Application of Milling End EDM Machining
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Transcript of Application of Milling End EDM Machining
|AgieCharmilles GF
|Application of Milling and Electric Discharge Machining
Application of Millingand Electric DischargeMachining
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Introduction on High-Speed and High-Performance Milling
High Speed Cutting (HSC)
The typical application of this technology is the machining of complex three-dimensional
surfaces. As the specific parameter of the process may be considered the workpiece surface
machined per unit of time (cm2/min). NC programmes provide the geometric information eit-
her in form of coordinates or vectors. The data amount to be processed by the machine
control is a function of distance between the coordinates and the programmed machining
feed. Increasing machining feed demands improved calculation speed and intelligence of the
control. High speed spindles are required to match the process. Mainly used cutting tools
are ball nose end mills, flat end mills and toric end mills from solid carbide.
High Performance Cutting (HPC)
In contrast to High Speed Cutting, this technology mainly is used for the machining of two-
dimensional geometries. The cutting depth ap and the stepover ap along with the machining
feed allow calculation of the material removal per unit of time (cm3/min). This process in
particular is suitable when it comes to the removal of large volumes of material or the
machining of difficult to cut materials. High power, high torque spindles are a must. Primarily
used cutting tools are insert type milling heads, specific high performance end mills, drills,
boring heads and special tooling.
The preceding definition is primarily directed towards the extreme facets of both processes.
In reality the limit between High Speed Cutting (HSC) and High Performance Cutting (HPC)
is not static, in fact it overlaps. The analysis of application and environment typically decides
about which process will result in optimum machining performance.
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Introduction on Electric Discharge Machining (EDM)
Two conductive materials (electrode/workpiece) submerged in an insulating liquid, are con-
nected to a source of current which is switched on and off. When the current is switched
on, an electric voltage builds between the two parts. If the parts are brought together to a
certain distance, the voltage is discharged and a spark jumps across. Where it strikes,
the metal is heated up so much that it melts. Innumerable such sparks spray one after the
other (never simultaneously), and gradually shape the desired form in the piece of metal.
Several hundred thousand such sparks must fly per second for efficient EDM.
Two different processes
Die-sinking EDM
In the case of die-sinking EDM, the required shape is formed in the workpiece with a
three-dimensional electrode. By superimposed movements in the main axes X, Y, Z, C, varied
shapes, indentations and cavities are created, such as cannot be achieved by any other
machining system.
Wire-cut EDM
In the case of wire-cut EDM, the metal is cut with a special metal wire electrode. The wire
travels along a pre-programmed path. By differing movements of the upper and lower wire
guides, angled or conical surfaces can be produced to the highest accuracy and with the
finest surface finish.
Powerful technology
The performance of modern EDM equipment is extremely high: high cutting speeds, highly
efficient automation, interlinking and storage of very long and recurring machining cycles.
And thanks to electronic monitoring and fully automated correction of the EDM process, no
supervision is required.
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Electric Discharge Machines (EDM)
High-Speed and High-Performance Milling Centers
HSM Spindle Technology
Tooling / Automation
Consumables
AgieCharmilles GF
Brands and Products
Contact
www.agiecharmilles.com
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AgieCharmilles GF
AgieCharmilles GF is the world’s leading provider of machines and system solutions to the
tool and mold making industry and to manufacturers of precision parts. It is the GF
Machine Tools Group of its majority shareholder Georg Fischer. AgieCharmilles GF’s pro-
ducts range from electric discharge machines (EDM) and high-speed (HSM) and high-
performance milling (HPM) centers through tooling, services, spare parts, wear parts and
consumables to automation solutions. EDM and HSM are the two key technologies in tool
and mold making. They are indispensable in the manufacturing of molds and press tools
for the series production of plastic, metal and glass parts and for the machining of high-
quality precision components. As a globally active group, AgieCharmilles GF maintains a
presence at 50 sites worldwide through its own organization.
AgieCharmilles GF views focusing on customers' needs as an integral factor in success.
The Group has longstanding trust-based relationships with many of its customers, often
stretching back to the founding of the customer's business. The values the market most
frequently attributes to AgieCharmilles GF are high quality, precision, reliability and out-
standing professionalism in service and technical support. AgieCharmilles GF owes its
growth in a difficult market environment and its installed base of over 100,000 units
worldwide to this customer-centric approach.
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AUTOMOT
Production of complex components as well as cavities and tools for
the production of plastic parts, castings, forgings and stampings.A
uto
mo
tive
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O-IVE
Iterations into the early
stages of the produc-
tion cycle. Lifecycle-
management and cost
pressure demand
flexibility and integrated
processes leave no
room for error. Partner-
ship demands trust,
reliability and coopera-
tion.
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MOTSPOR
Mo
tors
po
rtProduction of high-value components.
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TOR-RTNew regulations, individual requirements, local characteristics,
consecutive product improvements, exotic and partially new
materials result in an eternal prototype stage. In-time delivery,
despite the need for flexibility and calculated risk, makes winners.
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AERONTIC & ASPACEA
ero
na
uti
c &
Ae
ros
pa
ceProduction of complex, high-value components in
high-temperature resistant alloys, titanium, aluminium
and other materials.
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NAU-AERO-
E
Costly tests and authoriza-
tion procedures, regulations
and difficult to machine
materials are the challenges.
Superior performance,
innovation and security are
equally important,
while the factor of eco-
nomic viability is
increasingly gaining
importance.
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MEDICALIMPLANTSTRUMEN& APPLIAM
ed
ica
l Im
pla
nts
, In
stru
-m
en
ts a
nd
ap
pli
an
ces
Production of implants, instruments and components from corrosion-
resistant alloys, titanium or conventional materials.
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L TS, IN-NTS
ANCES
Special demands for the biological compatibility of the materials used for implants as
well as the medical surroundings in general are impact production procedures and processes.
To go to new ways means high investments to transact, but new trends require new
approaches.
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ELECTICS & MATRON
Ele
ctro
nic
s &
Me
cha
tro
nic
s
Excessively short product life cycles require flexibility, short
production times and leave no room for manual rework.
Controlled processes and automation are indispensable. New
technologies make innovative approaches possible and are
prerequisite for competitiveness.
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RON-MECH-
NICS
Molds and tools for the mass production of plastic parts, castings, and stampings.
Production of chassis components and elements for high-value electric appliances.
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HOUSHOLD
Ho
us
eh
old
Plastic injection molding, alu-
minium die casting, punching
tools as well as blow molds for
one-way packages, one-way
articles, mass ware and design
articles.
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SE-D
Appliances and utensils for daily household use are diverse.
Exclusive design and customer requirements require
continuous research into new manufacturing approaches.
The expenditure for the production of seemingly ordinary
goods often is enormous, ensuring precision in details
where no one would suspect it.
A RELIAPARTNEA PASSIEXCELLE
ABLER WITH ON FOR ENCE
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LEISU& SPOL
eis
ure
& S
po
rtProduction of parts from alumi-
nium, plastic, steel alloys or
other materials. Injection molds,
aluminium casting dies and
punching dies.
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URE ORTS
New fashion trends in sport
and leisure generally are
interconnected with new
design. The one who reaches
the market first reaps higher
margins. Shorter time to
market and flexibility pay off.
24 |
GENERMACHG
en
era
l M
ach
inin
gProduction of parts for a multiplicity from applications
and in a large variety of materials.
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RALINING
Lead time is the essential criteria in this sector. Flexibility and
short set-up times for individual parts and small batch production
are as important as autonomy and reliability with larger series.
26 |
LUXUGOODL
ux
ury
Go
od
sProduction of accurate parts or
for the luxury goods segment,
including designer pieces from
stainless steel, brass, titanium
or precious metal. Molds and dies
for the mass production of com-
ponents for trend and fashion
items.
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URYDSExotic materials and intricate details, perfection in the detail and high customer
expectations result in a particular situation. These unique requests require
suitable concepts and specific know-how.
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POWERGENERTION
Po
we
r G
en
era
tio
nMachining of high value components in temperature resistant
alloys; dies for the manufacture of semi-finished products.
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RRA- Complex geometries and
extreme material char-
acteristics necessitate
special production pro-
cesses and concepts. The
advancement of tools,
machines and processes
provide potential for ra-
tionalization, their per-
formance decides on
the feasibility.
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AUTOMAT
Au
tom
ati
on
Improvement in productivity, increase of flex-
ibility despite fluctuations in demand,
changing production priorities and the need
for the shorter lead time.
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O-ION
The integration of production facilities into existing networks
and processes requires careful planning and implementation.
Multiple machine concepts and the combination of production
and control processes in production cells present new
ways of reacting to the challenges of a globalized market.
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SERVICE ACADEMCOMPETECENTRES
Se
rvic
es
Aca
de
my
&C
om
pe
ten
ce C
en
ters
AgieCharmilles GF attaches great value to the superior
skills and continuing education of its staff. Personnel from
the areas of after-sales service and application must
demonstrate ability to understand and resolve our cus-
tomers’ problems. Through on-site support, training and
one-on-one advice, our staff provides optimal customer
support.
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Y &ENCES
1200
1000
800
600
400
200
0 2002
526
2003
764
Jan-Jun 2005
485
2004
1039
The technological progress of machine tools and manufac-
turing processes requires a continuous learning process.
Fundamental and advanced know-how are taught in training
courses, while project-oriented workshops allow resolution
of individual issues. Know-how and the exchange of expe-
rience help to secure a technological lead and are an
important complementary service to the machine tool.
Trained participants within Service Academy
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http://www.agiecharmilles.com/en/addresses.htmlM
ain
Lo
cati
on
s
Headquarters
Agie Charmilles Holding Ltd
Bundesplatz 1
CH-6300 Zug, Switzerland
Tel. +41 (0)41 711 13 76
Fax +41 (0)41 711 13 71
E-Mail [email protected]
Agie Charmilles Management
Agie Charmilles Management Ltd
Case postale 373
Rue du Pré-de-la-Fontaine 8-10
CH-1217 Meyrin 1 / Geneva, Switzerland
Tel. +41 (0)22 783 34 69
Fax +41 (0)22 783 32 68
E-Mail [email protected]
Agie Charmilles Management Ltd
Amsler-Laffon-Strasse 9
CH-8201 Schaffhausen, Switzerland
Tel. +41 (0)52 631 26 21
Fax +41 (0)52 631 28 68
E-Mail [email protected]
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Agie Charmilles Management Ltd
Via dei Pioppi 2
CH-6616 Losone, Switzerland
Tel. +41 (0)91 806 91 11
Fax +41 (0)91 806 95 15
E-Mail [email protected]
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|AgieCharmilles GF
|2006
Agie Charmilles Management SAVia dei Pioppi 2, CH-6616 Losone
Tel. +41 (0)91 806 91 11Fax +41 (0)91 806 95 15www.agiecharmilles.com
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