New EDM Series for Medical Machining at MD&M West
February 9, 2016GF Machining Solutions will demonstrate the performance and productivity of its new AgieCharmilles CUT E (efficiency) 350 as part of the CUT E Series of wire EDMs at MD&M 2016 on February 9-11 at the Anaheim Convention Center, Anaheim, CA. Along with the new series, the company will spotlight other advanced high-precision machining systems such as the AgieCharmilles FORM 20iRTC sinker EDM and the Mikron HSM 200U LP (linear performance) milling machine all designed specifically for demanding medical part-processing applications.
“The CUT E Series incorporates a broad range of technologies that help medical manufacturers increase their flexibility and accelerate their time to market,” said a company spokesperson. These include new, large-touchscreen human-machine interfaces (HMI) that are intuitive in operation and feature onboard Intelligent Collision Protection, built-in machining strategies and flexible job management. Information about geometries, machining processes and command programs is processed in a single file, allowing jobs to be transferred among different machines within the CUT E Series. The machines then automatically manage all necessary modifications.
Additionally, more than 10 automated measurement cycles are available to assist with workpiece preparation. And the machines’ onboard AC CAM Easy systems allow operators to prepare ISO files and post-process them into a job during machining.
The CUT E Series features the Intelligent Power Generator (IPG) to further improve cutting speed, precision and surface quality. The machines can use dedicated wire for decreased part cost and increased throughput, and the POWER-EXPERT modules automatically determine the optimal power to send through the wire, which is especially beneficial in stepped medical parts. The Corner Strategy module automatically adjusts parameters during changes in direction to produce sharp angels and small radii. “These features combine to reduce cutting times by up to 18% as compared to standard machines,” said the spokesperson.
Machine ergonomics and design have also been enhanced with the CUT E Series. The machines feature compact, space-saving stacked-axis designs as well as wet bases that incorporate the dielectric tanks within them – all of which are designed to boost rigidity and cutting accuracy. Drop doors provide access to worktables, and side-by-side filters are accessible to speed up and simplify maintenance.
Integrated glass scales are designed to preserve long-term, repeatable accuracy, require no recalibration and eliminate errors found in traditional screw systems due to backlash and wear. The CUT E 350 allows use of an optional large, 25 kg spool to facilitate greater levels of automation and unmanned machining. “It also features a reliable wire circuit system for perfect unrolling that does not disrupt the EDM process,” said the spokesperson.
The GF Machining Solutions FORM 20iRTC is one of the first machines to incorporate the company’s AC Form HMI (human machine interface). It is engineered for user friendliness and intuitiveness in today’s medical part machining operations. The machine features enhances connectivity capability and performance and a modern compact design.
Additionally, the organization and layout of screens within the AC FORM HMI are designed to make it easy to use, especially for inexperienced operators. “New operators as well can quickly learn it and confidently run the machine,” said the spokesperson.
From simple Z-axis-level measuring to rotating workpieces around machine C-axes, the most common measuring cycles are also integrated into the interface. Manual adjustments and alignments to workpieces are unnecessary, so non-burn times are reduced. “Plus, novice machine operators are able to easily achieve expert die-sinking EDM results,” said the spokesperson.
As a Windows-based platform, the FORM 20iRTC can be integrated into workshop management systems. Other new features, including GF Machining Solutions’ eConnect, eSupervision and eTracking, are designed to boost machine functionality for process control and outside system connectivity.
“At the heart of the FORM 20iRTC is GF Machining Solutions’ proprietary Intelligent Power Generator (IPG) with built-in quality-boosting and cost-saving intelligence. With every machine pulse, the 70 amp generator on the FORM 20iRTC continuously optimizes the EDM process and reduces electrode wear as well as provides uniform surface finishes,” said the spokesperson. The machine generates surface finishes of Ra 0.1 micron and radii down to 0.0007”.
Also embedded within the FORM 20iRTC machine is GF Machining Solutions’ TECFORM module that is engineered to eliminate the need for operators to adjust the machine generator parameters. “Optimized performance, efficiency and increased production time are all achieved automatically,” said the spokesperson.
Designed with a shop’s valuable floor space in mind, the FORM 20iRTC is compact, yet provides axis travels of 13.78” x 9.84” x 9.84” (350 mm x 250 mm x 250 mm). The FORM 20 machine even includes an integrated four-position linear tool changer.
“On the milling side at MD&M 2016, the GF Machining Solutions Mikron HSM 200U LP – available in 3- and 5-axis versions – brings speed, efficiency, precision and superior surface finishes to the machining of small, highly complex components such as steel denture bars, medical implants, tiny sinker EDM electrodes and other similar highly detailed parts,” said the spokesperson.
The machine is built to accommodate the medical industry’s need for lean manufacturing via small-footprint, high-speed machines. Additionally, the compact size of the Mikron HSM 200U LP allows it to fit into most facilities having limited floorspace, such as dental labs.
The Mikron HSM 200U LP can produce workpieces via 5-axis simultaneous machining. Linear motor technology in the main machine axes and optimized direct-drive motors for the B- and C-axes result in high precision and part surface finishes as fine as Ra 0.05 µm. Furthermore, the machine’s 50,000 RPM, 11.4 HP Step-Tec spindle also contributes to enhanced part details and surface finishes.
The Mikron HSM 200U LP has the capability for 24/7 unattended machining using its optional Mikron pallet magazines with System 3R and Erowa interfaces. These fully integrated pallet magazines can be loaded without interrupting cutting operations already in progress. The automation of tool or workpiece handling is possible from three sides of the machine.
A Heidenhain iTNC 530 control system and Smart machining modules on the Mikron HSM 200U LP provide monitoring critical to the production of precision medical parts. 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.
To avoid inconsistent loading of small tools and 3-D geometry errors due to the inaccurate measurement of those tools, the Mikron HSM 200U LP features Intelligent Tool Measurement (ITM). ITM records the complete tool tip up to a diameter of 0.47” on image sensors. Special software cleans and measures the recorded tool geometry for repeatability in the micrometer range.
For more information contact:
Gisbert Ledvon
GF Machining Solutions
560 Bond St.
Lincolnshire, IL 60069-4224
800-CTC-1EDM / 847-913-5300
gisbert.ledvon@georgfischer.com
www.gfms.com/us
MD&M West Booth #3839
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