Measuring, testing

Profilprojektor Starret VF 500

tesa microhite plus

«Ed wire-cutting machines from GF AgieCharmilles of-fer an enormous technology potential. our know-how coupled with many years of experience in Ed wire cutting exploits this optimally.»said Jens Schulze, Managing Director and

Co-owner of KSF Feinwerktechnik GdbR.

PUNCHES AND DIES WITH SMALLEST CUTTING PLAY

KSF received the order to manu-facture a small series of carbide punches, as well as the accom-panying dies for a blanking die. The punches were wire cut with one full cut and eight trim cuts, and were just 0.2 mm thick at their thinnest points. KSF used the finest CCA Microcut wire of 0.05 mm diameter and achieved a surface quality of Ra 0.08 µm. Internal user knowledge enabled KSF to connect the punches in such a way that they could be detached in conclusion with a separation cut. Thanks to the fully automatic double spool op-eration on the AC Vertex 1, it was possible to wire cut the die in one clamping operation in a fully automatic sequence. The inside radii were just 0.1 mm, which is nearly identical with the wire diameter. 100 percent linearity and the finest surfaces produced a clearance of just 1 µm between the punch and die.

PRECISE WIRE EDM CUTTING FOR PRECISE EYE OPERATIONS

KSF received pre-engineered parts made of special steel for the prototypes of an eye operation instrument. Andreas Krüger, re-sponsible for 2D and 3D programs at KSF, optimised the CAD model from a production engineering respect for ED wire cutting. The 13.5 mm high outside and inside contours were ED wire cut on an AC Vertex with one full cut and four trim cuts. The requirement for an exact fitting fixture for the operating scalpel was fully met by fine surfaces and exact linearity.

WIRE EDM CUTTING MAKES MICRON-ExACT FIxING POSSIBLE

A further application example completes the spectrum of KSF’s services: The fine wire application with a fixing aid. Meandering slits had to be cut into metal blocks with an area of 19 x 12 mm by means of ED wire cutting. Eight thin metal plates were then packaged and clamped in each case between two of these blocks. These 0.2 mm thin plates were slit into emitter slats which are used in medical technology. The slit width of 0.06 mm with 5 µm tolerance was also cut on an AC Vertex 1 using fine wire technology.

The carbide punch was cut with one full cut and eight trim cuts. It is just 0.2 mm thick at its thinnest points, has a surface quality of Ra 0.08 µm and the smallest inside radii are just 0.1 mm.

A metal block with curved slits serves as a fixing aid for parts in medical tech-nology. Eight thin metal plates are then packaged and clamped in two of these blocks, and emitter slats are manufac-tured in small series by making 0.06 mm thin slits with ± 5 µm tolerance using ED wire cutting.

The prototype for an eye operation instrument made of special steel is deliv-ered pre-engineered. The final machining of the 13.5 mm high inside and outside contours is then carried out by means ED wire cutting. With one full cut and four trim cuts, a surface quality of 0.1 µm is achieved.


MEDICAL INSTRUMENTS | KSF 23

1 mm

MORE FREEDOM AVAILABLE WITH FIVE-AxIS MILLING

For over a hundred years, Prontor GmbH has been a reliable system partner for world-famous undertakings. Concep-tion, process-control design, optimizing, construction and series production on schedule are the fields of competence nowadays for medical technology, precision mechanics and lithograph optics. EDM and Milling machines from GF Agie- Charmilles are used by preference at Prontor GmbH for spe-cial productions.

OFFERING ECONOMIC SOLUTIONS TO SUIT PRODUCTION

Bad Wildbad-Calmbach is the idyllic location of Prontor GmbH, which was founded in 1902 and today has 280 employees on its payroll. The company is part of the Mechatronics Group, an independent system supplier for famous industrial undertakings. The main field of business is the development and manufacture of assemblies and subsystems in precision mechanics and medical technology. With its Special Production Depart-

The casing for optical systems was continuously planned, designed and optimised with ProEngineer.

Thanks to an exchangeable touch probe, the zero point reference can be set and the levels aligned directly on the MIKRON UCP 600.

ment, Prontor GmbH focuses on customers’ wishes. «Our scope of supply ranges from highly complex unique items to a few prototypes for test purposes,» Michael Zwadsich, head of this department explains. In fact, the competence of the Special Production Department satis-fies nearly every customer goal and need. Whether it is a matter of complicated molds, unusual materials or even tight delivery deadlines, economic solutions to suit production are always found, as the example of a casing for optical systems shows.


MECHATRONICS | PRONTOR 24

www.prontor.de

PRONTOR GMBH

Gauthierstrasse 56

d-75323 Bad Wildbad

Germany

tel. +49-(0)7081-781-1

Fax +49-(0)7081-781-499

Contact

Jochen Wacker, Sales Engineer

Michael Zwadsich, Head of Special

Production

[email protected]


- 1 MIKRoN UCP 600 Vario

- 1 MIKRoN HSM 600U

- 1 FI 2030 tW-SI

- 1 FI 6030 SI

Clamping system

Mecatool from System 3R (Ed wire

cutting)

Vischer & Bolli (milling)

Programming

ProEngineer

«For us in the Special Pro-duction department, the MIKRoN UCP 600 Vario is the heavy-duty machining center with which even customers’ most unusual wishes can still be manu-factured economically,»

said Michael Zwadsich, Head of Special

Production at Prontor GmbH

Only on the physically real finished part it is possible to imagine how much know-how was required, both in designing and in programming and milling, in order to achieve this result.

Michael Zwadsich, Head of Special Production, discusses a new machining task for the MIKRON UCP 600 Vario with an employee.

In the Special Production department of Prontor GmbH the wire EDM machines FI 2030 TW-SI and FI 6030 SI from GF AgieCharmilles are also used.

PLAN, DESIGN AND MANUFACTURE CONTINUOUSLY

Beginning with the customer’s first requirements with regard to material, precision and geometry, milling from the solid was speci-fied as the machining process for the casing for optical systems. The CAD design was carried out with ProEngineer from which the CAM machining technologies were then derived. In conclu-sion, the milling strategies were optimised and checked, and it was then possible for the block to be clamped. Michael Zwadsich commented, «With our continuity

WITH THE SMALLEST INTERFERENCE CIRCUIT IN THEIR CLASS

The zero-point reference was de-termined and the levels aligned on the square ingot made of the alloy AlMg 5 using the exchange-able touch probe of the MIKRON UCP 600 Vario. Twenty-nine milling cutters were employed for the machining in order to cut the intended surfaces, walls, ap-ertures, drill holes, recesses, un-dercuts and webs from the solid. It was possible to utilize the milling cutter’s optimal acces-sibility to the workpiece on the MIKRON UCP 600 Vario to the full. The swivelling and rotational

axes of the table, together with the longitudinal, transverse and vertical axes give attractive travel paths with a low interference circuit. And, thanks to the unim-peded view of the workpiece, the operator has an overall view of the progress of machining at all times. MIKRON UCP 600 Vario also combines dynamism for rapid acceleration and decelera-tion perfectly with stability and compactness for precision on the workpiece. Thus the tolerance in the case of level surfaces on the finished casing lies at ± 10 µm. The casing for optical systems was delivered with pride to the customer on schedule.

from the design through to the first milling path, we reduce the error rate to nearly zero.» He went further to say, «Machining is hardly likely ever to be error free, because the human factor is also involved.» Neverthe-less, in the Special Production Department they are proud of the fact that nearly everything succeeds100 percent straight off. The MIKRON UCP 600 Vario, a five-axis heavy-duty machining center from GF AgieCharmilles with an optimal swivelling range from -30 to +110 degrees, was chosen for the challenging ma-chining of the casing made of the alloy «AlMg 5».


MECHATRONICS | PRONTOR 25

EDM AND MILLING FOR WORK-PIECE PRECISIONbomo trendline Technik GmbH developes solutions for technical injection molding. With design, tool-mak-ing, assembly and production, the Black Forest-based company is a competent producer for the automo-tive, medical, office supply and cosmetic branches. Milling, wire and die-sinking EDM are used in demanding mold-making as the precision-giving production processes.

RETAIN QUALITY AND PRODUCTION COMPE-TENCE WITH COMPLETE PRODUCTION

bomo trendline Technik GmbH was established in 1985 and today employs 140. For the com-pany based in Hardt on the edge of the Black Forest, tool-making is the basis for the optimal realization of technical plastic parts. bomo trendline ensures continual competence from the development, design and tool-making departments all the way through to the production of the demanding plastic parts. The

The solid model of the mold insert has been generated with «SolidWorks,» showing the various wire and die-sinking EDM segments.

Already in the CAD design phase, the mold insert is segmented in accordance with the machining processes.

company has 80 injection mold-ing machines at its disposal for these types of processes, which in part due to state-of-the-art technology, no longer close hydraulically, but electrically. A four-way injection molding tool for the production of a functional part for car door locks demon-strates the manufacturing com-petence of bomo trendline with the combined use of wire and die-sinking EDM equipment, as well as a high-speed machining center – all from the GF Agie-Charmilles.


MOLDING | BOMO 26

www.bomo.de

BOMO TRENDLINE TECHNIK GMBH

Gewerbestrasse

d-78739 Hardt

Germany

tel. +49-(0)7422-951 60

Fax +49-(0)7422-951 40

Contact

thomas Haberstock,

Managing director

[email protected]


- 1 MIKRoN HSM 800

- 1 MIKRoN WF 3

- 1 Fo 550 S

- 1 Fo 200

- 1 Fo 40

- 1 FI 440 SLP

- 1 FI 510

- 1 Hd 8

Clamping system

System 3R

Erowa

Programming

SolidWorks (designing)

MasterCam (Ed machining, milling)

«With GF AgieCharmilles machine tools, we have invested in state-of-the-art machining technolo-gies which conform with our company’s philosophy of high precision.»

said Michael Hug, Head of Tool-making

at bomo trendline Technik GmbH

DETERMINE THE MANU-FACTURING PROCESS DURING THE DESIGN

bomo trendline received the order for its Automotive Division to produce identical func-tional parts for right-hand and left-hand car door locks. The plastic part made of POM and subject to high stress environ-ments was to be produced in a quantity of 5 million. As a result, one injection molding tool each was envisioned for the right-hand and left-hand door side respectively. Both tools were planned with four mold cavities, whereby the mold cavities were mirror-inverted on one tool. The client’s data were recorded with SolidWorks and segmented already during the CAD design in accordance with the machining technology. Large areas were planned for hard milling on the MIKRON HSM 800, and the new FO 550 S and FI 440 SLP respec-tively were assigned for the wire and die-sinking machining jobs.

LETTING MILLING AND EDM INTERACT ECONOM-ICALLY

The CAM data for the milling and wire EDM cutting were gener-ated and optimized from the CAD program so that the pre-milling of large cavities and also the production of copper electrodes could take place without issue on the MIKRON HSM 800. The in-serts made of steel, hardened to 52 to 54 Rockwell, were then cut using 0.25 mm thin brass wires with one main cut and three trim cuts on the FI 440 SLP, and the copper electrodes produced with 0.05 mm undersize were exchanged automatically on the FO 550 S for the roughing and fine finishing of the molds and cavities. All the form-giving segments showed a surface quality of VDI 24 after machin-ing. An interaction of three GF AgieCharmilles brand production processes which bomo trendline employed optimally in accord-ance with economic and qualita-tive aspects.

The latest investments for tool making at bomo trendline: A MIKRON HSM 800 high-speed machining center, FO 550 S die-sinking machine and an FI 440 SLP wire EDM. All three machines are equipped with state-of-the-art techno-logy, making it possible to monitor by means of a mobile phone from home.

The segmented mold inserts with offset tool separation are fitted in the 4-way injection molding tools and have a tolerance of just 10 µm to one another. Tempered nozzles with cold channel subdistributors make a cycle time of just 15 seconds possible.

The articles have been selected from the branches for which bomo trendline Technik GmbH develops, designs and produces.

The finished functional parts made of POM for car door locks must show an accuracy tolerance of 50 µm on the square socket.


MOLDING | BOMO 27

Achieve more...

Thin vane electrodes can be milled from graphite, making wear-free EDM of the finest, stepped slits possible.

The graphite electrode was used with state-of-the-art technologies.

Thanks to iQ technologies, this graph-ite electrode could be used wear-free.

GF AgieCharmilles is one of the first to offer ED die-sinking machines with an electrode wear of nearly zero.

DIE-SINKING EDM WITHOUT WEAR

Furthermore, graphite has a special property, which explains its outstanding resistance to wear. Graphite does not melt, but sublimes at 3470° C. On the other hand, copper melts at 1083° C. As soon as the EDM process begins, the mate-rial removed wanders with the decomposition products from the carbon-content dielectric to the graphite electrode. GF AgieCharmilles’ new iQ technol-ogy controls the reduction in temperature so that the carbon precipitates onto the electrode surface. A layer forms there, protecting the original electrode. iQ controls the growth of the layer in real time and keeps it in balance. Wear-causing impulses take place on the protective layer. The original electrode remains protected, as it is nearly zero.

The wear that is caused by EDM impulses, thus takes place on the protective layer, and not on the original electrode. This requires the use of suitable process: Very fast and efficient electronics to analyse the spark features and a generator, which is in a position to generate and adapt to the appropriate current form in real time, such is the case with the new generators from GF AgieCharmilles.

© Agie Charmilles SA, 2009The technical data and illustrations are not binding.They are not warranted characteristics and are subject to change.

259.804.622

Imprint

PublisherGF [email protected]

AppearanceTwice a year in English,German, French, Italianand Spanish.

PrintingPoncioni SA, 6616 Losone,Switzerland Copies50 000

No 4© GF AgieCharmilles2009

EditorGlobal Marketing Team: Product ManagementMichael Katz, Elke BucherPicturesMarco MilaniMichael KatzGraphic DesignerFiorenza SimonaTillmann Andrea

ZERO WEAR - THE «PERPETUUM MOBILE» OF DIE-SINKING EDMElectric discharge machining without wear is the result when the plane of action of the graphite electrode is built up a new again and again, balancing out the wear actually occurring. One is almost tempted to say, zero wear is the «Perpetuum Mobile» of wire EDM.

ELECTRODE MATERIALS

The materials used for elec-trodes in die-sinking EDM are graphite, copper, copper-graph-ite and tungsten-copper. In micro EDM processes, hard metal and tungsten are used. The two most important materials are graphite and copper, whereby prefer-ence is given more and more to graphite. The reasons are clear, because the advantages are ob-vious in electrode production:

- Low cutting forces- No vibration- Burr-free- No material tensions- Dry machining with HSM- Faster than copper machining (5x)

With regard to EDM, graphite also presents advantages:- Up to 40% more removal rate compared with copper- Stable process- Graphite with medium grain size is 20 - 30% more cost effective than copper- Thermally stable- Lighter than copper (large electrodes)

STATE OF TECHNOLOGY

The problem of wear has plagued electrical discharge machining since its inception. The process itself was invented when the Russian husband and wife Lazarenko team tried to reduce the contact wear on electric switches. In fact, electri-cal discharge machining always causes wear on both electrodes. However, the traditional appli-cation technology does offer a compromise between intensive-removal settings and slower, but low-wear settings. GF Agie-Charmilles offers die-sinking EDM machines of the latest generation (FO 350 and 550, FORM 2000 and 3000) for this, which counteract the wear with various measures:- Dosed, less frequent impulses- Rapid removal of the particles from the spark gap- Maximizing the removal effectiveness of the individual impulses - Monitoring the local distribu- tion of the discharges- Interrupting dangerous impulses in real time- Using appropriate amperage on the active electrode surface- Optimized control of the dynamism.


iQ-TECHNOLOGY 28

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