Agie Charmilles LLC
Please visit: GF AgieCharmilles
560 Bond St.
Lincolnshire, IL 60069 US
GF AgieCharmilles positioned to honor brand promise: 'Achieve more'
As a single brand with the single aim of enabling its customers' success, GF AgieCharmilles is now uniquely positioned with a full range of electric discharge machines, high-speed and high-performance milling products, tooling and automation solutions and the industry's most comprehensive service package, all designed to make GF AgieCharmilles' customers more successful than their competitors. At the heart of every GF AgieCharmilles product, service and solution is the brand promise, "Achieve more." Effective July 1, 2007, GF AgieCharmilles announced the merger of its former product brands Agie, Charmilles and Mikron under the single brand GF AgieCharmilles, concentrating the group's strengths in the electric discharge machining and high-speed and high-performance milling sectors and further extending the group's leading position as a manufacturer of machine tools for mold and tool making and the production of precision components. GF AgieCharmilles' full range of EDM and milling machines, previously sold under the Agie, Charmilles and Mikron brands, and all related services are now marketed with a single brand name through a unique, centralized distribution channel and backed by a global workforce of 3,099 employees, all committed to helping GF AgieCharmilles' customers achieve more than their competitors.
Charmilles has announced the release of the Robofil 240SL, a machine replacing the standard Robofil 240 wire EDM. Designed to keep users competitive in the global market, the new machine features a variety of improvements designed to provide high quality performance at an affordable price. Among the most noticeable of the changes to the machine design is a new lower head. Coupled with symmetrical XY and UV tables, this allows the machine to handle maximum taper angles of up to 30 degrees to the full part height. A new 3D part alignment system allows easy setup for heavy and tall parts. The Robofil 240SL also includes a new filter system, featuring four filters, rather than 2. The system increases individual filter life by 2.5 times compared to the previous design and drastically lowers operating costs. The Robofil 240SL features CT-Millennium CNC, a Windows? based operating system. Dynamic Screen Function (DSF) aids in setting up and taking references of a job to be executed, using animated 3D drawings to illustrate the job. The system also allows a machine to be integrated into a local area network (LAN) and performs remote job notification through SMS. The Robofil 240SL constantly measures water levels in the work tank, making adjustments as needed to allow for unattended machining of parts with differing heights. With a fill rate of 132 gallons per minute, the machine has maximum fill and drain times of just 30 seconds. The Robofil 240SL can machine parts up to 39.17 in. wide by 21.65 in. deep by 8.66 in. tall, weighing up to 1,653 lbs. Also present in the machine is Charmilles’ ThermoCut automatic wire threading system. The system stretches and cuts the wire under the effect of heat and then quickly and accurately threads it. Compatible with any type of wire, whether brass or coated, ThermoCut requires minimum maintenance and threads reliably up to 24 in. tall parts. To best minimize maintenance costs and ensure long-term accuracy, the Robofil 240SL implements Integrated Collision Protection (ICP) on all 5 axes. Charmilles has also unveiled the Robofil 440SL as a replacement to the standard Robofil 440. Containing all of the same improvements present in the Robofil 240SL, the larger Robofil 440SL is able to handle parts measuring 47.24 in. wide by 27.56 in. deep by 15.75 in. tall, with a maximum weight of 3,306 lbs. Optionally, both machines can be equipped with a new FS-Threading feature that allows automatic threading, fully submerged, to the maximum z-axis height.
Charmilles’ new ROBOFORM 350 MicroTEC diesinking EDM offers innovations in precision, speed and productivity for even the smallest die and mold applications. As the new milestone in the world of EDM, the new MicroTEC pushes the limit of quality and profitability to meet the most demanding market challenges. In industries including automotive, aerospace, electrical connections, medical and watch making, miniaturization of components and the precision of geometric shapes is of the utmost importance to ensure that finished products work correctly. This necessitates the development of increasingly smaller molds. To meet these increasingly demanding requirements, the new ROBOFORM 350 MicroTEC integrates new discharge circuitry with the double thermostabilization system and the industry leading DPControl and Expert Systems. The new MicroTEC discharge circuitry enables EDM power to be modulated, with the flexibility necessary to maximize material removal, while allowing a reduced electrode undersize of =0.002 in. This allows for higher machining outputs, while maintaining the geometry of the electrodes due to an extremely low wear rate. The double thermostabilization system of the ROBOFORM 350 MicroTEC is a world first in preventing the impact of temperature variations, allowing for maximum accuracy. Pulsed air, circulating in the cabin, is cooled in real time according to the temperature of the dielectric, by a double differential temperature probe. The whole of the main frame and the X, Y and Z axes are thermostabilized in the same way as the whole of the machine. Circulation of the dielectric is integrated into the work table, which prevents the risk of thermal shocks when filling the tank. In addition to the discharge circuitry, the ROBOFORM 350 MicroTEC also features Charmilles’ industry leading DPControl. With DPControl’s new functionality, the DPControl will suggest ideal electrode undersize and rationalize the number of electrodes necessary for effective machining. DPControl also allows direct access to measurements performed on a preset station and allows for organization of jobs according to the users priorities. The DPControl will also allow for close monitoring with the automated production features of Expert Systems, and all information related to machining status can be transmitted directly to the operator via SMS. DPControl also evaluates a completed job by automatically creating a full report on job execution readily accessible to the operator via the network or directly on the machine. The ROBOFORM 350 MicroTEC also features Accura-C, a high precision C-axis that provides a dramatic increase of positioning accuracy, ensuring down to 3.6 Arc seconds. To counteract the effects of pulsation movements in the dielectric fluid and increase stability, the C-axis is built to withstand maximum inertia of up to 1708 lbs in2. This boosts productivity and allows precise machining with electrodes weighing up to 110 lbs. Additionally, Accura-C features a liquid cooling system to eliminate inaccuracy from thermal instability. Offered as an option, the ROBOFORM 350 MicroTEC is available with a rotary tool changer can store up to 160 electrodes that vary from one cavity to another. The largest tool changer of its kind in the industry, it significantly increases the speeds of the loading process and reduces unnecessary movement. In addition a double gripper is used and it allows you to change from electrode to electrode in less than 60 seconds. The new MicroTEC also offers the option of a Renishaw probe. This high precision measurement probe ensures perfectly accurate positioning to within a micron, by using optical transmission from a light beam. This optical probe is more precise and reliable than an electrical touch system. In addition, the DPControl automatically generates a measurement report of the probe, enabling rigorous checking and monitoring which lead to higher precision.
Charmilles’ recently unveiled Robofil 2050TW sets a new standard for wire EDM performance. This groundbreaking twin wire machine provides levels of precision and accuracy that surpass every EDM that has come before. The award-winning Robofil 2050TW brings high speed, improved surface finishes and unsurpassed accuracy to the Top End Wire class of EDM. Throughout the machine’s design, accuracy was given special consideration. High precision glass scales measure increments down to .05 µm and thermo-stabilization of the entire machine eliminates inaccuracy caused by thermal instability. The Robofil 2050TW features a new, fully digital generator that offers absolute mastery of every spark. The new generator provides a surface finish as fine as Ra .05 µm in carbide and total respect of surface integrity, whatever the material machined. The newly designed mobile console provides easy accessibility and allows the end user to monitor the Robofil 2050TW very close to the work area. Windows XP® and ‘Twin Wire’ software technology were implemented into the machine’s controls, creating an intuitive interface that encourages productivity and the integration of automation. The Robofil 2050TW works with two spools of wire, ranging from 0.02 mm (0.00078”) to 0.33 mm (0.013”) in diameter. Full automation of the wires’ complete operational sequence further ensures high levels of productivity. In the 4th quarter of 2004, the Robofil 2050TW was awarded the prestigious Golden Micron award at Micronora 2004 in Besancon, France. Also available is the Robofil 6050TW. This machine offers all of the advantages of the Robofil 2050TW, but accommodates larger parts. The Robofil 6050TW is capable of machining workpieces up to 49.61” x 24.02” x 14.17”, as opposed to the Robofil 2050TW’s capacity of 39.98” x 20.08” x 10.24”.
The Agiecut Progress V 2 established a new benchmark for wire EDM cutting speed at 47 in²/hr. using standard 0.013” coated wire. Now part of Agie’s groundbreaking V Series, the Progress will be paired with a System 3R Workpal palletized workpiece changer to form an automated cell. The Workpal handles up to eight pallets for workpieces up to 12-inch square, feeding them into the Progress for up to 80 hours of uninterrupted processing. Among the host of innovations being introduced on V Series wire EDMs are the IPG-V generator and Agievision 5 control based on the Windows XP platform. Processing speed, surface finish and accuracy are all improved, along with user-friendliness of the Agievision control, which provides enhanced 3D graphics, real time adjustments, and direct-select activity bars. The Progress system’s eCut generator technology makes it possible to get surface finishes as good as 0.8 µm Ra with one precision cut – a process that is completed in half the time required by technologies that incorporate a main cut and trim cut. In addition, the faster precision cut requires 40% less filter and resin and results in 60% less wire consumption. Unlike competitive systems, the Progress can achieve speeds up to 37 in²/hr. even in the tightest radii (and even during a precision cut) due to Agie’s unique Wire Bending Control. Other standard features on the Progress improve speed in another way – by reducing idle times. With 15-second wire threading, the Progress has greatly reduced all wire-related barriers to speed. Agie’s standard wire guide permits threading of all wire sizes and types (never requiring annealing after a break) and allows taper cutting of ±30º.
-- To complete its family of high-speed, eCut generator technology Progress wire-cut EDM systems, Agie US has introduced the Agiecut Progress V 4, which features work table dimensions and axis travels to process workpieces up to 51 in x 39.4 in x 19.7 in and 6,600 lbs. The entire working area can be used for detailed machining on large workpieces or for clamping of multiple workpieces of differing sizes and heights. Like the Progress V 2 and V 3, the new system’s eCut generator technology makes it possible to achieve surface finishes as good as 0.8 µm Ra with one precision cut – a process that is completed in half the time required by technologies that incorporate a main cut and trim cut. In addition, the faster precision cut requires 40% less filter and resin and results in 60% less wire consumption. The precision cut also reduces the number of trim cuts needed for surface finishes of 0.2 to 0.7 µm Ra. The Progress can cut up to 47 in2/hr using standard 0.013” coated wire. In addition, the system can achieve speeds up to 37 in²/hr using 0.012” Bercocut brass wire, even in the tightest radii due to Agie’s unique Wire Bending Control. Other standard features on the Progress improve speed in another way – by reducing idle times. With 15-second wire threading, the Progress has greatly reduced all wire-related barriers to speed. Standard Agie wire guides permit threading of all wire sizes and types (never requiring annealing after a break) and allow taper cutting of ±30º. Another unique feature performs real-time detection of the workpiece cross-section and automatically optimizes generator power. The new Progress V 4 is a fixed table design to ensure positioning accuracy when processing very large, heavy workpieces. The system includes a dual measuring system that continuously measures and corrects the axis positions to achieve accuracy in the µm range. These features and many others on Agie systems guarantee performance that is solidly sustainable over the life of the machine.
The Agiecut Vertex 1 and Agietron Micro-Nano let you EDM on a nanometer scale! Get surface finishes down to 0.05 µm Ra in continuous operation.
Charmilles’ ROBOFIL 240cc/440cc uses the CC generator to dramatically improve machining speed while preserving the surface integrity of the machined material. With the machine, Charmilles has brought the technology of high-speed EDM to the wire EDM market. The cutting speed in tool steel can reach a high of 42 square inches an hour, once again raising the top speed barrier, which had previously been about 37 square inches an hour. The CC generator is a digital generator based on high-tech components. From roughing to finishing, the CC generator is ‘zero voltage’ to protect parts against electrolytic effects. As a result, users of the 240cc/440cc receive the fastest cutting speed on the market plus anti-electrolysis in rough and skim cutting. The cutting speed increases apply even when a tall part is being cut, up to 15.75” on the 440cc. The key to the 240cc/440cc’s speed is Charmilles’ new spark design. The maximum ignition voltage has been increased by 25%. The maximum amplitude has been tripled from 400 amp. to 1,200 amp. The high quality of the surface finish is another advantage of these revolutionary machines. The machine achieves finer surface finishes with fewer skim cuts. An important application segment of the CC generator is the medical industry, which uses a lot of titanium on titanium alloys that frequently are placed into the human body as artificial parts. The CC generator prevents oxidation on the titanium and maintains surface integrity free of brass and zinc materials originating during the cutting process from the wire electrode. In carbide applications the machine minimizes cobalt depletion, the effect of which is to hold tungsten together. This insures a higher bearing capacity of punches or dies. The new generator shines as well in cutting PCD (poly crystalline diamond) form tools. The surface finish and edge sharpness is at least equal and, in most cases, better than grinding. The 240cc/440cc also comes equipped with ThermoCut and collision protection. ThermoCut is a unique high-speed and maintenance-free wire threading system that stretches the wire and cuts it under the effect of heat, regardless of wire diameter and material. The collision protection provides effective protection on all five axes of the machine during manual or unattended operation. It boosts performance and cuts down on maintenance costs in the event of programming or manual positioning errors. Charmilles’ Taper-Expert option is also available to be added on the 240cc/440cc. This feature makes it possible to cut very high-precision angles, up to 30°. An accurate taper is especially important for moldmakers.
With an eye on the ever-changing world of consumer goods, automotive components and household and industrial appliance design, Charmilles developed GammaTEC for its ROBOFORM 350 and 550 machines. The creation enabled the company to meet the high quality and finish demand and time requirements in the mold manufacturing portion of the design process. During the design phase, consumer goods often undergo frequent modifications and must maintain or increase its initial quality. Equally imperative is that its molds maintain an equally high standard of excellence. To uphold the high levels of mold manufacturing involves long hours of fine finishing with EDM followed by hand polishing. It is here in the polishing process that the risk of geometrical distortion is increased. Polishing is also a time consuming effort that is both expensive and not ideal for accessing in and around small details. GammaTEC, with its many patents, maintains the surface quality of the molds and has approximately 30% less electrode wear. GammaTEC also reduces time loss in the process of tool manufacturing. Not only is the need for hand polishing avoided in most cases, total tool manufacturing time is also compressed. “The GammaTEC solution combines optimization of the dielectric system with enhancements of technology and a specific pre-mixed additive, GammaMIX 50,” said Gisbert Ledvon, marketing manager, Charmilles. “GammaTEC is designed to focus on high performance in die sinking EDM and to assure repeatability on parts coming out of the work tank.” The GammaTEC technology shortens the discharge ignition time; it results in an increase in frequency of erosive discharges, accelerates the EDM-Process and produces a homogeneous diffusion of spark energy. Machining with GammaTEC and standard EDM are both possible on the same machine.
GF AgieCharmilles’ revolutionary AC Vertex is the most accurate wire-cutting EDM in the world. The AC Vertex’s ultra-high precision makes the machine ideal for micro and nano machining, using wires of just .02 mm diameter and IPG-V’s eCut technology to achieve surface finishes down to 0.05 µm Ra in continuous operation. The AC Vertex is as productive as it is precise. Agieduo makes it possible to work with dual wire spools of different wire type, making it possible to switch between wires of different diameters automatically. Programmable via the machine control, the forward feed of the wires, just like the threading, takes place automatically and is monitored by patented sensors. The Vertex also boasts a table design that separates the X and Y-axes on a patented monobloc. A traveling table on the machine bed carries the work tank and moves the workpiece in the X direction exclusively. A second axis slide, also movable in the horizontal plane on the machine frame, accommodates the upper part of the C-frame and moves the wire in the Y direction. This configuration delivers ideal travels, positioning accuracy and taper cutting capability for machining complex, high precision parts. To simplify machine setup and increase uptime, GF AgieCharmilles incorporates the Agiesetup 3D probing system, which measures flatness and skew to automatically locate the workpiece in the work area. Capable of being programmed off-line and executed unattended, Agiesetup is 100% automatic and saves an average of 20 minutes per part when compared to traditional methods of workpiece set up. Additionally, the AC Vertex is equipped with Agievision, an intuitive control system developed specifically for wire cut EDM that enables flexible data input in accordance with workshop environment.
Mikron’s UCP 600 Vario is a high speed 5-axis system designed to handle a wide variety of machining configurations, including automated production applications. The UCP 600 Vario delivers a number of efficiency-boosting features. Capable of delivering a number of efficiency-boosting features, the modular, scaleable tool changer system can hold 100 to 220 tools and fits optimally into the compact machine layout. Additionally, the UCP 600 Vario provides economical, automated production with the cost-effective integration of a 7-position pallet changing system that can machine workpieces with a maximum height, weight and surface area of 14”, 176 lbs., and 13”x13”. Equipped with Mikron’s revolutionary “smart machine” technology, the UCP 600 Vario uses smart machine sensors that allow machinists to utilize the advanced process system (APS) for monitoring and recording spindle vibrations. The machine also includes an intelligent thermal control (ITC) system to automatically compensate for thermal deviations, as well as a remote notification system (RNS) to allow real-time control / access at any location for reliable, unattended machining. Built with a state-of-the-art chip management system, the UCP 600 Vario is offered with three different high-speed spindle options (12,000, 20,000 and 42,000 RPM), as well as a highly versatile rotary/tilt table that swivels between -115° and +30° for superior milling flexibility.
Mikron recently released the HSM 400U ProdMed, the newest member of the Mikron ProdMed line of high-speed and high-performance machining centers that are specially suited for the medical manufacturing industry. The HSM 400U ProdMed offers the levels of reliability, traceability and accuracy required for machining medical implants, equipment and other components. The HSM 400U ProdMed includes a Heidenhain iTNC 530 control system and smart machining modules that provide advanced levels of monitoring critical to the production of medical implants and equipment. The system allows the machine to automatically check and evaluate tools and workpieces, inspect tools for breakage and perform measurements of the workpiece. Additionally, the smart machine modules automatically monitor spindle vibration, calibrate machine geometry and transmit process status messages to an operator’s cell phone. With powerful vector spindles available at 30, 42 or 54,000 RPM, the HSM 400U ProdMed provides excellent surface finish and part detail, while significantly reducing machining time for semi-finishing and finishing operations. The machine’s high dynamics, with 1.7g acceleration, facilitate the reduction of non-productive time and help to maximize spindle utilization. The HSM 400U ProdMed possesses the capability for 24/7 unattended machining through the inclusion of a palletchanger with 20 pallets. The machine’s automation potential is further enhanced through an automatic table and workpiece cleaning system, efficient chip evacuation and the ability to measure workpieces arranged outside the machine. The HSM 400U ProdMed’s unique monoblock bridge design achieves high precision by maintaining a high level of rigidity. The machine’s polymer concrete construction provides increased performance in the areas of dampening, thermal stability and tool life. Also, attention to the ergonomics of the machine’s design allows for uncharacteristically easy access to workpieces.
The Mikron HPM 1350U is a high performance machining center that offers simultaneous five-axis machining, while also providing dynamic performance and high precision. Specially designed with linear motor technology for the rotary axis, the HPM 1350U allows for large axis movements with unrestricted access and is the ideal choice for heavy cutting and precise machining. Built with a versatile milling head and a 43.42 in. diameter rotary/tilt table, the HPM 1350U handles loads up to 3,306.9 lbs. with a rotational speed up to 40 rpm. A direct drive high torque motor drives the milling head, assuring faster and more dynamic machining with a 38kW spindle output at 15,000 rpm with 193 torque. Mikron’s use of the torque motor precludes the need for a gearbox, as well as any belts or wires that could affect the machine’s precision. Additionally, the milling head is constructed to swivel simultaneously with a spindle up to 136 degrees, and the swivel axis can be indexed degree by degree to make precise use of the spindle motor’s high torque ability. The presence of a hydraulic clamping device for the spindle allows boring and machining procedures to be carried out from any position. The HPM 1350U is also outfitted with Mikron’s revolutionary Smart Machining Modules, which use sensors to allow machinists to utilize the Advanced Process System (APS) for monitoring and recording spindle vibrations. Designed to switch between vertical and horizontal multi-axis machining processes in 1.7 seconds, the HPM 1350U can accommodate a wide variety of applications, ranging from production type prismatic parts to complex tool and die work, in a single set up. Mikron also suited the HPM 1350U with a standard 46-position tool magazine, and a powerful Heidenhain iTNC 530 control system that offers a host of features, including 3-D graphics and cutter compensation, advanced high-speed functions, a 2.0 Gigabyte hard drive, and a 15 in. TFT flat screen.
The Mikron HPM 1850U is a high performance, traveling table type machining center that offers simultaneous five-axis machining for workpieces up to 56.5 ft3 in volume. Weighing 661 lbs. less than comparable machines containing conventional cast slides, the HPM 1850U boasts a pallet size of 49.2” x 39.4”, as well as high dynamics in the X and Y-axes and greater accuracy and surface finish. The HPM 1850U is equipped with a HSK63 tool interface and a milling head driven by a direct drive high torque motor, which generates torsional force without the use of belts or gears. The machine offers a 35 kW spindle output at 15,000 rpm with over 190 Nm torque. Additionally, the spindle housing is tightly attached to the rotor, allowing gear clearance and virtually eliminating signs of wear and tear. The Mikron HPM 1850U contains a number of user-friendly features optimized for use in the workshop. Mikron’s revolutionary Smart Machining Modules enable the HPM 1850U to use sensors that allow machinists to utilize the Advanced Process System (APS) for monitoring and recording spindle vibrations. Further, the machine’s iTNC 530 Heidenhain control system provides operators with free contour programming, freely definable sub-programming, and pre-set work cycles for automation during unmanned hours. Operators also benefit from the presence of two stations to minimize downtime, as well as a 3-position pallet changer that enables a response to urgent orders without requiring the tear down of set-ups. Designed with the operator’s comfort in mind, the HPM 1850U is equipped with a lifting mechanism on the pallet changer that provides a comfortable loading height. The machine is also fitted with rotating loading and unloading stations that contain equipment ideal for turning and securing large workpieces. As apart of its innovative design, Mikron removed the pedestal typical to large machines from the HPM 1850U and replaced it with an apparatus that lifts the pallet to the height of the worktable. This innovation makes the HPM 1850U the only machine of its size with ground-level access to both loading stations.
Agie Charmilles is setting new standards in the field of high-speed machining with the HSM 500, a vertical machining center that provides three-axis high-speed milling in a compact design. Capable of machining cubic workpieces up to 200 kg, the HSM 500 is designed with the operator in mind. GF AgieCharmilles equipped the Mikron HSM 500 with an HSK-E40 tool interface and a vector controlled motor spindle for short run-up and brake times and high torques at low speed. To ensure a high-speed spindle output of 13kW at 42,000 rpm with over 4.2 Nm torque, the Mikron HSM 500 is also outfitted with ceramic hybrid ball bearings and liquid-cooled stator jacket and bearings. The HSM 500’s base is made of monobloc polymer concrete with high vibration damping properties, providing strength and rigidity essential for high-speed machining. The single casting construction also improves machining accuracy, producing better thermal stability for excellent work piece surface quality and minimal tool wear. Additionally, the HSM 500 is fitted with absolute optical linear scales on the X, Y and Z axes that operate with a measuring step of .02 µm to guarantee incomparable positioning precision. Constructed with an ergonomic design to improve security and accessibility for operators, the HSM 500 is equipped with a large sliding door to give access from three sides, as well as a side window for maximum monitoring of the milling process. The HSM 500 also offers a low loading depth, excellent access to the tool changer and an easy to clean work area. The Mikron HSM 500 also contains a number of user-friendly features optimized for use in the workshop, including Smart Machining Modules, which operate sensors that allow machinists to utilize the Advanced Process System (APS) for monitoring and recording spindle vibrations. The machine’s iTNC 530 Heidenhain control system provides operators with free contour programming, freely definable sub-programming and pre-set work cycles for automation during unmanned hours.
The Agietron Spirit 3 was designed to be the simplest and fastest CNC die sinking EDM system in the Spirit line. Capable of handling workpieces up to 43” x 30” x 15”, the Spirit 3 performs in a comprehensive range of applications, from simple repair jobs to complex multiple cavities. Featuring a CE Compliant design that improves thermal stability over long periods of time, the Agietron Spirit 3 has a unique manual-centering mode that precisely centers an electrode in an existing cavity, extremely useful for mold repairs minimizing time spent on CNC programming. Additionally, the integration of the C-axis adds capability for rotation, indexing and complex erosion, while the inclusion of AgieBril™ technology within the spark generator provides finishes as fine as Ra 0.2µm in steel using copper electrodes. The Spirit 3 is a true "Plug & Play" EDM system that enables start up and production within an hour of delivery. The highly flexible user interface reduces programming times to minutes instead of hours by simplifying complex job programming for multi-cavity, planetary, helical shape, deep rib and four-axis erosion. The system also provides full erosion path contouring capabilities. The Spirit 3 also contains Automatic Erosion Programming that makes it easy for users to select erosion technologies by application type, set minimum wear and maximum removal priorities, and get perfect results on the first try. Additionally, the unit includes some of the following built-in planetary (orbiting) application technologies: Equimode, circular orbit, 2D vector, 3D vector, continuous rotation, continuous circle or sphere, and contouring.
The latest innovation from Agie Charmilles is the Mikron VCE 800 Pro-X, a vertical machining center designed for universal applications. Efficient and fully equipped, the VCE 800 Pro-X substantially reduces machining times, offers repeatable measuring results and lessens the difficulty of producing items like thin-walled workpieces. The VCE 800 Pro-X is able to withstand the challenge of machining both hard and soft molds while producing cost-effective volume chip removal and high quality surfaces. Fitted with a Step-Tec inline motor spindle, the machine achieves an output of 15kW with nearly 100 Nm torque. Though these characteristics enable the use of face cutters with a diameter of up to 3.3 in. and drilling tools up to 2.4 in., machining with smaller tool diameters allows for a maximum continuous operation speed of 16,000 min-1. Additionally, the VCE 800 Pro-X boasts feed rates of 118 ft/min (X,Y) and 79 ft/min (Z) for cost-effective machining of three dimensional cavities like forged, diecasting and injection molding dies with low to medium complexity. The machine’s range of application is extended by an optional 4th axis that is fully controlled by the Heidenhain 530 TNC CNC and suitable for milling in both positioning mode and simultaneous machining procedures. The Mikron VCE 800 Pro-X also contains measuring probes and 3D Form Inspect software that allow workpieces to be measured on the machine while still in the clamp. While measuring, the software also calibrates the measuring probe machine deviations. This results in reliable, repeatable measuring results for increased accuracy and reduced total machining times.
HSM 200U LP
Technology advancements encourage moldmakers to think about surface treatment, mold maintenance and repair issues earlier in the mold build process to obtain better mold performance and life.
Janler’s business philosophy centers on “running the operation as a business, not a shop.
GF AgieCharmilles, a leading provider of EDM systems, milling machines and laser texturing solutions, is now collaborating with the Virginia-based Commonwealth Center for Advanced Manufacturing (CCAM) to help accelerate the transfer of research innovation from the laboratory to commercial use.
At the recent International Manufacturing Technology Show in Chicago, EOS and machine tool maker GF AgieCharmilles demonstrated additive and subtractive processes working together to produce a titanium tibial tray for knee implants.
Motorola has placed an increased emphasis on adding new software tools to improve its engineering and manufacturing operations. For its moldmaking business, this has meant implementation of new procedures in Cimatron-E and implementation of a Hexagon PC-DMIS solution on the shop floor.
Evolving customer needs continue to drive industry-leading machining solutions
Advancements in EDM processes in terms of machining speed and surface finish improve overall accuracy, productivity and profitability.
A live demonstration of embracing both subtractive and additive manufacturing was one of the highlights for me at IMTS. Machine tool builder GF AgieCharmilles and EOS showcased an innovative start-to-finish manufacturing process chain that creates actual titanium tibial trays for surgical knee implants.
With a focus on aerospace and aeronautics, THRUST, GF AgieCharmilles’ new interactive magazine, will make its debut during IMTS 2012 and on Apple’s App Store.
Implementing new technologies across the entire shop floor improves overall accuracy, productivity and profitability.
Agie Charmilles will unveil its new Competence Center during a two-day grand opening and educational event from July 25-26, 2012. The center, located in Lincolnshire, Ill., supports the company’s continued focus on providing the best solutions to manufacturers who specialize in specific market segments, such as aerospace, medical and die and mold.
EDM and milling technologies.
This systems approach to micromachining includes multiple cavities in the molds for the plastic injection over molding portion of the LED manufacturing process.
A roundtable of machine tool suppliers reviews the advancements in machining technologies that push machining and tooling to their limits—and can kick every moldmaker’s capability up a notch.
See Us at MD&M Booth 3889
FORM 200 mS
Recent advancements in the technology behind low-wear capability have drastically improved the machining speeds at which low-electrode-wear application settings can be applied.
HSM 600U LP
When it comes to retaining its winning edge over the competition, the LotusRenault F1 Racing Team puts its trust in GF AgieCharmilles high performanceelectro-discharge machines to play a central role in all its triumphs.
GF AgieCharmilles, a partner of choice to the tool and moldmaking industries as well as manufacturers of precision components, invites members of the manufacturing world to its Charlotte, N.C. and Yorba Linda, Calif. offices next month to celebrate Tektoberfest.
GF AgieCharmilles, a leading supplier of high-speed milling machines, EDMs, laser ablation systems and automation solutions, recently partnered with Metalcam, a developer of CAM software solutions, on the release of a new software that easily automates the programming for the highly advanced Drill 20 EDM drilling system from GF AgieCharmilles.
With a focus on improved performance and new applications, GF AgieCharmilles Technology Days 2011 offered educational seminars and machine demonstrations to an estimated 170+ customers, technology partners, and industry press.
GF AgieCharmilles has announced that it will be holding Technology Days 2011 on June 29 – 30 at its North American headquarters in Lincolnshire, Illinois. The two-day event will include educational seminars and training sessions, as well as technology demonstrations.
MSI Mold Builders: Redefining Mold Manufacturing with Incremental Approval Approach.
EDM/5-Axis Milling; Eastec Booth #1224
United Tool & Mold, Inc.: Charging Forward with Unique Mold Repair Niche.
A multiple-machine moldmaking process—combining DMLS, high-speed five-axis machining and EDM— produces conformal-cooled molds in a seamless automatic process.
How moldmakers can improve the level of control exerted in surface texturing.
Specializing in high precision molds with interchangeable components, RMM has supplied the industry with a wide variety of tools including, single face, stack, unscrewing, multi-material, rotary cube technologies—and considers its customers’ needs a number-one priority.
GF AgieCharmilles (Lincolnshire, IL) offers the CUT 20P wire EDM featuring a variety of new evolutions, including a new dielectric unit with three vertical Grundfos pumps for increased performance.
With an average leadtime of eight weeks, Mold Craft, Inc. (Willernie, MN)—this year’s Small Shop Leadtime Leader Award Winner—builds tight-tolerance, high-volume, multi-cavity and multi-mold projects that produce small, intricate, precision plastic parts.
The emergence of today’s technologically advanced oil-based wire EDMs is an opportunity for the average U.S. mold builder to set himself apart from the competition.
GF AgieCharmilles (Lincolnshire, IL) offers its CUT 20, an innovative wire-cutting EDM that combines outstanding performance with remarkable ease-of-use.
The use of automation continues to rise as mold manufacturers respond to industry demand of constantly shrinking leadtimes. Manufacturers and suppliers have taken action with better, faster equipment and processes.
GF AgieCharmilles' (Lincolnshire, IL) FI440CCS wire EDM is flexible and fast, capable of machining materials with a wide variety of wire diameters, enabling it to yield a 38-in2/hr. production rate with a 0.012" Econotec brass wire to save up to 30 percent cutting time and reduce wire cost.
Advances in EDM technology—including increased automation and combining machining processes to get the job done as efficiently as possible—help EDM stay afloat and keep moldmakers successful.
The industry’s demand for higher quality, faster turnaround times and lower prices in the last decade has resulted in dramatic improvements in high speed machining as well as controls and spindles
Progress in the realm of software offers moldmakers the opportunity to maximize the potential of their machining processes when it comes to maintaining extremely high surface finishes.
The Agietron Spirit 3 was designed to be the simplest and fastest CNC die sinking EDM system in the Spirit line.
The Mikron HPM 1350U is a high performance machining center that offers simultaneous five-axis machining, while also providing dynamic performance and high precision.
The Mikron HPM 1850U is a high performance, traveling table type machining center that offers simultaneous five-axis machining for workpieces up to 56.5 ft3 in volume.
Agie Charmilles is setting new standards in the field of high-speed machining with the HSM 500, a vertical machining center that provides three-axis high-speed milling in a compact design.
The latest innovation from Agie Charmilles is the Mikron VCE 800 Pro-X, a vertical machining center designed for universal applications.
As wire costs continue to increase, twin wire will be recognized as a strong tool for fine tuning wire EDM performance and reducing cost.
This moldmaker flies high with a combination of specialized processes and modern technologies required for the extremely tight tolerances and exotic material concerns in the aerospace industry.
Mikron’s (Lincolnshire, IL) HPM 1850U high performance, traveling table type machining center offers simultaneous five-axis machining for workpieces up to 56.5 ft3 in volume.
GF AgieCharmilles’ (Lincolnshire, IL) AC Vertex wire-cutting EDM is suitable for micro and nano machining, using wires of just .02 mm diameter and IPG-V’s eCut technology to achieve surface finishes down to 0.05 µm Ra in continuous operation.
For moldmakers considering making their foray into micromoldmaking, a solid understanding of the benefits of new EDM technologies is necessary to make the transition as smooth as possible.
A rule to lightweight preform necks and closures could require more than 1,000 new molds.
GF AgieCharmilles’ revolutionary AC Vertex is the most accurate wire-cutting EDM in the world.
The Agiecut Progress V 2 established a new benchmark for wire EDM cutting speed at 47 in²/hr. using standard 0.013” coated wire.
-- To complete its family of high-speed, eCut generator technology Progress wire-cut EDM systems, Agie US has introduced the Agiecut Progress V 4, which features work table dimensions and axis travels to process workpieces up to 51 in x 39.4 in x 19.7 in and 6,600 lbs.
The Agiecut Vertex 1 and Agietron Micro-Nano let you EDM on a nanometer scale!
Mikron recently released the HSM 400U ProdMed, the newest member of the Mikron ProdMed line of high-speed and high-performance machining centers that are specially suited for the medical manufacturing industry.
Charmilles’ ROBOFIL 240cc/440cc uses the CC generator to dramatically improve machining speed while preserving the surface integrity of the machined material.
With an eye on the ever-changing world of consumer goods, automotive components and household and industrial appliance design, Charmilles developed GammaTEC for its ROBOFORM 350 and 550 machines.
Mikron’s UCP 600 Vario is a high speed 5-axis system designed to handle a wide variety of machining configurations, including automated production applications.
This moldmaker plays it close to the vest with strategies and practices, but one can learn from its serious investment in the latest technologies to provide quick-turn and RP tooling in record time.
Heavily relying on lights-out manufacturing coupled with a niche market in complex mold manufacture, this moldmaker lands its fourth accolade as a Leadtime Leader—three times as a winner and this year’s Leadtime Leader: Small Shop Honorable Mention.
Learning the intricacies of die cast die building offers moldmakers an alternative to mold manufacturing and can generate more repeat business.
This moldmaker garners the 2007 Leadtime Leader Award: Small Shop by being flexible with its customers, going lean, competing globally and uniting with other moldmakers.
Design and performance capabilities of components fabricated in state-of-the-art molds enhance the appeal of new vehicles.
This school works hand-in-hand with suppliers and shops—relying on their expertise and input to stay on top of industry trends and help develop a tailor-made curriculum in precision machining and moldmaking.
Design and fabrication capabilities of advanced tool-cutting processes give toolmakers an edge in developing new business.
The ProdMed line of High-Speed and High-Performance Machining Centers from Mikron (Lincolnshire, IL) was developed for the manufacturing of medical implants (including dental and orthopedic) and medical equipment (including surgical and general instruments). These machines—which include the HSM 400U ProdMed, HSM 400U ProdMed Dental and the UCP 600 Vario ProdMed—offer the reliability, traceability and accuracy that is required for machining medical parts.
One school—with industry’s help—is a model for our future moldmakers’ education.
Moldmakers are starting to change the way they think and incorporate automation into all aspects of their operation—combining a multitude of processes in a single cell for optimal productivity.
Advanced engineering and mold building techniques give North American toolmakers entrée to emerging electronics applications.
Before you move your shop into full blown automation, integrate a pallet system and process management software.
This moldmaker’s firm belief in continuous education for its employees combined with advanced training and cutting-edge technologies increases total delivered value of its products.
Charmilles’ (Lincolnshire, IL) ROBOFORM 350 MicroTEC diesinking EDM offers innovations in precision, speed and productivity for even the smallest die and mold applications.
This moldmaker empowers its employees and wisely invests in technology to ensure its survival for the long haul.
At IMTS, Charmilles will display the ROBOFIL 640cc, the latest and largest EDM to take advantage of the CC generator.
Measuring 100.4” x 128.7” x 101.0”, Charmilles’ (Lincolnshire, IL) ROBOFIL 640cc wire EDM has been added to company’s CC line of machines.
Commodity-oriented consumer manufacturing left North America, but mold industry survivors are finding strong growth in technical market sectors.
HSM technology helps U.S. moldmaker maintain world-class productivity and business growth.
Drive and determination results in a decade of success for this small moldmaker specializing in multi-cavity precision molds.
Tool and die/precision machining industry trends are amazingly uniform worldwide. Business is tough almost everywhere, but getting better.
When technology, quality and speed step to the fore in the medical world, so does the North American mold and die industry with some innovative products and processes.
The Charmilles (Lincolnshire, IL) Robofil 240cc wire EDM features turn and burn capability that combines a servo-controlled, moving B-axis with a wire cutting in the X and Y axes to machine complex 3-D shapes; and uses the CC generator to dramatically improve machining speed while preserving the surface integrity of the machined material.
Strategies for attacking the lack of ongoing training dilemma that directly impacts our shops.
A combination of lean strategies coupled with niche moldmaking garners this shop the MoldMaking Technology 2006 Leadtime Leader Honorable Mention: Large Shop.
Improved process reliability, optimized machining performance and reliable unmanned operation are the results of smart machining implementation.
Charmilles (Lincolnshire, IL) will be displaying GammaTEC at the MoldMaking Expo.
The Robofil 240cc featuring “turn and burn” will be displayed at Westec by Charmilles (Lincolnshire, IL). The Robofil 240cc uses the CC generator to dramatically improve machining speed while preserving the surface integrity of the machined material.
It’s time to adapt or die as business evolution dictates development of new business and manufacturing approaches.
Charmilles (Lincolnshire, IL) has developed the GammaTEC for its ROBOFORM 350 and 550 die sinking machines to meet the high quality and finish demand and time requirements in the mold manufacturing portion of the design process.
Charmilles’ (Lincolnshire, IL) new SIGMA software offers users the total package for managing and producing specific data for EDM machining.
Getting up close and personal with the latest current and emerging technologies affecting the mold industry is the best way for mold manufacturers not only to see what is out there.
Mold shops need to pay attention to the potential impact wear parts and consumables can have on their overall production.
An increased interest in five-axis machining—coupled with advances in controls and cutting tools—add up to finer surface finishes at higher speeds.
Charmilles’ recently unveiled Robofil 2050TW sets a new standard for wire EDM performance.
Charmilles has announced the release of the Robofil 240SL, a machine replacing the standard Robofil 240 wire EDM.
Charmilles’ new ROBOFORM 350 MicroTEC diesinking EDM offers innovations in precision, speed and productivity for even the smallest die and mold applications.
Charmilles’ (Lincolnshire, IL) Robofil 2050TW—a twin wire machine—brings high speed, improved surface finishes and unsurpassed accuracy to the top end wire class of EDM.
EDM experts reveal that trends in increased automation combined with unattended machining result in better accuracy and surface finishes in wire and diesinking EDM applications.
Steps to help maximize the potential of your current die sink or wire EDM system.
The HSM 600U is a machining center developed for simultaneous high speed five-axis machining of large workpieces.
HyperSpark machining is said to increase ram EDM speeds by focusing on intelligent flushing rather than simply increasing the drive speed (rapid lifting movement). This EDM process is performed in three stages - asymptote detection, current increase and pulse interrupt - to optimize removal while maintaining the highest surface quality.
The Agietron Advance 2 CNC ram EDM features a small footprint to fit in a compact 8' × 10' work zone.
Mold shops should look to race shops for technologies and strategies to help reduce their mold build leadtimes.
An increase in productivity of approximately 30 percent, and up to 100 percent with pre-milled molds, is possible with new EDM technology.
In order for moldmakers to compete with overseas forces and their huge labor cost advantages, automation is no longer an option...it is a necessity.
The Secrets to Hard Milling Success
Manufacturing blow molds has kept this moldmaker in the black for more than fifty years-and has earned them an Honorable Mention in MoldMaking Technology magazine's Leadtime Leader competition.
Using the latest technology and a team effort approach yields sales aplenty-and an Honorable Mention in MoldMaking Technology magazine's Leadtime Leader competition.
To remain competitive in the mold manufacturing market every mold shop needs to answer three questions about its diesinker EDM.
A California moldmaker makes the most of state-of-the-art machine tool and design technology to deliver competitive advantages for a medical device customer.
In the last two years, there have been many exciting developments in high-speed machining relative to machining centers and controls, tooling and CAD/CAM systems.
By focusing on such aspects as maintenance, tooling and training, moldmakers can increase the productivity of their wire EDM significantly.
Today, it is popular to talk of eliminating electrodes for hard die milling.
Recent developments in automation are providing benefits for the high-performance machining (HPM) of electrodes and steel mold components.
A number of recent EDM developments offer significant solutions to obstacles facing the moldmaking industry in the millennium.