GF AgieCharmilles: automation, speed and precision

Only a few days after the world's largest machine tool fair, EMO Hanover, closed, Jürg Krebser, Head of GF AgieCharmilles, summed up on a positive note: "We showed the visitors our innovations in electric discharge machining and high-speed and high-performance milling. These included more productive machines and automation solutions, along with comprehensive service concepts and even greater customer focus." On 1 July 2007, all activities of the former Agie, Charmilles and Mikron brands were united under a single umbrella brand – GF AgieCharmilles. The different distribution channels around the world were brought together, and in future the machines will be distinguished by a new, clear form and design idiom. This milestone was reached at the same time as numerous product innovations were launched. Guests at the Technology Day 2007 had the opportunity of seeing this change for themselves. As representative of the thirteen world "firsts" presented at EMO, GF AgieCharmilles showed a CUT 20 for wire cut EDM, a FORM 2000 for diesinking EDM and a Mikron XSM 400 U for ultrahigh-speed milling.

The Corporate Group manufactures the CUT 20/30 series completely at its factory in Beijing, though the high-performance electronics are delivered from Switzerland. "This series gives our customers access to high-precision manufacturing at affordable prices – and for us it opens up an additional, promising market segment," says José Luis Moral, Head of EDM and responsible for the plants in Switzerland and China. CUT 20 and CUT 30 meet the market's demand for affordable wire-cut EDM solutions. They can be used for a wide range of applications, for instance the manufacture of precision parts and electrodes. Another impressive feature is the machine's low operating costs. The intuitive user interface, which is especially important in Asia, is a key characteristic of this series.

User requirements were the focus of attention in the development of the FORM 2000/3000 series. This electric discharge machine makes it possible to manufacture precise, perfectly formed geometries with a very fine surface. The parts are finished to a precision of +/- five micrometres (or five thousandths of a millimetre) and internal radiuses to < 5 micrometres. This order of precision sets new standards in this segment. The core of the FORM 2000/3000 is the machine generator, which is equipped with the latest in EDM technology.

One of the outstanding features of the FORM 2000/3000 is an automation package for electrodes and workpieces that is integrated into the machine. With this modular, expandable solution, productivity can be significantly increased. An optional feature for customers is two user interfaces (HMI).

"Moulds have to be exact to a few thousandths of a millimetre, and process speed, for instance when changing machining tools, is decisive for the machine's cost effectiveness. That's why ongoing technological development in high-speed milling is so important," says Michael Hauser, Head of the Milling business unit at GF AgieCharmilles. Based on the current HSM/XSM series, GF engineers have developed two new machine models with outstanding precision and surface quality. These machining centres combine the accumulated technical know-how and extensive development experience of GF AgieCharmilles. They are designed both for tool and mould-making and for medium and small-scale serial production of high-quality parts.

Reducing vibration extends tool service life and improves surface quality. By using polymer concrete rather than grey cast iron, the GF engineers have achieved extreme rigidity and outstanding damping for the entire machine. This reduces vibration during the machining process and spares the tools. The machining is further improved by a damping unit in the swivelling top plate. The unit has been developed and patented by System 3R, a subsidiary of GF AgieCharmilles.

The axes are moved by so-called linear motors. Using the same principle as that employed in maglev trains, the saddles on which the workpieces or tools for machining are situated are no longer driven mechanically but by means of non-contact inductive motor technology. The advantage of linear motor technology is primarily the precision of circular movements and changes in direction that can be achieved as well as the reduced heat generated by the system. This latter feature results in greater precision and less wear and tear on the components used.

In industrial use, tools can become dirty or suffer wear and tear, thus producing suboptimum results. The usual practice is therefore to measure the tools by means of laser beams prior to machining. However, such laser measurements will not tell the operator whether the tool is simply dirty or whether it has suffered dangerous wear and tear. GF AgieCharmilles has developed a completely novel tool detection system by means of which the tool can be optically recorded and measured. On the basis of the contamination or wear and tear detected, the system can then decide whether the tool has to be exchanged automatically or only cleaned (meaning that it can be left in the machine). The machining process thus becomes controllable, and the precision and surface quality of the machining are constantly reliable.

Well over 500 customers of GF AgieCharmilles have invested in workpiece automation in the past two years. This trend to automation looks set to continue, with the focus on Northern Europe, North America and Asia. "Whereas in Northern Europe the decisive factors are hourly rates for the machines and the related wage costs," says Michael Hauser, "hopes in the developed Asian countries are centering on better, reproducible quality and large quantities." In Northern Europe and North America, an additional need is for higher productivity and lower unit costs. Moreover, a reduction in shift and weekend work and flexible adjustment to the order situation also play a role. A common feature of all markets is the demand for a reduction in lead and delivery times.

Automation solutions are independent of markets and industries. The basic solution is integrated workpiece automation, which is factored in at the development stage and is integrated in the mechanical, electric and instrumentation design of the machine tool.

Where greater flexibility and capacity are required, technical and economic aspects move to the forefront. In such cases, external workpiece automation is combined with GF AgieCharmilles standard components. Automation @ GF AgieCharmilles gives customers the opportunity of transferring to the Corporate Group responsibility for the entire project from specifications to implementation and acceptance.

People are setting increasingly high standards as regards the functionality, design and reliability of products. Market success often depends on the precision and efficiency with which the products are manufactured.

GF AgieCharmilles has expertise in all the technologies associated with electric discharge machining, high-speed and high-performance milling and automation. Its know-how supports the manufacturers of modern products in mould and tool-making and in the production of precision parts.

GF AgieCharmilles is a Corporate Group of the Georg Fischer Corporation (Switzerland) with 50 locations worldwide. 3,200 employees generated sales of about CHF 1.14 billion in 2006.