Flexible, compact and modular forms of automation and a wire electrical discharge machine (EDM) designed for aerospace work will take center stage in the GF Machining Solutions booth. Throughout the show, the company will focus on how manufacturers affected by the skilled labor shortage can maintain growth by using technology to expand their capacity.
The company's automated part-processing systems will include an advanced pallet changing system on a MIKRON HPM 800U high-precision machining center, a standalone robot paired with an Agie Charmilles CUT 2000 S wire EDM and a fully automatic tool/electrode changer with an Agie Charmilles FORM 20 iRTC sinker EDM. Targeting aerospace work, as well as other complex parts, GF Machining Solutions will present the new Agie Charmilles CUT 200 Dedicated wire EDM for aerospace parts. System 3R will also be featured in the booth, with a focus on the new TRANSFORMER modular automation system. Tying everything together will be MTConnect functionality, with GF Machining Solutions showing this standardized protocol designed to make it easier to control, monitor and improve production systems.
In addition to a variety of new machines, GF Machining Solutions will also feature live presentations in an in-booth Technology Forum, covering a range of topics of interest for today's manufacturer.
The CUT 200 Dedicated features a built-in, B-C tilt/rotary table to cut complex aerospace alloy components such as turbine disks using C-axis rotation and +/- 20-degree B-axis tilt. It also incorporates on-machine, in-process inspection that encompasses a measuring probe and supporting software and the ability to control production costs for manufacturing in the aerospace industry as well as the mold and die, medical and contract machining industries.
According to the company, to significantly reduce non-cut times, the CUT 200 Dedicated features fast axis speeds, integrated collision protection and quick, smart wire threading. The latest Agie Charmilles spark generators allow the machine to cut up to speeds of 38"2/hour (400 mm2/min) and up to 30-degree tapers in the Z-axis height while also minimizing the heat-affected zone in aerospace alloys. Additionally, energy saving functionality and advanced software help reduce operational costs and provide increased system connectivity.
On the self-contained automation side, GF Machining Solutions will demonstrate the performance and productivity of the full five-axis MIKRON HPM 800U through its integrated pallet changer and tool magazine options that accommodate up to 210 tools.
Designed for the production of tools, molds and high-value parts, the HPM 800U features a sturdy and compact design with a large working space. Maximum X-Y traverse paths are 31.5" each, with a Z-axis that provides 27.6" clearance between the table surface and spindle nose. Workpieces of up to 31.5" diameter and 23.6" height can be machined on five sides.
According to the company, the HPM 800U's Step-Tec spindle provides high performance, even in applications such as large steel drilling with high torque requirements. Inline motor spindle options include a 20,000-RPM version for general machining or 28,000-RPM version for machining with small tools. Both options feature the HSK-A63 interface and are designed for complex open-die surfaces or machining basic materials. The 28,000-RPM spindle uses CoolCore, a water-cooled rotor shaft, to maintain thermal stability and maximize accuracy.
While typically paired with sinker EDMs, a System 3R WPT1 robot, together with the CUT 2000 S (Swiss high precision) model, will comprise a completely automated wire EDMing cell in the GF Machining Solutions IMTS booth. Available in four configurations, the robot is also compatible with milling and laser equipment. The system is designed to give end users a full range of automation options suited to their applications and to provide the capability to address parts and tooling for two machines at once. The robots are flexible and sleekly designed and accommodate a wide range of part sizes and weights.
"Enhancing automated unattended operation and boosting productivity, the CUT 2000 S incorporates the company's new THREADING-EXPERT module for dependable, fully automatic threading under difficult conditions. It also features the second-generation Integrated Vision Unit (IVU Advance) for in-process inspection and the well-known Agie Charmilles Automatic Wire Changer," said a company spokesperson.
"The machine raises the bar in the speed arena thanks to its Intelligent Power Generator (IPG) technology with Direct Power Supply (DPS) module. The machine has been proven to reduce machining time by 30 percent and produce high-quality surface finishes of Ra 0.08um," said the spokesperson.
Visitors to the GF Machining Solutions booth will also experience the automated FORM 20 iRTC (integrated Rotary Tool Changer) sinker EDM. The system is designed to allow shops to automatically accommodate jobs that require either multiple electrodes or several workpieces varying in size and geometry.
According to the company, the iRTC boosts part processing flexibility while it ratchets up uninterrupted unattended production capability. It accommodates electrodes weighing up to 22 pounds and measuring 5.9" x 3.94" or up to 5.9" in diameter as well as in height. And depending on electrode/workpiece size, the changer holds either 8 or 16 electrodes or workpieces.
"The Form 20 and iRTC combination forms an ideal solution for manufacturers looking to maximize their die-sinking EDM operations while minimizing their environmental footprint. The efficient sinker machine provides exceptional performance, yet consumes less power via what the company considers to be one of the most advanced sinker EDM generators currently available. The company's proprietary Intelligent Power Generator requires just 3.7 kW/h at full power," said the spokesperson.
According to the company, the FORM 20's Intelligent Power Generator includes built-in quality-boosting, cost-saving intelligence. With every machine pulse, the 70-amp generator continuously optimizes the EDM process and reduces electrode wear as well as provides uniform surface finishes. The machine's iQ Technology generates surface finishes of Ra 0.1 micron and radii down to 0.0007".
The FORM 20 features the recently developed Agie Charmilles AC Form HMI. This CNC provides a user-friendly, easy to learn flexible control.
The new unveiled TRANSFORMER modular automation machine from System 3R will also be featured in the booth. This product can be integrated with a single machine, but can also be expanded to include up to twelve machines within a cell. The system accommodates a range of machining technologies and simplifies unifying diverse machines into a production cell.
For more information contact:
Gisbert Ledvon
GF Machining Solutions
560 Bond St.
Lincolnshire, IL 60069-4224
800-CTC-1EDM
gisbert.ledvon@us.gfac.com
www.gfac.com/us
IMTS 2014 Booth S-8754