AgieCharmilles DRILL 300 - GFMS · 2020. 8. 14. · cutting tools, automotive, medical and die...

GF Machining Solutions

DRILL 300AgieCharmilles

2 AgieCharmilles DRILL 300

Swiss design and quality

GF Machining Solutions : all about youWhen all you need is everything, it’s good to know that there is one company that you can count

on to deliver complete solutions and services. From world-class Milling, electrical discharge

machines (EDM) and Laser texturing machine tools through to first-class Automation, Tooling

and software systems — all backed by unrivaled Customer service and support — we, through

our Mikron, Liechti, AgieCharmilles and System 3R technologies help you raise your game and

increase your competitive edge.

The winning solution

High-speed EDM drilling

Fine hole quality

Powerful control

Quick preparation

High degree of autonomy and Automation


4

6

8

10

14

16

18

Contents

DRILL 300The winning solution for cooling hole machining of components in aircraft enginesIn today’s aircraft engines, the temperature in the combus-

tion chamber can be close to the melting point of the nickel

alloy used. In order to create a film of cooling air on the

surface of components to prevent the nickel alloy from

melting, cooling holes are needed on the curved surface of

components such as turbine blades, vanes, and shrouds.

Machining these cooling holes with high quality and pro-

ductivity is always the main concern for aircraft engine

component manufacturers.


The DRILL 300 is equipped with GF Machining Solutions’

latest digital generator, allowing the drilling process to be

continuously optimized with every pulse. As a result the

machining speed has been increased significantly com-

pared to conventional EDM drilling.

Technology is chosen according to the desired results. For

example, by selecting “quality” technology, the electrode

wear will automatically be reduced and the heat-affected

layer is reduced to a few microns. Conversely, the operator

can select “speed” technology to produce holes with the

fastest possible erosion rate.

With six-axis configuration, holes with different positions

and angles can be freely programmed and machined, al-

lowing for greater part flexibility and design. Single setup

machining reduces unproductive time.

By using the automatic electrode/guide changer (AEC/AGC),

multiple holes with different diameters can be machined au-

tomatically and the machine attains longest autonomy.

Due to wide range of optimized technologies for electrically

conductive material like Inconel, steel and hard metal, the

DRILL 300 is a winning solution for cooling hole machining in

aerospace as well as other industrial applications such as

cutting tools, automotive, medical and die plates.

The GF Machining Solutions’ answer


With 60 years of experience building Electrical Discharge Machines, GF Machining Solutions has developed a new EDM drilling machine, the DRILL 300. This machine is manufactured in Switzerland to deliver top performance in machining cooling holes for aircraft engine components.


100 mm

60 mm

High-speed EDM drilling

Increasing your productivityThe EDM generator has state-of-the art powerful electronics to increase production output by utilizing efficiently controlled EDM processes that include FPGA technology, digital data recording and fully digitized pulse control. The drilling process is continuously optimized with every pulse, thus the fastest drilling speed is achieved.

Drilling time

Without breaktrough detection

With advanced breaktrough detection

20 mm100 mm

48 s280 s

Depth

Electrode: brass, Ø 1.0 mmWorkpiece: steelSpeed technology

Conventionaldrilling time

28 s170 s

DRILL 300drilling time

DRILL 300up to 40% faster

Conventional EDM drilling

DRILL 300

Fast and reliable breakthroughWithout breakthrough detection, the machining time at

breakthrough is even longer than the entire hole drilling

time when the flushing process breaks down. With advanced

breakthrough detection on the DRILL 300, the process is

monitored in a real time; the technology is adapted automat-

ically to exit technology; the reliable process is attained and

the breakthrough time is shortened by 50-70 percent.


Steel

Hard metal

Inconel 718

Aluminium

Copper

5

5

5 510

20

510

20

40

10

20

40

60

40

80 80

10

20

40

10

20

40

60

80

10

40

60

80

10

40

5050

40

60

80

100

40

80

100

1010

202020

40

80

10

20

40

60

80

100

10

20

40

80

10

20

40

60

80 80

100

120

150

10

20

40

20

40

60

40

60

100

120

150 150

80

20

40

150

80

20

40

150

40

80

3 3

510

3

3

510

20

3

4040

10

20

10

31 31 31

49

31

49

1010

202020

5 510

3 3 3

40

20

3

10

53

0.1 0.15 0.2 0.3 0.4 0.5 0.6 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.00.8

0.1 0.15 0.2 0.3 0.5 1.0 1.5

0.3 1.5

2.0 3.0

Copper

Brass

Carbide

0.8

0.3 0.5 1.0

1.0

1.5 2.00.8

Optimal technologiesOne type of technology cannot meet all of your requirements.

According to the workpiece material and your stringent met-

allurgical requirements, the DRILL 300 has the optimized

technologies to focus on either quality or speed. The quality

technology achieves minimum heat-affected layer and better

hole integrity, while the speed technology focuses on short

drilling time.


Fine hole quality

The new standard in hole-drilling EDM

Minimum heat-affected layerHeated-affected layer has significant influence on the fatigue

lifetime of components and the safety of aircraft engines. The

DRILL 300 is designed for achieving the best result in terms

of heat-affected layer and avoiding cracks in the components.

The DRILL 300 digital generator allows the finest pulse dura-

tion of a few microseconds. When quality technology is used,

the heat-affected layer can be dramatically reduced to a few

microns with a reasonable machining speed.


with FirstSpark

without FirstSpark

Electrode: brass, Ø 1.0 mmWorkpiece: steel, 20 mm heightQuality technology

Consistent hole dimensionWhen machining cooling holes with conventional EDM drilling,

the spatters at the hole entrance are always a problem,

especially if there is a small angle between the hole and

surface of components. The DRILL 300 has a fine pulse ap-

plied with the first spark function, then the technology is

automatically adapted to the standard parameters. There-

fore, the spatters in the hole entrance are avoidable and a

perfect profile is achieved.

In order to optimize the machining of the most complex

holes, the DRILL 300 provides the way of programming

parameters corresponding to the machining depth. Multi-

parameters can be used in the same hole.

With advanced breakthrough detection “Breakthrough Strat-

egy” on the DRILL 300, the hole exit technology is optimized

and the exit electrode length is programmable, and back-

striking can be prevented. Meanwhile the quality technology

also helps attain the right hole dimensions at the bottom of

the hole.


Powerful control

To manage sophisticated hole machining

CNC controlIn order to meet the demands of different applications, the

DRILL 300 can be configured with different kinematics:

XYZW, XYZWBA, XYZWAB, XYZWB1C1, XYZWB1, XYZWAB1.

With single setup the holes with different diameters, posi-

tions and angles are freely programmable and machined.

Control unitThe graphical user interface is based on the Windows oper-

ating system and allows real time control of the EDM pro-

cess. The system works with descriptive picture symbols

and conversational screen pages following one after another

in a logical way. This allows even new users to understand

the EDM principle quickly and means time to production is

very short.


Manual operation – Easy DrillMain functions include all setup cycles, easy and fast pro-

gramming for single hole machining (one hole on one page)

as well as electrode and guide management.

Work preparationThe machine can import the entire work in the format of

XML.NCC, ISO.NCC and PAT.NCC (compatible with AC CAM

DRILL) directly or prepare the work manually with TEACH

function. The parameters of every machining can be modi-

fied with Edition. The work can be graphically checked.

Work executionThis page activates the work and executing measuring cy-

cles. All machining, parameters and hole positions are

monitored on this page.


Quick preparation

Single setup machiningWith different kinematics of six axes, holes with dif-

ferent diameters, positions and angles can be freely

programmable and machined even with single setup,

allowing for greater part flexibility and design. Single

setup machining eliminates the need for additional

expensive fixtures and avoids multiple setups to re-

duce unproductive time.

Reducing the un productive time

Fast setup cyclesThe universal console is equipped with the touchscreen

based on the Windows operating system. The setup cycles

probe, edge finding, corner finding, center finding, etc., help

to prepare the job in a convenient way.

Less down timeTo ensure the longest life and reliability of the electronics,

a closed water-air cooling circuit is contained within a dust-

proof cabinet, in which the temperature is also monitored and

stabilized with multi-sensors.

With this design, the lifetime of the electronics is guaranteed

even in the most difficult conditions.


High degree of autonomy and Automation

Automatic filtration and conductivity controlWith the 200-liter water tank and a 10-liter resin bottle in a

standard configuration, the water filtration and conductivity

are automatically controlled and cycled.

For maximizing productivity

Automatic part changerWith the optional Automation kit, the DRILL 300 can connect

to external robot to automatically manage part changing.

Automatic electrode/guide changerThe optional linear 16/4 electrode/guide changer and 50/8 ro-

tary electrode/guide changer are available on the DRILL 300.

AEC/AGC 16/4 is affordable solution and AEC/AGC 50/8 is a

solution with the longest autonomy for max productivity.


DRILL 300

DRILL 300

MachineMachine dimensions (L x W x H) mm (in) Without tilting head: 2320 x 1400 x 2180 (91.34 x 55.12 x 85.83)

With tilting head: 2320 x 1900 x 2180 (91.34 x 74.8 x 85.83)Net weight kg (lbs) 2500 (5512) without variants and options

Machining areaElectrode diameter mm

in0.3 ~ 3.0 (option: 0.1, 0.2, 4.0, 5.0, 6.0)0.012 ~ 0.12 (option: 0.004, 0.008, 0.16, 0.20, 0.24)

Max. workpiece dimension mm (in) 1000 x 700 x 500 (39.37 x 27.56 x 19.69)Max. workpiece dimensionwith tilting/rotary axes

mm (in) Ø x L = 350 x 320 (13.78 x 12.60)

Max. workpiece weight kg (lbs) 1000 (2205)Max. workpiece weight with tilting/rotary axes

kg (lbs) 25 (55) including clamping weight

Worktable dimension mm (in) 800 x 600 (31.50 x 23.62)Worktable type 4 bars (2 stationary, 2 adjustable)Distance from table surface to floor mm (in) 850 (33.46)Accessibility Front

AxesTravel X x Y axes mm (in) 600 x 400 (23.62 x 15.75)Travel W x Z axes mm

in450 x 450 (650 optional)17.72 x 17.72 (25.59 optional)

Tilting/rotary axes (option) º ± 100 / 0~360Max. axis motion speed m/min. (ft/min) 4 (13.12)Measuring system for Z, W axes EncoderMeasuring system for X, Y axes Encoder (linear glass scales optional)Lubrication Manual

Dielectric unitDielectric type Industrial water or civil waterDielectric capacity l (us gal) 200 (53)Max. flushing pressure bar (psi) 80 (1160)Filter accuracy µm 5Capacity of deionizing bottle l (us gal) 10 (2.6)Cooling system Water/water heat exchanger

Technical data


DRILL 300

GeneratorGenerator type ISPGMax. mean working current A 60Cooling system inside cabinet Air/water heat exchanger

Numerical controlFlat screen 17” flat touchscreenKeyboard StandardMouse StandardStorage capacity > 230 GB HD, 1024 MB RamInterface port USB and EthernetMeasurement unit Metric/inchCommand format Absolute/incrementalCoordinates system Machine, partMax. number of machining in the program 500Servo controlled axes X, Y, Z, W, A, BImport files XML.NCC, ISO.NCC, PAT.NCCOnboard CAD/CAM AC CAM DRILL as standardFirst spark detection StandardElectrode wear compensation StandardBreakthrough detection StandardOnboard documentation Standard

Electricity supplyThree-phase input voltage V 380 or 400Permissible variations from +10% to -10%Main frequency Hz 50 or 60Power consumption kVA 4.2Nominal current A 6

Cooling water when heat exchanger usedFlow minimum required l/min (gal/min) 20 (5.2)Temperature °C

°F< Tworkshop – 9° C< Tworkshop – 18° F

Compressed airPressure range between bar (psi) 6 to 8 (85 to 113)Flow minimum required m3/h (yd3/h) 5 (6.54)Connection pipe external diameter mm (in) 10 (0.4)

Main optionsAutomatic electrode/guide changer AEC/AGC 16/4, AEC/AGC 50/8Tilting head ° Max. ~ ± 45 Large travel of Z axis mm (in) 650 (25.59)Rotary/tilting table


DRILL 300

DRILL 300 tilting head

1400/55.12’’ 2375/93.5’’

800/31.5’’

Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 ’’

600/23.62’’

40/1.57’’

600/

23.6

2’’

400/

15.7

5

730/28.74’’ 1120/44.09’’

1998/78.66’’

700

27.56’’

1260/49.6’’

598

23.54’’

3393

/133

.58’

’

2280

/89.

76’’

100

3.94

’’

583

22.9

5’’

510

20.0

7’’

2375/93.5’’

800/31.5’’

Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 ’’

600/23.62’’

40/1.57’’

600/

23.6

2’’

400/

15.7

5

730/28.74’’ 1120/44.09’’

2280

/89.

76’’

100

3.94

’’

1900/74.8’’

2248/88.5’’

250

9.84’’

1400/55.11’’

348

13.7’’

3392

/133

.54’

’

583

22.9

5’’

1270

/50’

’

510

20.0

7’’


The DRILL 300 easily drills cooling holes in turbine blades. For this demo blade, 180 through holes and blind holes (Ø 0.5 mm and Ø 1.0 mm) were machined in only 75 minutes, using a single setup with the automatic electrode and guide changer.



EDM (electrical discharge machining)AgieCharmilles wire-cutting, die-sinking

and hole-drilling machines.

For over 60 years we have been at the forefront of every EDM develop-

ment: designing and refining the EDM process and building machine

tools that deliver peerless part accuracies, surface finishes, cutting

speeds and process reliability. Today, our AgieCharmilles wire-cut-

ting, die-sinking and hole-drilling machines are recognized through-

out the world as the best in the business. Our continuous research and

development in digital generator technology, control systems and in-

tegrated Automation systems are evidence of our commitment to

keeping your EDM operations on the leading edge of technology.

MillingMikron high-speed (HSM), high-performance (HPM)

and high-efficiency (HEM) Milling centers.

Customers operating in the mold, tool and die and precision compo-

nent manufacturing sectors stake their reputations on being able to

quickly and cost-competitively meet their customers’ demands.

That’s why they invest in Mikron machines. Incorporating the latest

and most advanced technologies and premium-performance com-

ponents, Mikron HSM, HPM and HEM machines help you increase

your production capabilities and improve your productivity. Designed

and built for speed, accuracy and reliability, the machines, like you,

are proven performers.

Liechti Dedicated Aerospace and Energy machining Centers.

Aerospace and power generation turbine manufacturers increas-

ingly turn to Liechti dedicated five- and six-axis machining centers

to machine complex, high-precision airfoils on blades, disks, blings,

blisks / IBRs and impellers. It’s easy to see why because these ma-

chines, with their specific profile machining technology, specialized

CAD / CAM software and engineering competence for ultra-dynamic

machining in titanium, Inconel, nimonic, titanium-aluminide and

high-alloy steels, yield productivity gains as much as 30 percent,

thanks to reduced machining times. In the globally competitive aero-

space and power generation manufacturing sector, that’s definitely

worth shouting about.

Step-Tec Spindles.

At the heart of every Mikron machining center is high-performance

Step-Tec Spindle. Step-Tec Spindles are essential core components

of our machining centers. Highly accurate and thermally stable Step-

Tec Spindles ensure that our machines can handle everything from

heavy-duty roughing to fine-finishing operations.

AutomationSystem 3R Automation, Tooling and software.

Productivity is the key to manufacturing success, and automating a

manufacturing process is a proven method of increasing its efficien-

cy, effectiveness, quality and reliability. System 3R’s integrated Au-

tomation, Tooling and software solutions — simple workpiece pallet

and electrode changers and flexible manufacturing and robot han-

dling systems — increase your competitive advantage.

Customer ServicesOperations Support, Machine Support and Business Support.

To help you get the most and the best from your machine tools and

equipment, we offer three levels of support. Operations Support cov-

ers our range of original wear parts and certified consumables (EDM

wires, filters, resins, electrodes etc.) to ensure that your machines

are performing at the highest levels. Machine Support maximizes,

through our best-in-class technical support, preventive services and

quality spare parts, your machine tool uptime. Business Support is

designed to help you make a real step-change in your productivity

and performance with solutions tailored to your specific needs.

LaserAgieCharmilles Laser texturing machines.

Laser texturing is a fully-digitized surface engineering process that

has huge potential. The technology enables precise 2D and 3D tex-

tures or engravings to be machined accurately and directly onto

complex parts or molds to improve and alter their aesthetic appeal,

functionality and performance. The process is infinitely repeatable

and offers many distinct environmental and economic advantages

over conventional texturing processes.

Laser Additive Manufacturing (AM).

GF Machining Solutions has partnered with EOS, the global leader

for high-end AM solutions, to integrate this innovative technology

and further develop it into its current solutions to fully benefit the

mold industry, by focusing on injection efficiency : optimized cooling

design to reduce cycle time, lower energy consumption, higher qual-

ity of plastic parts.


259.

805.

752–

EN

© G

F M

achi

ning

Sol

utio

ns M

anag

emen

t SA

, 201

5

The

tech

nica

l dat

a an

d ill

ustr

atio

ns a

re n

ot b

indi

ng.

They

are

not

war

rant

ed c

hara

cter

istic

s an

d ar

e

subj

ect t

o ch

ange

.

At a glanceWe enable our customers to run their businesses efficiently and effectively by offering innovative Milling, EDM, Laser, Spindle, Automation and Tooling solutions. A comprehensive package of Customer Services completes our proposition.

www.gfms.com

AgieCharmilles DRILL 300 - GFMS · 2020. 8. 14. · cutting tools, automotive, medical and die...

Documents

Transcript of AgieCharmilles DRILL 300 - GFMS · 2020. 8. 14. · cutting tools, automotive, medical and die...