-dimensional geometry of the. fiorenza E EXPERIENCE 28 January 2007 geometric dimensioning and tolerancing ......
PARTNER TO THE BEST
NO. 28
000.000.000
T H E E D M
A G I E M A G A Z I N E
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no. 28 T H E E D M
A G I E M A G A Z I N E
The synthesis of high precision with high productivity
2
Zehatz Spain
4
Grávalos Spain
10
Swisslan Spain
14
Fabbri Italy
18
Mime Italy
24
Sønderborg Denmark
28
Hamilton Lichfield England
34
SFT Germany
40
Cover immage: The italian company Fabbri snc is the worldleader in highprecision sportsriffles. Wire and sinkerosion are manufacturing steps in the production of gunlocks.
+GF+ AgieCharmilles EDM Marketing and Sales Support CH-6616 LOSONE TEL. +41 91 806 91 11 FAX +41 91 806 92 60 www.agie.com
[email protected]
January 2007 Appears in English, French, German and Italian. Edited and text by: M. Katz
[email protected] Graphics and pagination: R. Grizzi, F. Simona Printed by: Tipografia Poncioni SA Losone - Switzerland
© AGIE An Agie Charmilles Group Company. No responsibility is accepted for technical data or the content of articles.
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Dear Reader,
Combining high precision with high productivity is a challenge! In ED wire cutting it now has a name: «Challenge».
The synthesis of high precision with high productivity
The new Agiecut Challenge V2 and V3 ED wirecutting machines have numerous standard and optional features available which increase the productivity of ED wire cutting and further improve the outstanding standard precision. Agiecut Challenge V machines have ideal prerequisites for automated sequences: Lowerable working tanks, 25-kg wire spools, clearly defined
AGIECUT VERTEX
1 1F
interfaces, automated threading, long service
VERTEX
2 2F 3 3F
CHALLENGE V
2
3
PROGRESS V
2
3
CLASSIC V
2
3
lives of the filter and deionising systems, long 4
VERTEX
life of the power leads and wire guides as well as plannable maintenance and service intervals. The EDM performance is strikingly improved with IPG-V (Intelligent Power Generation Vertex) and eCut technologies, with a lower energy requirement at the same time.
CLASSIC
PROGRESS
CHALLENGE
VERTEX
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With the interaction of dual measuring systems, the control unit and the mechanism, a precision concept is implemented on Agiecut Challenge V which also meets the special requirements in the case of high and large workpieces. A surface quality of Ra 0.2 µm is achieved as standard and innovative functions ensure accurate linearity, highest form accuracy, as well as increased precision of the angular accuracy. Corners and radii, as well as stepped workpieces or ones with apertures can be cut at an optimal speed.
We are convinced that, with the new Agiecut Challenge V2 and V3, we have conceived ED wire-cutting machines which best combine high precision with high productivity. The articles in this issue also show how productively and precisely our customers solve complex production tasks with ED machining. I now wish you stimulating reading
Michael Katz Technical Editor
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Zehatz
The Zehatz company, founded in 1992, manufactures precision tools, medical implants, mechanical and micro components which it supplies to worldwide branches such as aerospace, automotive, food canning, microelectronics and medicine. The north Spanish
Country
Spain
Production
-
Target market
Europe
Employees
40
Founded
1992
EDM
1 Agiecut Vertex 2F 1 Agiecut Progress V3
Programming
- Mastercam - Unigraphics - Catia
Clamping
Erowa
Measuring, testing
- Leitz PMM 12106 - Sirocco-Record, Microval 343 and Image Global 775 from DEA - Mitutoyo Crysta Apex C 574, Quick Vision Pro-Hyper, LH-600B and microscope - Tesa MicroHite Plus M600 and M350 - Baty Projector R 400 - Mahr Formtester MMQ40, Perthometer PGK-Plus Roughness and Perthometer PCV 200 profiles - Ernst AT-180 Durometer
Food canning Aerospace Automotive Microelectronics Medicine
company has 40 employees on its payroll and is Zehatz
known for its ultra precise production. For this
P. Industrial Kurutz Gain 12-13
Zehatz has invested in a unique measuring,
20850 Mendaro
checking and testing centre which guarantees
Spain Tel +34 943 757 180
quality at every stage of production.
Fax +34 943 755 041
[email protected] www.zehatz.es Contact
Alfonso Urzainki, Managing Director Josu Mugartegui Lejardi, Sales Manager
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Zehatz
When the «µm» is split by ED wire cutting Ultra precision knows no frontiers Zehatz, based in the Basque region to the east of Bilbao, was founded in 1992, has 40 employees on its payroll today and is the manufacturer of a wide variety of products, such as high precision workpieces, spare parts, tools and components. The north Spanish undertaking supplies them to the aerospace, automotive, food canning, microelectronics and medicine industries worldwide. Zehatz' company philosophy builds entirely on mutual trust and cooperation with customers. This includes the joint development of critical components, such as production and checking tools, specimen parts and templates – always under the viewpoint of offering the customer solutions that are competitive and improve products. This is implemented with an innovative design department, an ultra modern range of machine tools and also, as the heart of the company, a measuring centre for the highest standards. Ultra precision thus becomes visible, measurable, demonstrable and comprehensible for customers. An important argument, with which Zehatz has positioned itself right at the top in global competition. Recently, Zehatz has also integrated an Agiecut Vertex 2F into its ultra precision concept. The ED wire-cutting machine proves that it meets the demand with its precision results: surface roughness Ra 0.05 µm, fitting accuracy ± 1 µm and inside radii of 0.03 mm with finest wire and automatic threading are standard features.
Quadruple copper electrode with which mould inserts for a blanking tool are ED machined. The outside and inside contours are ED wire cut to an exact fit. During blanking, the tool inserts give the form for the pull openers for food cans. The three-dimensional representation generated with a CAD program shows a current Zehatz project. Before the production stage, the new type of tool is tested virtually and optimised in accordance with production engineering requirements. The Agiecut Progress V3 ED wire-cutting machine is set up by means of the «Agiejogger» handbox. The operator can carry out all the important control functions with it.
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Data input on the Agiecut Vertex 2F is reduced to a few workpiece features and quality targets. The «Agievision» control generates the best possible cutting technologies from this. ED wire-cut and die-sunk mould inserts and mechanical components are the best illustrative examples for Zehatz’ high performance standard. A double mould milled from a whole piece is ready for machining on the Agiecut Vertex 2F. The precision and
ED wire cutting in the ultra precision concept «When Agie expanded the Agiecut Vertex series to include larger models, it was clear to us that the size 2 as F-model would be the ideal ED wire-cutting machine for our requirements», Alfonso Urzainki, the managing director of Zehatz, commented on the purchase of the Agiecut Vertex 2F. «We certainly do not need the complete range of performance, which the machine offers, for every machining job, but we have deliberately invested in the future in order to be prepared for new challenges». Zehatz is thus continuing its strategy of achieving ultra precision in all sectors of the company.
Digitally controlled generator pulses With the IPG-V, the Agiecut Vertex 2F has a generator of the latest generation available which improves the EDM performance and controls the EDM process efficiently. This is made possible by a programmable, digital component, which increases the form factor of the pulses and shortens the pulse duration. How advantageous the effect of this is on the workpiece is to be seen by the fact that the machining technology is generated exactly in accordance with the workpiece height and it is no longer necessary to choose between two given workpiece heights. The technology parameters are thus adapted exactly to the given cutting height so that the best possible machining technology is employed. These individually generated technologies bring more precision to the workpiece straight off. The operator at Zehatz thus has the best possible machining technology for every workpiece in accordance with material, height, the wire type used as well as the precision and roughness required, without having to make compromises.
form-giving parts are completed with ED wire cutting and die sinking. Afterwards the mould insert can be fitted exactly into the blanking tool. Finest surfaces and tightest contour tolerances then ensure the precise production of the pull openers for food cans during blanking. Josu Mugartegui Lejardi, Sales Manager of Zehatz, using an optical measuring machine. Showing the tight tolerances of the contours of a workpiece.
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Zehatz
Quality check at all stages of production The material quality, the tools used and the machining processes are influencing variables which have an effect on the precision of a tool. Milled workpieces often make a mirror-like impression, but sometimes have microcracks under the surface concealed by the milling. By contrast, with ED machining, material faults often first become visible through the removal process. Zehatz therefore checks the precision and quality at every stage of production. In this way, tool breakage, reworking or replacement production are for the most part avoided, and consequential costs kept to a minimum. The investment in efficient quality management is doubly worthwhile for Zehatz: Ultra precision becomes comprehensible for the customer and ultra precision helps to save costs sooner or later.
A workpiece is plotted optically on a measuring machine. The contours can then be displayed on the screen in the µm range and checked for diverging contour tolerances. The workpiece is shown three-dimensionally on the screen and every point plotted with the touch probe is provided with the appropriate measurement data. The Zehatz measuring and checking centre lets you see at a first glance what great importance is attached to quality assurance.
“
The Agiecut Vertex 2F is the ED wire-cutting machine with its quality results, best fits into our concept of ultra precision. Convincing also the many standard features on the Agievision control system, which markedly shorten the set-up and EDM times.
”
Alfonso Urzainki, Managing Director of Zehatz
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The workpiece data Name
Mould insert for a six-way blanking tool
Finished part name
Pull opener for food cans
Finished part material
Tinplate
Workpiece material
Hard metal, tool steel
Mould insert service life
60 million
Electrode material
Copper
Electrode production
High-speed milling with Mikron HSM 400 U
Wire type
CCA 0.25 mm diameter
Number of cuts
1 main cut, 2 - 3 trim cuts
Surface roughness
Ra 0,2 µm
Contour tolerance
± 2,5 µm
Mould insert production time 1 hour ED wire cutting 6 hours ED die sinking
We would like to thank Zehatz, in particular their Managing Director Alfonso Urzainki and Sales Manager Josu Mugartegui Lejardi, for their kind support and helpful cooperation with this report. Responsible Sales Engineer: Carlos Grijalba, +GF+ AgieCharmilles
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Grávalos, s.a. Country
Spain
Production
-
Target market
International
Employees
100
Founded
1946
ED machining
1 Agiecut Challenge 2 1 Agiecut Challenge 3 1 Agiecut 150 HSS 1 Agietron Hyperspark 2 1 Agietron Impact 3 1 Agietron EMS 20
Programming
- P-Cam - Unigraphics
Clamping
- System 3R - Own solutions
Measuring, testing
- Etalon coordinates measuring machine - Nikon profile projector - Olympus microscope
Components for consumer electronics Components for the automotive industry Components for white goods Electrical contacts
Grávalos, s.a. Ctra. Castellón, km. 15,500 Polígono Industrial «La Noria» 50730 El Burgo de Ebro (Zaragoza) Spain Tel +34 976 104 808 Fax +34 976 104 090
[email protected]
Grávalos s.a. is the leading manufacturer of components for household appliances, the automotive industry and consumer goods in northern Spain. The company has an over 60-year tradition and is being run in the third generation as a family business. With its own development, design, production and tool making, Grávalos s.a. offers its customers a complete service, is for the most part independent of subcontractors and, with 100 employees, is of the right size in order to be able to react quickly and flexibly to product changes.
www.gravalos-sa.com Contact
Joaquín Grávalos del Río, Management Assistant
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Agie brand ED machining has been in use since back in 1972 Family business as a strong point in international competition El Burgo de Ebro lies 17 km from Zaragoza and is the base of Grávalos s.a. The company was founded in 1946 and is today being run in the third generation as a family enterprise. Grávalos s.a. has 100 employees on its payroll and supplies components for die automotive, household appliances, consumer goods and connector industries. The company offers a complete service for this, going beyond merely manufacturing customers’ articles:
- Designing and developing according to the customer’s article drawing or sample. - Optimising tools in accordance with economic and manufacturing technique aspects. - Automating the assembly lines with own construction of jigs and fixtures. - Delivery on schedule by synchronising all the manufacturing sequences. In addition, Grávalos s.a. endeavours in all phases of manufacture, whenever possible, to manufacture and produce everything
itself in order thus to be independent of subcontractors. This gives the company the flexibility to be able to react quickly to product changes, new orders and fluctuations in order quantities. One example are Scart connectors which Grávalos s.a. produces using a dual punching tool for the electrical contacts and a dual injection moulding tool for the casing. For both tools, the production share of ED machining is over 80% - the key technology for high precision on the tool and thus also on the finished Scart connector.
Grávalos s.a. carries out all the production stages from the design in accordance with the customer’s drawing to the dispatch of the Scart plugs: Tool construction, manufacture of the injection moulding and punching tool, punching of the electrical contacts, injection moulding of the plastic casing, final assembly, testing and checking and dispatching the Scart connectors according to schedule. Already at the CAD design stage at Grávalos s.a. Scart connectors are optimised in accordance with production technique aspects, with customers’ specifications being strictly observed.
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Grávalos, s.a.
ED machining for exactly fitting punches and dies The abbreviation SCART stands for the French «Syndicat des Constructeurs d'Appareils Radiorécepteurs et Téléviseurs», meaning translated «Association of Radio and Television Receiver Manufacturers». These plugs and sockets are European standard today for the plug connections of audio and video appliances. Thus the Scart sockets did not have to be newly designed when Grávalos s.a. received the order to produce them, as the dimensions and pin assignments are specified. However, with minor design modifications, Grávalos s.a. was able to optimise the production technique for the tools and the punching tool’s precision-giving stations were of modular production. Punches and dies made of hard metal were ED machined with one main cut and four trim cuts. Three Agievision control functions were classified by Grávalos s.a. as being especially useful in this connection: - «Agiesetup 2D» which allowed rapid setting up, without precise alignment of the workpiece. - «Variocut» which mastered stepped parts or parts with openings without problems by adjusting the cutting power. - «Teccut» which gave the possibility of optimising cutting technologies with own experimental values, such as, for example, reducing the wire advance and the flushing pressure. As planned by Grávalos s.a., a surface roughness of Ra 0.3 µm and a contour tolerance of ± 2.5 µm were achieved on the active parts. The clearance between the punches and dies was optimal for punching the electrical contacts for the Scart connectors burr-free from the Ni-Sn-coated brass strips.
ED die sinking for high reproduction accuracy The casing for the Scart connector made of polycarbonate described in this article was manufactured using a dual injection moulding tool. Here, too, Grávalos s.a. employed EDM: High-precision and complex inserts were manufactured by the Agiecut Challenge ED wire-cutting machine and cavities by the Agietron Hyperspark ED die-sinking machine. In order to achieve high reproduction accuracy, Grávalos s.a. made use of the «Agie Equimode» function which formed the sharp inside edges and complex forms of the cavities perfectly and repeatably accurately by means of three dimensional planetary movements. Thus both ED die sinking and wire cutting, with their high precision, laid the foundations for a problem-free final assembly of the Scart connector.
The three tool inserts manufactured
On the second Agiecut Challenge,
with ED wire cutting and die sinking in-
Joaquin Grávalos del Rio is aligning the
dicate new projects at Grávalos s.a.
next ED wire-cutting job using System 3R
which will be coming into use in the
clamping systems. After clamping the
near future.
workpiece, Joaquin Grávalos del Rio will use Agiesetup 2D to determine the posi-
The upper and lower half of the dual
tion of the workpiece. This Agievision
punch for manufacturing the Scart con-
control function determines a possible
nector’s electrical contacts. All the ac-
offset in the level which is then taken
tive parts, such as punches and dies,
into account by the control system dur-
were ED wire cut with a surface quality
ing machining.
of Ra 0.3 µm. The standardised Scart connectors allow modular construction
Joaquin Grávalos del Rio, Management
so that replacements can carried out
Assistant, checks and optimises the tech-
quickly in the case of a tool breakage
nology parameters of a machining job in
or changes.
progress on the Agiecut Challenge 3.
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The tool data Dual punch Finished part name
Scart connector contacts
Dual injection mould Scart connector casing
Finished part material NiSn coated brass
Polycarbonate
Tool material
Tool steel
Hard metal for inserts Tool steel
Tool weight
100 kg
200 kg
Tool service life
over 100 million strokes
over 30 million shots
Wire type
CCA 0,25 mm wire
Number of cuts
1 main cut 4 trim cuts
Electrode material
Copper
Electrode manufacture Production time
Milling, ED wire cutting 90% ED wire cutting
60% ED wire cutting
10% ED die sinking
40% ED die sinking
Surface roughness
Ra 0,3 µm
Ra 0,3 µm
Contour tolerance
± 2,5 µm
“
We have always linked ED machining with the name Agie. The first generation of our family company already used these machines. And today, too, we know that, thanks to the Agie machines’ quality, we can guarantee the tightest tolerances and finest surfaces.
We would like to thank Grávalos s.a., in particular their Management Assistant Joaquin Grávalos del Rio, for the kind support and helpful cooperation with this report. Responsible Sales Engineer: Oscar Nicolau,
Joaquin Grávalos del Rio, Management Assistant at Grávalos s.a.
”
+GF+ AgieCharmilles SA
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Swisslan S.L. Country
Spain
Production
Jobbing ED machining for - Devices for extrusion tools - Mechanical components - Automobile components - Inserts for blanking and injection moulding tools
Target markets
Spain, Switzerland and Italy
Employees
4
Founded
2005
EDM
1 Agiecut Classic V 2 1 Agiedrill
Programming
P-Cam
a jobbing EDM business with two further em-
Clamping
Own solutions
ployees on its payroll in addition to the two
Measuring, testing
Tesa Microhite
Swisslan S.L. was founded in 2005 by Angel Ibarluzea and Antton Osoro. The company, based one hour’s drive by car from Bilbao, is
company owners. The young company sup-
Swisslan S.L.
plies mainly components for tool making and
Morkaiko n° 1-B° Urasandi
for mechanical applications to its customers
20870 Elgoibar (Gipuzkoa) Spain
in Spain, Italy and Switzerland.
Tel +34 943 748 866 Fax +34 943 743 669
[email protected] [email protected] Contact
Angel Ibarluzea, Company Owner Antton Osoro, Company Owner
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Classical applications of jobbing ED machining Innovative use of ED wire cutting as the basis for success If you drive along the E70 motorway eastwards from Bilbao for an hour, you reach the deeply carved valley of the Deba, a region with a long tool-making tradition. So it was not just by chance that in 2005 two young craftsmen, Angel Ibarluzea and Antton Osoro, set up their own company in the small town of Elgoibar. Customers’ orders were quickly generated and the prospering company invested in an ED wire-cutting machine of the latest generation: an Agiecut Classic V2. In addition to traditional machining jobs, Swisslan S.L. was now able to carry our jobbing EDM orders, too. Today, the number of employees has risen to four who carry out orders from Spain, Italy and Switzerland. The scope of supply concentrates mainly on the production of mechanical components, devices for extruded profiles, components for cars, as
well as inserts for blanking and extrusion moulding tools. Apart from reliable and punctual production, the strong point of Swisslan S.L. is to be able to offer its customers innovative solutions with ED wire cutting and complementary machining jobs. Swisslan S.L. often receives just sketches, descriptions or patterns for these from customers which then serve as the starting point for new solutions for machining. As already mentioned, the region has a long tradition of tool-making which is being continued by Swisslan S.L. with the innovative use of ED wire cutting.
Swisslan S.L. receives drawings of fixings for extrusion profiles from customers. These serve initially as the basis for the decision on which machining process will be employed for which workpiece parts. A collet chuck for finished extrusion profiles made of aluminium. The slits and inside contours were ED wire cut on an Agiecut Classic V2. Starting out from extruded profiles, the two ED wire cut workpieces serve as the fixing in the further production process for the automobile construction components.
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Swisslan S.L.
ED wire cutting in time with the incoming orders Swisslan S.L. is a typical jobbing EDM business in which the dayto-day business determines the work scheduling. Constant deadline pressure requires high flexibility, both on the staff and the machine side. Production sequences must be geared exactly to the machine and operator capacity. That is why Swisslan S.L. decided on an Agiecut Classic V2, as this ED wire cutting machine meets these requirements best: - Rapid data input - Great selection of cutting technologies - Rapid set-up - Rapid wire change - Lowerable tank for machining in the bath - Rapid insertion of express jobs - Reliable process with all geometries. In jobbing EDM, every machining step must be right. This maxim begins at Swisslan S.L. with the data input for the ED wire cutting of a workpiece. Angel Ibarluzea needs just a few workpiece details for this: Height, form, material, surface quality and accuracy. «Teccut» then generates the best possible technology and in addition makes alternative proposals
for the quality targets. So Angel Ibarluzea can choose whether the machining is to be carried out quickly, with the highest precision or both. In the case of the devices for the extruded sections, several of the generator’s functions then take effect: «AWO» Advanced Wire Offset – compensates for the wire wear and flushing. «Wire Bending Control» determines and corrects wire deviations resulting during the process. «Variocut» automatically adjusts the output in the case of stepped workpieces. Functions which are not, it is true, visible, but which do show on the workpiece and in the time required for a job.
The autonomy for unsupervised operation On account of the frequent clamping and unclamping operations, setting up and individual data inputs involved, jobbing EDM orders presuppose the presence of an operator in most cases. And yet there are orders where high machine autonomy is also decisive. Swisslan S.L. had to cut six extruded profiles with 1 main cut and 3 trim cuts from a 100 mm high aluminium block. Here «Agiejet» for reliable wire threading, the standard 25-kg wire spools as well as the long service lives of the filters proved their worth - especially in the case of aluminium machining jobs. For Swisslan S.L., Agiecut Classic V2 is thus the classic «all-rounder» of ED wire cutting.
«Teccut» makes technology proposals from a few inputs. Thanks to the state-of-the-art Vertex technology, Angel Ibarluzea, joint owner of Swisslan S.L., can then select and activate the best possible machining technology. Various devices for machining extruded profiles which are produced by Swisslan S.L. using ED wire cutting and as a complement to that milling all out. All three workpieces are made of hardened steel and have a surface roughness of Ra 0.4 µm and a contour tolerance of ± 5 µm. Antton Osoro, joint owner of Swisslan S.L., checks the progress of the cutting of the starting holes which are needed for ED wire-cutting jobs on an Agiedrill. Small electrode tubes of from 0.3 mm to 3 mm can be used for a depth of up to 200 mm.
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The workpiece date Workplace name
Fixings for extruded profiles
Finished part name
Components for automobiles
Workpiece material
58 HRC hardened steel
Finished part material
Aluminium
Workplace weight
approx. 2 to 3 kg
Duration of workpiece use
over several years daily round the clock
Wire types used
CCA 0.25 mm diameter CCA 0.10 mm diameter
Number of cuts
1 main cut, 2 - 3 trim cuts
Surface roughness
Ra 0,4 µm
Contour tolerance
± 5 µm
We would like to thank Swisslan S.L., in particular the two company owners, Angel Ibarlizea and Antton Osoro, for their kind support and helpful cooperation on this report. Responsible Sales Engineer: Carlos Grijalba, +GF+ AgieCharmilles SA
The drawing and workpieces show the principle and variety of forms of the devices for extruded profiles.
“
Our success is based on innovative solutions which we offer our customers. We have the ideal ED wire-cutting machine for this with the Agiecut Classic V 2 which has the appropriate technology or function for nearly every machining requirement. Angel Ibarluzea, company owner of Swisslan S.L.
”
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Fabbri snc Country
Italy
Production
- Sporting shotguns - Hunting knives for collectors
Target market
International
Employees
13
Founded
1965
ED machining
1 Agiecut Classic V 2 1 Agietron Spirit 2
Programming
- Pro/Engineer - ISO
Clamping
Own solutions
Fabbri snc is a company that has perfected the gunsmith’s traditional craft with stateof-the-art production methods. Founded by Ivo Fabbri in 1965, the company based near Brescia today has 13 employees on its payroll. The founder’s son Tullio Fabbri today
Fabbri snc Don Filippo Bassi 6 25075 Nave (BS) Italy
manages a company that is a world market leader for highest precision sporting shotguns. The list of its international customers
Tel +39 030 271 53 00 Fax +39 030 271 53 01
[email protected] www.fabbri.it
also reads then like a «Who’s who» of prominent figures: His Majesty Juan Carlos, King of Spain or film producer Steven Spielberg – to name but two.
Ivo and Tullio Fabbri
Contact
Tullio Fabbri, Managing Director Ivo Fabbri, Company Owner
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Fabbri snc
With Agie no «shot» misses during ED machining The worldwide first address for sporting shotguns When Ivo Fabbri founded Fabbri snc more than forty years ago, he did not yet know what success he would have with his handmade sporting shotguns. An untiring urge for perfection, coupled with the innovative use of the latest technologies, quickly made sporting shotguns «made by Fabbri» famous beyond Italy’s borders. A success which is based on the company’s philosophy: - Each individual part is made in-house. - Only the best materials are used. - Everything is checked inhouse. - Quality as a symbiosis of artisan ability and the use of the most modern means of production. Thus all 13 of the company's employees are qualified specialists in their field. The skill of Fabbri snc now consists in making each individual’s ability available for the common goal of manufacturing «today’s bestlooking and most reliable shotgun in the world». A claim that is confirmed by prominent customers from all over the world and which Tullio Fabbri gladly demonstrates with a tour through the company. In air-conditioned, clinically clean rooms, the details are captivating: Company-designed and laid-out workplaces, underfloor cabling for the machine tools, orthopaedic floor coverings or state-of-the-art house automation. So the two ED machines from Agie do not only meet the Fabbri snc’s perfectionism with their high precision, but also with their striking design.
«Partner to the Best» – more than a slogan If you ask Tullio Fabbri what were the main arguments for buying Agie ED machines, you are quickly given the answer: «Partner to the Best». And further: «Not because it is the Agie slogan, but because the service, presence and assistance convinced me! To feel that you are being taken seriously as a partner, just as we give our customers the feeling that they are real partners to Fabbri». Of course, it was not only non-material values that convinced Tullio Fabbri, but also genuine facts. The three-dimensional solid models of the shotgun lock show the complexity of the geometries which have to be machined out of the whole.
Tullio Fabbri himself designs the complex form of the shotgun lock with Pro/Engineer. Many years of experience are necessary in order to give mechanically highly stressed parts in later use the right radius, to dimension web widths optimally or design recesses, checks and openings functionally.
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ED wire cutting with efficient functions When manufacturing, such as in the case of a shotgun lock, every machining step must strike home. Because with each milling, turning, ED machining or grinding step, one error can make the workpiece just fit to be thrown away. That is why the «Variocut» function is so important for Fabbri snc when ED wire cutting, because in the course of manufacturing the shotgun lock, cuts through offsets or apertures have to be made. The illustration with the solid model of the shotgun lock prepared in CAD shows this clearly with the cutting surface and the various positions of the cutting wire duly marked.
Tullio Fabbri defines the cutting technologies for the next machining job on the «Agievision» control using the «Teccut» function. By activating the «Variocut» function, the cutting cross-section is then continuously recorded by means of which the Agiecut Classic V 2 automatically adjusts the power in the case of stepped parts or openings in the workpiece.
For this, «Variocut» continuously records the cutting cross section and automatically adjusts the power to the changing conditions. The main cut and the four trim cuts can thus be carried out reliably in the course of the various cutting operations on the shotgun lock. Both wire-threading into starting drill holes with «Agiejet» and cutting technologies prepared with «Teccut» for the stainless steel-titanium alloy of the workpieces are carried out with great reliability.
The first machining step on the rectangular blank made of stainless steel-titanium alloy is the ED wire cutting of the contour which is coloured red in the solid model of the gunlock.
Prior to machining the rectangular piece of Titanium-stainless steel alloy material is heat treated, stress released, avoiding microcracks during machining. The first contours is cut on the Classic V 2 showing allready the rough form of the gunlock.
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Fabbri snc
ED die sinking for precision in the third dimension With the increasing progress of the production of the shotgun lock, each further machining step must be carried out with the utmost reliability and precision. Fabbri snc relies on Agietron Spirit 2 for ED die-sinking operations. Detail electrodes made of copper are used for the mainly small cavities on the shotgun lock. They have the advantage compared with complex form electrodes made of graphite that, after wear, they can be simply reworked by milling. In this way, Fabbri snc saves itself expensive electrode production which would
additionally tie up personnel and machine capacity. Here too, the employees’ mastery becomes apparent which runs like a central theme through all the production stations at Fabbri snc.
We would like to thank Fabbri snc, in particular their Managing Director Tullio Fabbri, for their kind support and helpful cooperation with this report. Responsible Sales Manager: Franco Corti, +GF+ AgieCharmilles
All 150 individual parts of a sporting shotgun are made by Fabbri snc themselves. This begins with the selection of finest materials from all over the world, continues with constant material tests on in-house testing devices, goes on further through the production of even the smallest screws, and ends, after over 1500 mechanical and manual production steps, with the testing and adjusting of each shotgun in the company's own underground shooting range. Each of the 13 employees at Fabbri snc is a master of his
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“
The Agiecut Classic V 2 with its «Variocut» function is the ideal ED wire-cutting machine for us. With it, we carry out the first machining step which is decisive for the precision for all the further machining operations on the shotgun lock.
The workpiece data
Tullio Fabbri, Managing Director of Fabbri snc
” craft, when machining precious walnut or age-old ivory of the mammoth, when engraving unique works of art into the shotgun locks or when ED machining precious alloys. Thus Fabbri snc manufactures only about 30 sporting shotguns per year and customers have to be patient for at least four years after placing their order before they can hold their own shotgun in their hands.
Name
Lock for sporting shotguns
Workplace material
Stainless steel-titanium alloy with vacuum-heat treatment
Annual production
approx. 30 - 35 shotguns
ED wire cutting
Various machining operations are carried out with Berocut 0.25 mm brass wire with 1 main cut and 4 trim cuts in each case, and a surface quality of Ra 0.3 µm is achieved
ED die sinking
Various cavities are made using self-milled detail electrodes made of copper which can be used again by regenerating
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Mi-Me Minuterie Metalliche Meles S.p.A.
Mi-Me Minuterie Metalliche Meles S.p.A. is a company with a 56-year tradition. Not far from Bergamo, Mi-Me produces and assembles pre-
Production
Precision parts punched, stamped and assembled with own development, design and manufacture of automatic assembly, punching, stamping and progressive dies - Electromechanical and electrical industry - Automotive industry - Telecommunications industry - Computer applications
Main markets
Europe, Asia, USA, Brazil
Employees
105
Founded
1950
EDM
1 Agiecut Progress 2 1 Agiecut Evolution 2 SF+F WorkPal loading system from System 3R 1 Agiecut Evolution 2 1 Agietron Spirit 2 1 Agietron Mondo Star 20
Programming
- P-Cam for ED wire cutting - UG 3 D - CAM
Clamping
Mecatool from System 3R
Measuring, testing
DEA from Brown & Sharp
Certifications
ISO TS 16949: 2002 ISO 9001: 2000 ISO 14001: 2004
cision blanking and bending parts with its own tools on state-of-the-art high-speed presses
Head office, administration and dispatch:
from Bruderer and automatic punching and
Mi-Me Minuterie Metalliche Meles S.p.A.
bending machines from Bihler. Mi-Me supplies
Production:
Via Leonardo da Vinci, 19
Via Del Gambetto, 10/12/14
24030 Presezzo (BG)
24040 Bonate Sopra (BG)
renowned customers worldwide in the electri-
Italy
Italy
cal, automotive and telecommunications indus-
Tel +39 (0)35 61 22 98
+39 (0)35 90 02 02 01
Fax +39 (0)35 61 80 22
+39 (0)35 90 00 14
tries, as well as the computer applications
[email protected]
branch, offering a complete service from the
www.mi-me.it
development to the finished product.
Contact
Raffaele Meles, Company Owner Giovanni Pirola, Workshop Manager
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ED wire cutting – the heart of tool manufacture Constant progress for over fifty years Mi-Me Minuterie Metalliche Meles S.p.A. was founded in 1950 and today has 105 employees on its payroll. The company offers a complete service all around punching and bending. At the head office in Presezzo, tools are developed, designed and manufactured in accordance with customers' drawings. Tools are designed and optimised with CADCAM systems of the latest generation. For high precision, in addition to traditional machining centres, the tool making department has ED machines of the Agie brand at its disposal which, in the course of the years, have developed more and more into a key technology in tool making. Since 2001, the production of high precision punched and bent parts has been carried out in the neighbouring town of Bonate Sopra. For this, Mi-Me has a stateof-the-art range of machines installed in an area of 10,000 m2, with high-speed presses from Bruderer and automatic punching and bending machines from Bihler, each of which is coupled to production management by a computer system. Mi-Me can
thus organise its working cycles optimally and supply «just in time» to customers. This philosophy of «everything at the right time» can be traced back to tool making at Mi-Me. Tools are modular in construction and, thanks to ED wire cutting, the punches and also dies are manufactured to an exact fit, so that in the case of breakage or changes it is possible to react quickly. A typical example is a two-way progressive tool for which 40% of the total production time is taken up by ED machining, underlining the high standing of this machining technology.
The starting point for the produc-
In accordance with the thickness of
tion of electrical contacts was the
the material to be punched, the tool
customer’s drawing of the article.
was designed with a contour toler-
In addition came the requirements,
ance of ± 3 µm. Ra 0.3 µm on the
such as material, material thick-
punches and Ra 0.05 µm on the dies
ness and quantity. Mi-Me then de-
ensured optimal die clearance
signed and manufactured a two-
when punching.
way progressive tool with 25 stations for punching, stamping and bending.
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Mi-Me Minuterie Metalliche Meles S.p.A.
ED wire cutting for high precision punches and dies When the tool has been designed and optimised with CAD/CAM systems, the individual punches and dies are derived from this and the cutting contours for them are prepared with PCam. The programs are transferred to the Agiecut Progress 2. With a few details about the workpiece and wire, «Teccut» makes proposals in accordance with profitability and precision. The cutting technology then selected is allotted to the workpiece. In the case of machining jobs with drop-out parts, «Usersequence» can be selected. This function allows cutting sequences to be decided in accordance with time criteria so that e.g. all the cuts are made at night and the separating cut for removing the dropout part is scheduled for the time of the operator's presence. With the «Graficheck» function, the operator obtains certainty for the whole machining job as he can present the workpiece three-dimensionally and simulate the cutting sequences. The «Agiesetup 3D» function, with which the workpiece position is plotted three-dimensionally, and any possible offset is taken into account by the control system. Agiecut Progress has eCut cutting technologies at its disposal which achieve surfaces of Ra 0.8 µm with one single precision cut. This reduces the trim cuts and the required roughness of Ra 0.3 µm on punches and Ra 0.5 µm on dies can be achieved more quickly. All the active parts of the two-way progressive die are PVD/TiCN coated in order to achieve a longer service life and to prevent any breaking off as far as possible. However, if necessary, the high fitting and repeating accuracy achieved through ED wire cutting, allows punches and dies to replaced quickly and without any finishing work.
ED die sinking for complementary machining jobs If bending or stamping jobs have to be carried out on the finished part, ED die sinking is used at Mi-Me. For this, the electrode forms are derived from the CAD/CAM program for the tool design, the copper electrodes milled and the shaping inserts ED machined. The Agietron Spirit 2 is the ideal ED die-sinking machine for this, in order to achieve these three-dimensional cavities quickly and simply. The operator is guided through the program by self-explanatory symbols, automatic measuring cycles shorten the set-up time and an electrode magazine makes machining jobs possible at night, too. Arguments which have a name for Mi-Me in the case of ED wire cutting and die sinking: Agie.
Setup of a workpiece in an Agiecut
Part view of the EDM department at
Evolution 2. «Agiejogger» allows all
Mi-Me. Three Agiecut and two Agietron
important control functions required.
machines ensure high precision on the workpiece. The Agietron Spirit 2 is the ideal addition in blanking tool making. MiMe manufactures mould inserts for bending and forming stations with this, but drill holes for mountings are also made with this ED die-sinking machine. All the active parts, as well as the tool itself, too, are measured on the DEA measuring machine from Brown & Sharp at Mi-Me for the final check. With a contour tolerance of ± 3 µm and surface qualities of Ra 0.3 µm on punches as well as Ra 0.5 µm on dies, the two-way progressive die is designed both for a long service life and for high precision on the finished parts.
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The tool data Tool name
Two-way progressive die
Finished part name
Electrical contacts
Active part material
PVD/TiNC-coated high-speed tool steel HSS
Tool material
Tool steel
Finished part material
Brass
Tool service life
240 million parts, 8 million until resharpening
Tool weight
50 kg
Electrode material
Copper
EDM wire type
CCA 0.25 mm diameter
Number of cuts
1 main cut, 4 trim cuts
Surface roughness
Ra 0.3 µm punches, Ra 0.5 µm dies
Contour tolerance
± 3 µm
EDM time
40% of the total production time, and of that 10% for ED die sinking
The tool data We would like to thank Mi-Me Minuterie Metalliche Meles S.p.A., in particular the company owner Raffaele Meles and workshop manager Giovanni Pirola, for their kind support and helpful cooperation on this report. Responsible sales manager: Franco Corti, +GF+ AgieCharmilles
Tool name
One-way progressive die
Finished part name
Element for thermal regulation
Active part material
PVD/TiNC coated high-speed tool steel HSS
Tool material
Tool steel
Finished part material
Brass/Silver
Tool service life
120 million parts, 4 million until resharpening
Tool weight
400 kg
Electrode material
Copper
EDM wire type
CCA 0.25 mm diameter
Number of cuts
1 main cut, 4 trim cuts
Surface roughness
Ra 0.3 µm punches, Ra 0.5 µm dies
Contour tolerance
± 3 µm
EDM time
40% of the total production time, and of that 10% for ED die sinking
“
With the eCut cutting technologies of our Agiecut Progress 2, we can dispense with many a trim cut as high precision and outstanding surfaces are already achieved with the main cut. Raffaele Meles, Chairman of Mi-Me Minuterie Metalliche Meles S.p.A.
”
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Sønderborg Værktøjsfabrik A/S Sønderborg Værktøjsfabrik
Country
Denmark
Production
Development, design and production of multiple injection moulds, mainly for medical technology and related branches
A/S is a business partner in Target market
Europe
great demand for compa-
Employees
28
nies in medical technology
Founded
1973
EDM
2 Agietron Hyperspark Exact 2 with Multi-Robot from Erowa for 240 electrode and 30 pallet places with the JMS chip identification system from Erowa 1 Agietron Innovation 3 with ERS robot system from Erowa for 215 electrode and 15 pallet places with the JMS chip identification system from Erowa 1 Agiecut Challenge 2 with Easychange from Erowa for 20 pallet places with the JMS chip identification system from Erowa
Programming
- Unigraphics for CAD - Peps for ED wire cutting
Clamping
- Erowa - Own solutions
Measuring, testing
- Tactile 3D measuring machine from Johannsen - Optical measuring machine from Demeet - Presetting position from Erowa for all automated machine tools
when it is a question of the development, design and production of multiple injection moulds. The Danish company's philosophy is precision at all stages of production. This is achieved with automated manufacturing cells which nearly exclude human sources of error.
Sønderborg Værktøjsfabrik A/S Søndervang 9 DK-6400 Sønderborg Denmark Tel +45 74 42 82 42 Fax +45 74 42 22 11
[email protected] www.sv.dk Contact
Henrik Schwartz, Managing Director Kennet Filsø Madsen, Sales Manager Thomas B. Iversen, Sales Manager Peter Moisen, Head of EDM
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Automated EDM for 100-percent fitting accuracy
Cables are laid to each individual mould in the 24-fold injection mould. Sensors then check the pressure in the cavity for each injection moulding procedure.
Precision in design, production, control, supply Sønderborg Værktøjsfabrik A/S was founded in 1973, today has 28 employees on its payroll and is based in Jutland, the southern part of Denmark. The company is specialised in multiple injection moulds for the production by the million of parts for medical technology. Anyone successfully making moulds in the high-wage country, Denmark, must either reduce manual procedures as far as possible to a minimum or must be able to supply exceptional precision. Sønderborg Værktøjsfabrik A/S combines both perfectly and has thus acquired an outstanding reputation for itself in the field of medical technology. The key to success lies in automated production with ED machines from Agie. The consistency of the data and the clamping are further factors so that no µm precision is lost. As Henrik Schwartz, Managing Director of Sønderborg Værktøjsfabrik A/S said: «Precision is not just a matter of microns for us, but our company's philosophy is behind it, as is shown from the design until matching».
Sønderborg Værktøjsfabrik A/S receives CAD programs from the customer for the medical technology parts. These serve as the basis for the development and design of the injection mould.
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Sønderborg Værktøjsfabrik A/S
The electrodes required for the ED die sinking are designed in their turn from this with CAD. With these data, the milling cutting program for the production of copper electrodes are prepared. In most cases, the same mould is linked to one electrode four times. This multiple electrode is then turned over the C-axis in the EDM program so that the same electrode can be used for roughing and finishing. Peter Moisen clamps mould inserts to a pallet at the presetting position. Each individual mould is plotted. The measurement data are stored in the identification chip which is then read by the EDM machine and transferred to the program.
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Constancy of the data and the clamping Every manual intervention, whether through data input, reclamping or finishing, involves the danger of errors. This was Sønderborg Værktøjsfabrik A/S's basic consideration when they reorganised the production sequence for injection moulds. In simplified form, this looks as follows for a 24-fold injection mould: 1. Receipt of the CAD data for the customer's part. 2. From this 3D design of the tool using Unigraphics. 3. From this generation of the electrode moulds and optimising into multiple electrodes. 4. Surface grinding of the various tool plates. Making the standards available. Milling the closing and function surfaces.
5. Clamping the copper blanks, rough milling, cooling down, fine milling, plotting the electrodes at the presetting place and loading the measurement data into the identification chip. 6. Clamping the workpieces to pallets, plotting at the presetting position, and input of the measurement data into the ID chip. 7. Preparation of the ED diesinking programs externally with Agievision PC and the ED wire-cutting programs with Peps. 8. Loading the robots on the EDM machines. 9. Recalling the machining programs from the programming station to the EDM machines.
10. Check of the movement sequences on the ED diesinking machines for a machining with all electrodes as well as carrying out the measurement cycles. Once they have been clamped in place, workpieces and electrodes are thus no longer subject to manual intervention. The same applies for data. Once they have been input or recorded, they are just retrieved or transferred still.
The tool assembly is still 100-percent manual. However, all the more importance is attached to care and toolmaker know-how. A workpiece pallet is brought into one of the two Agietron Hyperspark Exact 2 by the loading arm of the Multi-Robot from Erowa.
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Sønderborg Værktøjsfabrik A/S
EDM becomes an automatic machining sequence If these 10 points, which do not make any claim to completeness, have been carried out, the actual EDM can be started. The EDM results are decisive for Sønderborg Værktøjsfabrik A/S: - Every mould insert must be 100% identical in shape and dimension. - 100% repeatability. - No finishing. - 100% fitting accuracy. Great demands on ED machining, because in part up to 8 tools have to be manufactured for the same part. Agie is thus the first choice in EDM.
The mould cores clamped on pallets are ED machined ready, and then plotted with the tactile measuring machine from Johannsen and compared with the specified dimensions. Electrodes in accordance with the design are represented three-dimensionally with CAD from Unigraphs. The milling machine for producing the copper electrodes is also loaded and unloaded automatically.
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The tool data
“
Name
24-fold injection mould
Finished part material
POM plastic
Tool material
hardened steel
Tool weight
1300 kg
Tool working life
10 million injection moulding cycles
Electrode material
copper
Electrode production
95% high-speed milling,
Not only are our tools precise. Our delivery times, our machines, all our employees' jobs are also precise. Precision is thus the com-
5% ED wire cutting EDM time
35% of the total production time
Oberflächengüte
CCA 0.2 mm für Hauptschnitte
forward-looking planning in our
CCX 0.1 mm für Nachschhnitte Surface quality
VDI 21
Position accuracy
± 5 µm over the whole tool
pany's philosophy and stands for company. Our ED die-sinking manufacturing cell, consisting of two
Look into the work area of an Agietron Hyperspark Exact 2 with electrode and workpiece
We would like to thank Sønderborg Værktøjsfabrik A/S, in particular their Managing Director Henrik Schwartz and also Poul Erik Skælbæk, Product Manager of A-V-N Maskin AS, for their kind support and helpful cooperation on this report.
clamped in place.
Responsible The 24-fold injection mould with various inside and outside mould cores, as well as ejectors.
Sales Manager: Flavio Guadagnini, Agiesales
Agietron Hyperspark Exact 2 with robot in the middle, is the best example for also being a step ahead of the others in future, too.
”
Henrik Schwartz, Managing Director of Sønderborg Værktøjsfabrik A/S
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Hamilton Lichfield Ltd.
Hamilton Lichfield Ltd., based to the
Country
United Kingdom
Production
-
PCD and PCBN ISO indexable inserts PCD slot drills and end mills PCD wear components PCD twist drills and reamers natural and synthetic diamond dressing tools
Fields of use
-
Aerospace Automotive industry Oil industry Technical materials (ceramics, alloys, metal composite materials, carbon fibre reinforced plastics)
Target market
85% United Kingdom, 15% Europe
Employees
23
Founded
1994
EDM
1 Agiecut Progress 2 with PCD module
Programming
Peps from Camtek
Clamping
Mecatool from System 3R
Measuring, testing
- CMM from Brown & Sharp - Optical tool presetter from Starrett precision optical - Profile 50 optical measuring system from Brown&Sharp
north of Birmingham in the English Midlands, was founded in 1994 and has over 20 employees on its payroll. The company has become specialised in two main categories of tools: Tipped with natural diamonds or polycrystalline diamonds. These lathe chisels, milling cutters and rotary tools are employed for machining the most varied materials.
Hamilton Lichfield Ltd. Kimberley Way, Units 16 - 18 GB-Brereton, Rugeley WS 15 1RE Tel +44 (0) 1889 57 45 75 Fax +44 (0) 1889 57 45 72
[email protected] www.hamlich.co.uk Contact
Kelvin Bushnell, Director Donald Culver, Director Jim Micallef, Sales Manager Kevin Baines, Workshop Manager
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Small in dimension – big job for ED wire cutting Individual customised solutions for PKD and diamond tools «Our daily challenge is to supply the customer with the optimum tool for his individual requirements on schedule with the maximum precision», is the response by Kevin Baines, Workshop Manager at Hamilton Lichfield Ltd. to the question about his company's guiding principle. Indeed, from the receipt of an order until the delivery of a tailormade tool, Hamilton Lichfield Ltd. needs just one week on average. Many years of experience and a profound knowledge of the latest materials enable the company to offer its customers a complete service for diamond and PCD tipped tools.
The PCD disks are supplied in two thicknesses so that Hamilton Lichfield Ltd. can quickly generate constantly reThe two symmetrical, tapering tip seats on
curring cutting technologies with the
the shank were ED wire cut with one main
«Workmodel» on the Agievision control.
cut using an Agiecut Progress 2. The grid model of a shaft head shows the three-dimensional geometry of the two tip seats.
Hamilton Lichfield's clientele is drawn from the most varied fields of application: - Automotive - Aerospace - Green ceramics - Carbon fibre reinforced plastics - MMC (Metal Composite Materials) - Non-ferrous metals - Woodworking - Hard turning - V-blocks - Wear parts. For Hamilton Lichfield Ltd. ED wire cutting is an important link in the production chain here, because this process takes on the precision-giving machining steps. The varied uses of the Agiecut Progress 2 ED wire-cutting machine can best be shown in the entire manufacturing sequence of a PCD tipped milling cutter.
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Hamilton Lichfield Ltd.
Versatilely employable ED wire cutting In general, the production of PCD-tipped milling cutters involves a large number of machining steps because two completely different materials are being machined which have to be matched highly precisely to one another. At Hamilton Lichfield Ltd. these are the main stages: 1. Receipt of the order as a tool drawing, tool description with dimensioning or description of the use of the tool. 2. From this the tool drawing is prepared complete with the geometries of the tip seats on the shank as well as of the PCD cutting tips. 3. The cutting contours of the PCD inserts are created with «Easycut».
The PCD cutting tips are attached to the shank's two ED wire-cut cassettes by means of induction welding.
The cutting contours for the PCD inserts are prepared with the Peps and positioned in such a manner that the space on the PCD-coated disk is optimally used during ED wire cutting.
The cutting contours prepared with Peps can
The clamped PCD disks are plotted with
be transferred to the Agiecut Progress 2,
«Agiesetup 3D» and the 0-point is deter-
complete with the cutting technologies, by
mined. The special PCD technology on
means of the Agie exclusive feature
Agiecut Progress 2 allows the cutting tips
«Scriptfile». All the operator still has to do
to be ED machined with one main cut.
is to allocate the measurement values determined with Agiesetup 3D to the reference points.
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4.
5. 6.
7.
8.
An optimum cutting technology is selected from «Teccut» or the technology is retrieved from «Workmodel», a module for repeatedly recurring jobs. The PCD disk is clamped on the Agiecut Progress 2. Agiesetup 3D carries out measurement cycles automatically with the EDM wire and the probe. In this way, the 0-point is determined exactly as the reference and the location of the PCD disk in the ED wire-cutting machine is fixed The contours are cut with a full cut using a Berocut 0.25 mm wire. The PCD cutting tips are taken out as drop-out parts and the PCD disk is unclamped.
9.
10.
11.
12.
13.
The milling cutter shank made of tungsten is then clamped horizontally. «Agiesetup 3D» then determines any possible twisting of Caxis so that the cutting of the shank to length will take place 100 percent in right angle. The milling cutter shaft is cut to exactly the required length with one main cut. In the meantime, the cutting contour for the tip seats on the shank is prepared with Peps. «Scriptfile» makes a direct transfer of the geometries, complete with the cutting technologies, to Agiecut Progress 2 possible. The shank is clamped vertically and also plotted with «Agiesetup 3D», with the probe in A, B and Z-axis direction and with the wire in
X and Y-axis direction. In accordance with the measurement data determined, the control system then organises the machining program around these values. 14. The symmetrical, tapering tip seats of the shank are ED wire cut. 15. The shank is unclamped and the PCD cutting tips are applied to the tip seats by means of induction welding. 16. The now complete milling cutter is clamped horizontally on to the Agiecut Progress 2 once again in such a way that the 2 PCD cutting tips are aligned horizontally. The measurement data on the milling cutter head are recorded with «Agiesetup 3D» so that the machining program can align again.
The slot milling cutter is checked once again for contour accuracy, symmetry and precision on an optical measuring system. PCD inserts are inductionwelded into the tip seats of the shaft.
17. The PCD cutting tips receive their final cutting contour by means of a taper cut by Agiecut Progress 2, with exactly the required angle. In this connection, 0.05 mm are left in place for the polishing. 18. As a final step, the PCD cutting tips are polished with a diamond lapping machine. The machining steps can, it is true, vary somewhat according to the order, however, they do show how rationally ED wire cutting can be employed for the production of PCD tipped milling cutters. The absolute highlight in this connection for Hamilton Lichfield Ltd. is the «Setup 3D» function which is employed for each set-up procedure. Multiplied over a year, a saving in time amounting to days results.
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Hamilton Lichfield Ltd.
The tool data Name
PCD tipped slot milling cutter
Tool material
Shank made of tungsten carbide Cutting tips made of PCD (polycrystalline diamonds)
Tool working life
100 times longer than conventional groove milling cutters
EDM time
5 minutes for cutting the shaft to length 20 minutes for the two symmetrical, tapering tip seats 5 minutes for PCD cutting tips
Number of cuts
1 main cut in each case
EDM wire type
Berocut 0.25 mm diameter
“ ”
The Agiecut Progress 2 is the most versatilely employable machine tool for our application requirement. The Agiesetup 3D function especially has strikingly reduced the set-up times.
We would like to thank Hamilton Lichfield Ltd., in particular their Managing Director, Kelvin Bushnell, and Workshop Manager, Kevin Baines, for their kind support and helpful collaboration with this report. Agie Specialist: Max Swinbourne, +GF+ AgieCharmilles Ltd.
Kevin Baines, Workshop Manager of Hamilton Lichfield Ltd.
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Stanz- und Formtechnik GmbH & Co. KG SFT X. Settele Stanz- und Formtechnik GmbH
Country
Germany
Production
Development, design and manufacture of punches and follow-on tools for the production of: - contacts - terminals - pins - fastening elements - welded parts - assembly parts
& Co. KG is a medium-sized company based in the Allgäu region in southern Germany which with its own tool-making focuses on
Target market
Europe
the production of precision, punched and
Employees
50
bent parts. The over thirty-year old company
Founded
1973
EDM
1 Agiecut Vertex 1 Agiecut Excellence 2F eCut 1 Agiecut Excellence 2 eCut 1 Agietron Spirit 2 1 Agie Präzidrill
Programming
- CAD ME10 - Peps from Camtek
Clamping
Mecatool from System 3R
Certification
DQS - DIN EN ISO 9001:2000
SFT X. Settele, Stanz- und Formtechnik GmbH & Co. KG Mühlweg 23 87642 Halblech Germany Tel +49 (0) 8368 841 Fax +49 (0) 8368 1045
[email protected] www.sft-halblech.de Contact
Roland Settele, Company Proprietor Horst Zuleger, Sales
has 50 employees on its payroll and supplies all sectors of industry, such as the electrical equipment, electronics, automobile, household appliances, furniture and other fields.
E EXPERIENCE 28
24.1.2007
8:11
Pagina 41
41 AGIE experience No 28 January 2007
Agie’s top model for top precision for tools The article drawing of the SIM card, for which contacts were to be produced, served SFT for the design of the tool. From the geometry and material of the contacts, as well as the quantity required, resulted a three-step follow-on tool with 13 stations for cutting, bending and stamping. The active parts of the three-step follow-on tool, such as punches and dies, were ED wire cut on the Agiecut Vertex with 1 main cut and 6 trim cuts. The punching strip and contacts respectively are made of a thin beryllium alloy which required tolerances of just 1 µm in the tool. The drawing shows the construction of the three-step follow-on tool as a side view.
Quality and performance grew with the company In spring 1973, Xaver Settele founded the SFT Stanz- und Formtechnik company. In step with the growing demand, the company has been constantly enlarged. Today SFT has 50 employees on its payroll, a production area of 2000 m2, in addition a 1000 m2 warehouse and a very modern machine outfit at its disposal, both in tool-making and in production. SFT's performance spectrum includes:
- Development of new punched parts - Design of economic punches and bending tools - Production of high precision tool-making parts - Assembly of complete tools - Mounting and testing the tools on automatic punching machines - Large batch production of precision, punched and bent parts in connection with other process cycles, such as thread tapping, welding, assembling, sorting and magazining
- Safeguarding all the machining processes by modern quality assurance systems. In addition to the traditional machining processes, milling and grinding, in accordance with the high precision requirements, SFT has been putting increasing emphasis on ED machining. Taking the example of a three-step follow-on tool, the important role played by top Agie brand products at SFT is explained: Repeatable high precision on the work piece guarantees smooth punching without downtimes.
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24.1.2007
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Pagina 42
42 AGIE experience No 28 January 2007
Stanz- und Formtechnik GmbH & Co. KG
ED wire-cut active parts are the best guarantee for precision When the automatic bending machines or high-speed presses chatter without any standstill at SFT, this is also proof for the company proprietor, Roland Settele, of the high standard of their own tool-making. For years, SFT has always invested in the latest machine tools in order to keep in step with rising precision requirements, or even to be one step ahead of them. The latest investment is the Agiecut Vertex ED wire-cutting machine, whose productive capacity is demonstrated taking the example of a three-step follow-on tool. Thus on this tool, all the active parts made of hard metal were ED wire cut or die sunk. SFT used the Agiecut Vertex for dies with the finest slits requiring inside radii down to 0.1 mm or punches with a tolerance of ± 1 µm. For this, first of all, start holes were made in the dies using Agie Präzidrill, the starting hole drill. The small electrode tubes used have a diameter of often just 0.15 mm. The starting holes are drilled without any problem, because the surface destruction in the case of hard metal lies below 20 µm. At the same time, all the shaping inserts, such as e.g. the bending stations, are manufactured on the Agietron Spirit 2 ED die-sinking machine. The cutting contours for the punches and dies prepared with Peps were transferred to the Agiecut Vertex. The operator selected the best possible technologies for his requirements from «Teccut» and allocated them to the individual machining jobs. In addition to roughness, workpiece height and material, another selection parameter was also the wire types used, Cobracut G with diameters from 0.2 mm through 0.15 mm down to 0.10 mm. Multiple clamping then also increased the efficiency of the ED machining.
Double spools make automatic wire change possible The «Agieduo» double spool system is felt by SFT to be extremely useful and time-saving. Thus, without any manual intervention, two different types of wire can be used for one machining job, such as e.g. all the main cuts of a multiple clamping with CCG 0.2 mm and all the trim cuts with CCG 0.10 mm. «Economic viability is elegantly combined with top precision here», say company owner Roland Settele. And in addition: «With Agiecut Vertex we are also equipped for future precision requirements».
The operator can select the best technology for his machining job in each case from the comprehensive Agiecut Vertex database. With the «Agieduo» double spool system, two different types of wire can be used in autonomous, automatic operation, e.g. for main and trim cuts. An Agie Präzidrill is prepared for drilling the starting holes. In the case of dies with the smallest slits and openings, drill hole are often required which make the use of electrode tubes of just 0.15 mm diameter necessary. The Agietron Spirit 2 is used at SFT for the ED die sinking of mould inserts in tools, such as e.g. bending stations in a follow-on tool. The tools from the company's own production have proved themselves in the automatic punching and bending machines from Bihler and the high-speed presses from Bruderer. The beryllium punching strip runs through 13 stations where it is cut, bent and punched.
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43 AGIE experience No 28 January 2007
The tool data Name
Three-step follow-on tool
Finished parts name
Contacts for SIM cards for mobiles
Finished part material
Beryllium alloy
Tool material
Tool steel, active parts hard metal
Tool weight
20 kg
EDM time
60% of the total manufacturing time
Wire types
CCG of 0.2 mm, 0.15 mm and 0.10 mm diameter
Surface quality
Ra 0.15 µm
Contour tolerance
± 1 µm
We would like to thank SFT X. Settele, Stanz- und Formtechnik GmbH & Co. KG, in particular the company proprietor Roland Settele, for their kind support and helpful cooperation on this report. Responsible sales engineer: Ronny Schroeder, Agie GmbH
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24.1.2007
8:12
Pagina 44
“
The trend in our business is towards ever more complicated precision, punched and bent parts requiring high-precision. Tolerances of ± 1 µm or inside radii of just 0.1 mm are nothing unusual. As a long-standing Agie customer, it was then very quickly clear for us that the Agiecut Vertex is the right investment in the future. Roland Settele, Proprietor of SFT X. Settele,
”
Stanz- und Formtechnik GmbH & Co. KG
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