MILL P 1400 U – Consistent stability and precision for the largest applications

The Mikron MILL P 1400 U is a high-performance Milling solution, ideal for the manufacturing of aerospace, machinery and automotive precision parts as well as large molds, in the range of a few microns. Its superior precision and stability allow high productivity. With its set of smart process-reliability functionalities, the MILL P 1400 U gives you a unique competitive advantage for heavy and big parts.

Mikron MILL P 1400 U Front View

 

 

Advanced machine accessibility and visibility     Clean, clear design and unrestricted access to all integrated machine peripherals. Load and unload easily. Perform maintenance efficiently.

 

More flexibility in your workshop     With its exceptional precision and reliability the Mikron MILL P 1400 U is an advanced hybrid milling and turning solution. Achieve high precision on complex parts. Secure performance across all fives axes simultaneously

High productivity

The integrated smart machine modules in combination with turning capabilities bring the level of the machine to the highest. Machine easily and faster heavy and large parts without compromise.

Superior precision

High quality components and machine architecture development make this solution not only precise but also stable. Reach the highest precision anytime.

 Additional Information: https://www.gfms.com/en-nl/machines/milling/5-axis/mikron-mill-p-u-series.html#mill-p-1400-u

REQUEST QUOTE: https://www.peakedm.com/ContactPeakMachineSales.html?i515589:default[Product%20Title]=Mikron%20MILL%20P%201400U

The automated cell at the heart of GF’s Medical Center of Competence includes a Form P 350 die-sinker EDM, a Mikron Mill S 400 U, inspection equipment, storage racks and a robot that manages it all.

The Automated Heart

At the heart of GF’s Medical Center of Competence is an automated cell bringing together several of the company’s machine lines. Both low-volume, high-mix and high-volume, low-mix applications are possible on this demonstration cell, which includes a Mikron Mill S 400 U milling machine, a Form P 350 die-sinker EDM, 3R workholding devices and cell management software, a FANUC robot and a CMM. The S 400 U also has a grinding option and a wet electrode cutting option, while all machines benefit from 3R’s one-minute setup times and repeatability within several microns.

GF positions itself as being able to make previously impossible parts, using this cell and the rest of the machines within the Center of Competence to demonstrate new design possibilities to shop owners and product design teams.

Killing the Right Sparks

Of note was GF’s wire EDM technology. This includes both the Cut F 600, a mid-range offering making its North American debut at the unveiling, and the Uniqua control technology on both this machine and a higher-end Cut P machine.

Both the new Cut F and higher-end Cut P EDMs include ISPS and iWire functionality in their controls. These features adjust sparks and wire feed rate to optimize cutting time and wire consumption rates.

The Cut F features increased accuracy compared to the budget Cut E machines, with more durable ballscrews, a liquid-cooled Y-axis, and an X-axis repositioned to benefit from this cooling. Visitors to the unveiling also saw a demonstration of GF’s iWire technology, which senses height differences between sections of parts and automatically compensates, reducing wire consumption. Company representatives say this feature saves an average of 27% of wire — but the demo part on the Cut P boasted 60% savings. This technology works in conjunction with GF’s ISPS (Intelligent Spark Protection System) technology, which uses a sensor close to the cut zone to analyze Z-axis sparks along the wire.

As with the height differences iWire observes, the control uses this information to adjust cut parameters, reduce wire breakage and maximize operation speed. Erik Poulsen, GF’s medical marketing manager, says the technologies in the Uniqua control provide an unmatched level of fine control — even predicting the strength of individual sparks and killing single, overpowered sparks to maintain a smooth process.

GF’s also showcased an important update to its die-sinker EDM technology: iGap. This software ensures sparks only form on the front of the electrode, not the sides. By controlling the location of these sparks (and concentrating the machine’s power), electrode wear decreases and average cycle times are 30% faster.

Laser Focus

The company has also been quietly developing powerful laser technology to perform not just texturing operations, but full-on micromachining. Visitors to the Medical Center of Competence opening event glimpsed both applications.

GF’s laser texturing software enables users to scan a desired texture and replicate it with a laser texturing machine, such as the Laser P 400 U on display in the Medical Center of Competence.

Texturing is more than a simple finishing operation for medical applications, with Poulsen describing laser-created textures that assist in osseo-integration and friction reduction, as well as textures that are hydrophobic, hydrophilic or anti-bacterial. Users can create these textures with relative ease, as GF’s laser machines are accurate to within tens of microns — enough to eliminate the need for masking — and texture programming is streamlined through an ability to scan textures into the control system for replication.

While GF demonstrated its laser machines’ ability to perform laser texturing at the Medical Center of Confidence, it showcased laser micromachining at its nearby Microlution facility. The company pointed to three machine types for different applications: the MLTC for tube cutting, general purpose ML machines and MLDS machines that pair a laser with metrology or boring stations for a high-end multitasking solution.

These machines can use nanosecond and femtosecond lasers, with nanosecond pulses creating a heat-affected zone that adds variability and femtosecond pulses achieving low surface variability without a heat-affected zone. Control over the lasers is now so fine that the MLTC can create features that aren’t through-features, and both the MLTC and the ML5 can perform OD turning with lasers. Spot sizes average 20 microns, with one demo part pushing the MLTC to an 11-micron spot size.

The ML5 is climate-controlled, five-axis laser micromachining system. The company’s engineers say the laser uses prisms to strengthen the beam, ending up with hundreds of Megawatts of power for the tiny fractions of a second in which the laser is pulsing. Parts can have negative, positive or zero tapers, and parts-cleaning is all but eliminated.

GF Microlution is making strides in laser micromachining. The company says it cuts about 80% of its test parts from stock using lasers, and can also perform OD turning and create non-through features at accuracies within several microns.

GF mostly relied on demonstrating test parts on the Microlution floor, as many applications in the medical field and beyond are under strict NDAs. These test parts showcased the extremes these machines could meet, with the 11-micron part mentioned above being a stainless-steel pipe 0.012 inch in diameter with a 0.009-inch hole and tiny, non-through-part features. Other sample parts made with GF Microlution’s laser lineup included representatives of aerospace and electrical work that the company made available for inspection under microscopes.

Erik Poulsen is convinced that micro lasers will be increasingly vital to medical manufacturing. EDM and conventional machining can both currently create parts on a much larger scale, much faster for a fraction of the cost — but the precision and detail laser micromachining can offer (not to mention its current usefulness in texturing) enable product designers to explore new ideas and target new standards in the ever-growing medical market and beyond.

Originally Published by Modern Machine Shop on 6/14/23: https://www.mmsonline.com/articles/edm-laser-micromachining-and-more-at-gf-medical-demo-center

There is a clear market trend towards automation. Customers are looking for the best automation solution while thinking of a reduced footprint to increase the production per square meter. This is especially the case for competitive industries like aerospace and automotive, where the demand for aircraft and electrical vehicles continues to outstrip the supply of manufacturing. At the same time, manufacturers need to keep an eye on the production, and it is becoming increasingly important to track and improve the output of the workshop.

Based on these requirements, GF Machining Solutions has decided to redesign the well-established Mikron MILL P 800 U and to create the new high-performance milling machine Mikron MILL P 800 U S with the same performance and reliability. The access to the machine has been considerably improved by making it more accessible from the back by shortening the space between the table and the robot. The better connectivity between the machine and the robot makes the MILL P 800 U S a state-of-the-art solution with a compact layout, even with multiple machines. 

The MILL P 800 U S, which can be equipped with a Heidenhain TNC 640 or a Siemens Sinumerik control, delivers a high material removal rate thanks to its symmetrical gantry design that ensures stiffness and robustness, and to the 20,000 rpm Step-Tec Spindle of 36kW and 120Nm. The main water-cooled heat sources inside the MILL P 800 U S secure a long milling process and make the machine suitable for heavy roughing and finishing. 

As part of GF Machining Solutions’ DNA, the MILL P 800 U S is a high dynamic milling machine (with an acceleration of 1.7g). This is made possible by its standard specification (with a rapid axis traverse of 61m/min and an axis acceleration of 10m/s²) and the support on both table sides of direct (swiveling and rotary) torque motors. These ensure precision and accuracy, even during dynamic milling, and guarantee an unattended, risk-free process 24/7 thanks to the smart machine module called Machine Spindle Protection (MSP). With the MSP, even if a crash occurs during the milling process, neither the spindle nor the machine are damaged and the milling process can restart immediately. 

The combination of the performance and the compact automation layout in the MILL P 800 U S makes this new machine unique in the market. It can easily be connected to a robot and the scalability of the machine with automation is limitless because of the possibility to add a second, a third or even more machines of the same type into the robot cell. This allows to always keeping the best machine ergonomic and accessibility for the machine's set up or maintenance when needed. 

All machines in the MILL P 800 U range are rConnect ready. This central communications platform enables manufacturers to maximize their productivity and their control over production. Live Remote Assistance (LRA), process improvement modules, predictive maintenance and machine monitoring enhance the machine uptime and add more flexibility on the shop floor. LRA allows for customer-authorized remote assistance via real-time connection of machines to GF Machining Solutions. With LRA, the manufacturer using the system or a GF Machining Solutions technician can conduct remote diagnostics and inspections. 

The MILL P 800 U S will be offered to customers as part of a complete newly designed service package, which comprises full support with one supplier for the whole cell including automation. On top of that, they will receive extra support hours, quick access to experts to get the machine on track up to 12 times faster, remote support backed by the latest digital technologies and advanced diagnostics on the spindle and the robot's motions. Furthermore, customers can expect a worldwide spindle exchange service within 24 hours, as well as original parts and upgrade to the latest software, which reduces downtime significantly.  

GFMS Media Release Originally Published: 7/29/22

On the customer’s side, the manufacturing process is crucial to answer market demands. Fast time to market is a daily challenge. Due to the crisis COVID-19, the cost of raw materials has increased and producing the first part right is essential to keeping costs down and avoiding scratch material. A short machining process is key to increasing productivity and efficiency.

The Mikron MILL S/X (U) three- and five-axis milling series are known for accuracy, precision, high dynamics, iconic design, and ergonomics. Accessibility to the machines is easy and their footprint is small whether on a standalone machine or combined with an automation cell. With a fast process speed, parts can be produced to fulfill market demands with flexible production. The automated machine calibration (AMC) as standard on the series provides calibration, and the cooling of all machine components keeps the process stable during long milling and grinding processes.

The MILL S and X series include hybrid milling and grinding capabilities. The new machines can combine milling and jig grinding on the same machine without any impact on its footprint or performance. The grinding setup is designed to maintain standard workpiece dimensions and the clamping surface for automated processes. The laser measuring system and dressing spindle (with an adjusted rpm from 3,000 to 20,000) remain located closer to the working area for a quick and fast grinding process. In addition, the dressing spindle is installed with a slight inclination to dress any type of grinding tool without issue.

Through this two-in-one solution, the Mikron MILL S/X (U) series reduces the time and complexity of the customer's manufacturing process. The combination of milling and grinding technologies and high machine dynamics and consistent thermal stability due to Ambient Robust technology, ensure high accuracy and a fast ROI for high quality parts. The dressing spindle is equipped with an acoustic emission (AE) sensor to track and visualize the signal on the Heidenhain control during the tool dressing. The machine can be equipped with an additional AE sensor to track grinding operations and optimize the process further. Thanks to the additional AE sensors on the machine table, operators can adapt their process even more thanks to the automatic tool-piece detection cycle. This cycle, developed by GF Machining Solutions, avoids air grinding by detecting exactly when the grinding tool touches the part to start the process under optimal conditions.

originally published on Today's Medical Developments on 9/15/22

The Red Dot Design label has become established internationally as one of the most sought-after marks of quality for good design. Products are awarded in three categories: product design, which honors industrially manufactured, market-ready products, brands and communication design and design concept. The criteria by which the jury, consisting of around 50 international experts, evaluates the products are the following: functionality, aesthetics, usability and sustainability.

The LASER S 2500 U has been developed together with industrial experts such as Reichle Technologiezentrum GmbH, Europe's largest service provider in the area of laser texturing, and using the "Design Thinking" approach. Designed to answer upcoming trends like functional surfaces for branding features, this fast, accurate new machine within the S series of GF Machining Solutions' laser machine range makes textured surfaces possible, increasing product differentiation. New designs with a perfect replication on the final part could be achieved through rigorous testing. The table can accommodate large size molds of up to 10 tons, for example for dashboards and door trims, the monobloc tri gantry design combined with thermo-stabilized areas of the machine ensure the highest graining quality. Fully digitized texturing makes it easy to texture, mark, engrave and add functional surfaces to parts, molds and dies. Finally, the laser texturing technology supports sustainability and environmental considerations by replacing conventional technologies, which use chemicals or other potential pollutants.

However, not only the design, but also the functionality are paramount with this new laser machine. The LASER S 2500 U offers increased productivity during high volume machining thanks to specifically high displacement dynamics. Machining times are greatly reduced while the exceptional quality of ablation is maintained. The LASER S 2500 U answers to new geometrical demands while enabling customers to control the costs per part.

The LASER S 2500 U as awarded product will be featured in the Red Dot Design Yearbook and in the Red Dot Design virtual exhibitions. The award ceremony will take place in the Aalto Theater in Essen (Germany) on 20 June 2022. Additionally, all winning products will be part of the exhibition "Design on Stage" in the Red Dot Design Museum from June 2022 to May 2023.

The new LASER S 2500 U was able to convince the jury of the Red Dot Design Award.

Connected with Tokyo 2020, Bodor Laser machine cuts Olympic and Paralympic symbols

Tokyo 2020 unveils the victory ceremony podiums recently. On the podium, there are the Olympic and Paralympic symbols which are cut by Bodor 2kW laser cutting machine.

*Tokyo 2020 Olympic Official Website Screenshot

Tokyo’s 2020 Olympics will open on July 23. More than 70 sets of podiums, which will be used in Tokyo 2020 Olympic and Paralympic victory ceremonies, have been officially announced. The symbols on them and the frame structures inside are all cut by Bodor Laser machine.

*Tokyo 2020 Olympic Official Website Screenshot

The podium is designed by Asao Tokoro, who also designed the Tokyo 2020 emblems. It is made of recycled plastic and aluminum, and will be the first of its kind in Olympic and Paralympic history. Presenting a new model for a sustainable society with its design under the concept of 3R (Reduce, Reuse, Recycle), the podium also uses aluminum wastes from the temporary housing units built for families affected by the Great East Japan Earthquake in 2011 to express the Olympic and Paralympic symbols.

Exactly 10 years ago, the Great East Japan Earthquake devastated the Tohoku region of Japan. These aluminum wastes used convey wishes to bring together those whose lives have been affected to overcome disasters, get over sufferings, and surpass the old past.

*Tokyo 2020 Olympic Official Website Screenshot

In terms of processing these aluminum wastes, laser cutting technology is applied to shape them into Olympic symbols. The advanced laser technology and the idea of recycling materials are connected as well.

*Tokyo 2020 Olympic Official Website Screenshot

The sustainability concept of Tokyo 2020 is Be better, together, for the planet and the people. Holding the vision to change human life with laser technology, Bodor has the similar spirit, as it has been committed to providing better laser cutting solutions for clients since the beginning of Bodor history in 2008. Therefore, Bodor, as the laser cutting machine provider, is very proud to have connections with Tokyo 2020, to make contributions, and to go together with the world renewal. It will still do better with clients in the future, for better laser cutting solutions.

Learn More: Bodor Laser Cutting Machines are now available from Peak Machine Sales Check them out here: https://www.peakedm.com/BodorLaserCutting.html

https://www.bodor.com/us/news/company/tokyo.html

As gas lasers, and CO2 lasers in particular, are the most commonly used lasers on the market, we thought it would be useful to have a comparison of fiber lasers vs CO2 lasers. You can find more on that below.

Advantages of Fiber Lasers

No moving parts or mirrors

The fact that it has no moving parts means that your fiber laser setup is ready to get working from the get-go. And, should it be knocked, none of the parts will come out of alignment; resulting in costly production down time.

Lower maintenance costs

The second advantage to the fact that fiber lasers are extremely insensitive, as described above, is that it means maintenance costs are dramatically lower, as are operational costs and with ‘fit and forget’ technology there is no maintenance cycle or servicing to worry about.

Electrical efficiency

Another cost saving benefit is that fiber lasers are much more efficient when it comes to electricity, meaning lower running costs and a more environmentally friendly machine. For example, a 3 kW fiber laser uses only a third of the power of that of a 4 kW CO2 laser .

Good with thin materials

Although fiber lasers are good at working with materials of all thicknesses, they are particularly great at working with thin materials, including metals. Using the same comparison of lasers as above, the fiber laser is three times faster at cutting in a straight line on something like stainless steel with a 1mm thickness, and two times faster if the same material is 2mm in thickness.

Reflective metals

Fiber lasers can cut reflective materials without having to worry about back reflections that could damage the machine.

CO2 Lasers

Here are the advantages and disadvantages of a CO2 laser, which will cover many of the points above as a direct comparison. The main disadvantages that a fiber laser faces in comparison to a CO2 laser relates to cutting speeds of thicker materials; generally anything above 5mm in thickness.

Gas lasers most commonly use carbon dioxide as their medium

Advantages of CO2 lasers

Works well with thicker materials

Fiber lasers can work with thicker materials no problem, but generally a CO2 laser will leave a surface finish that is smoother.

Faster in a straight line

A CO2 laser is faster at cutting in a straight line, as well as having a quicker piercing time when the cut is first started.

Disadvantages of CO2 lasers

The main disadvantages of CO2 lasers are where the advantages of fiber lasers lie. Firstly, CO2 lasers are sensitive machines that require alignment, so should this get knocked out of place, usually an expert is required to fix it, resulting in long periods of down time when the laser is not being productive.

This also means they need more regular servicing, and the costs of this maintenance are higher. Alongside this, more power is needed, resulting in higher electrical costs. CO2 lasers are also slower at cutting thin materials, and aren’t able to work with reflective metals ( brass, aluminum etc) to a good degree.

	28221 Beck Road A-2 – Wixom, MI 48393
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A housing made out of 6061 T6 aluminum, from a 9.5” x 13.88” x 14.88” block with a starting weight of 200 lbs. and a finished machined weight of about 18 lbs. “We could have never made this part or received this order if we did not have 5-axis capabilities,” said Costa.

New Age Metal Fabricating is a New Jersey-based defense contractor continually looking for ways to improve its manufacturing processes. Recently the company sought to further expand its capabilities while improving productivity and efficiency. New Age Metal quickly realized that 5-axis capabilities would “allow us to secure new work we could not currently produce, as well as reduce set-up operations and simplify fixturing,” according to Mario Costa Jr., Executive Vice President, New Age Metal Fabricating. The majority of the company’s manufactured/machined parts are ruggedized dip-brazed chassis and enclosures used in the defense and aerospace industries. One project is the Programmable Power Supply (PPS) for the Vertical Launch System (VLS) Program. The PPS is made up of 14 machined components that get dip brazed together and partially welded. It measures 26” x 21.5” x 9.5” and weighs just over 80 lbs. when completed. In addition to machining, brazing and welding, New Age Metal also installs specialty hardware and bushings, and also chem films (a chemical conversion coating to protect aluminum from corrosion), masks and paints the unit. (l-r) Mario Costa Sr., President, and Mario Costa Jr., Executive Vice President, New Age Metal Fabricating        “This project really stands out because of its complexity, size and weight; it also requires most of our manufacturing capabilities. It is the largest and heaviest part we braze and one of the largest and heaviest parts we have manufactured,” said Costa. The company’s work is primarily in 6061 T6 aluminum. To meet its most recent goals, and after considering many alternatives, the company decided that a Campro U255C and a Campro CPV-1050B with a rotary/trunnion table would be the ideal solution. According to Costa, “We were able to get a large new contract because of the capabilities the two Campros gave us. Also, we have been able to reduce set-up time as well as run times on existing work. We have moved parts to the Campro that we previously ran on a horizontal machining center and a vertical machining center, which eliminated twooperations and 2.5 hours of set-up and significantly reduced total machining time. The reduced handling and set-ups also increased accuracies and virtually eliminated scrap.” With 5- axis capabilities, Costa said they can also now take on work with contours and features which otherwise would be impossible to machine with a 3-axis machine.

“Having a machine with 30 in. of Z-axis travel, box ways and still having 1,200 IPM rapid traverse rates and 12,000 RPM gives our company the flexibility it needs for heavy machining as well as high accuracy work for the jobs we run for the aerospace and defense industries,” said Costa. “Using the latest FANUC PLUS controls, as well as Marposs part and tool probes, adds to our productivity and efficiencies.” Features/specifications of the Campro CPV-1050B include: This unit is part of the Armored Multi-Purpose Vehicle (AMPV) Program for the U.S. Army. The components are all machined and then dip brazed at the New Age Precision Manufacturing NY facility. The final finishing is done in-house using the CARC application. FANUC Oi PLUS Control AI APC Contour Control XYZ travels 42” x 20.9” x 30.7” Allowable table load: 2,200 lbs. Trunnion table: max. workpiece dia. 26.7”; max. workpiece weight 220 lbs. CAT 40 BIG PLUS spindle 12,000 RPM spindle 20 HP (30 min.) high torque spindle motor Twin arm 24 tool ATC Rigid Tapping   According to Bob Morrison, Managing Director of Campro USA, “Campro has been a leader in 5-axis machining since 2012. We recently introduced our second generation of 5-axis capable machines and continue to work with manufacturers to provide machine tools to assist in making parts more efficiently.”

As Seen in July 2021 MANUFACTURING NEWS

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This is the shop floor of Westminster Tool after its technology investment. Photo Credit: Westminster Tool

This is a shop we’ve covered a lot over the years—after winning MoldMaking Technology’s Leadtime Leader Award in 2014. Once again they are making moves to continue their growth trend, so I had to share this news when it hit my inbox.

Amidst the hardships and ambiguity of 2020, Westminster Tool’s injection mold department has consistently grown faster than ever before in response to the increased demands in medical device manufacturing. For Westminster Tool, that meant investing over 10% of revenue in updating, replacing, and expanding equipment across the shop to improve efficiencies and keep up with the demand.

Westminster Tool shop floor before recent investment in equipment.
Photo Credit: Westminster Tool

The area that saw the largest enhancement was the hard machining department. An area with a single Mikron HSM500 is now comprised of three high-speed 3-axis machines and one high-speed five-axis machine, increasing the shop’s milling capacity by over 400%. “The goal was originally to increase throughput by reducing our overall lead time,” says Ray Coombs, President of Westminster Tool, “but the benefits have already begun to make an impact in other ways.”

By adding more machining capabilities—including faster milling times and more advanced automation—Westminster Tool can bring in more work entirely, a significant result from the equipment’s improved efficiencies. “The five-axis capabilities, for example, open us to more intricate types of jobs because we can now hit complex geometries and angles difficult to achieve before,” Coombs says. “And this will have major long-lasting benefits for how we do business,” he adds.

The automation alone currently provides a promising impact on unattended time for all the new machines. The adoption of automated pallet handling not only promises to reduce setup time but makes lights-out operation possible for the company. Once up and running, the new Mikron HSM_400U LP’s pallet pool attachment will make it even easier for the machine to run almost entirely unattended.

With new equipment comes a larger equipment footprint, so the company embarked on a complete reconfiguration of the shop floor over the holidays. “We spent weeks planning and re-imagining what operations will look like here with the new equipment,” says Vice President, Hillary Thomas. “Shutting down the shop for a few days allowed us to move equipment and fully optimize the shop’s workflow.”

The big move placed all milling equipment in a single, centralized cell. It also included moving the electrode milling machines closer to the new 5-axis machine with hopes of combining the two departments by mid-year.

Aside from doubling their machining capacity, one of the company's most valuable experiences with the new equipment has been with its workforce. By freeing up more machines in the milling department experienced machinists have more time to train and cross-train other Westminster Tool employees. “Cross-training is a critical part of our culture here, but sometimes production requirements made it really hard to use the machines for that training,” says Thomas.

Previously the company had enough work to keep the single mill running 24/7, leaving few opportunities for training. The new machine has already allowed hard mill apprentice, Amy Skrzypczak, to double her training progress in just three weeks, a milestone that would have taken double the time.

These investments are just the beginning of Westminster Tool's plans for increasing automation and robotics throughout the company. In addition to COVID-related demand, the medical industry continues to progress year after year. And as the demand for high-precision medical molds grows, Westminster Tool plans to continue rising to the challenge and growing its market share.

Originally Published by Mold Making Technology: https://www.moldmakingtechnology.com/articles/westminster-tool-invests-10-of-revenue-into-new-machining-equipment

Erosion by spark creates cavities, fine finishes in complex parts

The sinker EDM's carbide probe locates the work area. The probe also can check tolerances of features that are burned before removing the finished part. 

Electrical discharge machining (EDM) is a unique process. The shapes and tolerances produced by this method are next to impossible to create using traditional machining techniques.

These abilities, combined with a high demand for complex parts from the automotive, aerospace, and medical sectors, are making EDM a must-have for modern shops. Die-sinker EDMs, in particular, often can solve the problems posed by machining materials such as high-nickel-content alloys used in the aerospace industry. Also, the complicated shapes and deep pockets commonly found in the mouldmaking industry are two part features that pose a challenge to CNC chipping machines. However, these geometries lend themselves well to the CNC die-sinking process.

These machines can produce both through-cavities and blind cavities using a graphite or brass electrode.

How It Works

Die-sinker EDMs work by using an electrical discharge to erode workpiece material. 

When electrical voltage is applied and becomes high enough, a breakdown of the dielectric occurs. The electrical current circulates through the ionized channel and the discharge is created. Thousands of these discharges are created per second, with the number and intensity affecting cut speed and surface finish. Control and generator technology make it possible to control the duration and the intensity of the discharge.

It's actually a six-part process:

1. A “bridge” is created between the part and the electrode.
2. A spark is created.
3. The spark creates heat.
4. Plasma is created around the spark that melts the material.
5. The spark is turned off and the area implodes on itself, removing material.
6. The dielectric fluid flushes the zone to start again.

When the control senses irregularities in the discharge or gap voltage, it changes the system's on-time, off-time, jump cycle, and servo gain to adjust the conditions in the cutting gap to minimize wear of the electrode.

The dielectric fluid's role is to help control the spark by maintaining a precise conductivity. The fluid also flushes away burnt metal from the erosion zone.

Electrode Importance

The EDM's electrode is as important to the success of the operation as the hardware and software. No erosion can take place without some sort of an electrode.

The electrode also serves as the model that produces the desired forms. A negative of the electrode's shape is created in the workpiece during the erosion process. For every negative feature on the electrode, a positive feature is produced in the workpiece and vice versa.

The sinker EDM's adaptive control enables the machine to adjust parameters as surface area flushing and discharge gap conditions change. 

In most cases, it also takes several electrodes with varying shapes to develop the part's final form. However, advances in orbiting can reduce the number of electrodes needed for the process.

Improving Productivity

Having a productive die-sink EDM process is relatively straightforward: Create the correct work environment, use up-to-date technology, and eliminate rework.

Improving productivity in die-sinker work might not be top of mind because of the complex nature of the work and because it's a little bit slower process, but it still can make a difference. And it all starts at the beginning.

“Having your machine set up and ready with the right electrode and the right material all at the same time may sound simple, but it's an important first step. Having to wait because one piece of the puzzle isn't ready is a major waste of time,” said Eric Ostini, head of business development, senior product manager – EDM, GF Machining Solutions, Lincolnshire, Ill.

It's also different for a shop that has one die sinker as opposed to an automotive supplier that may have a whole line of them. As the number of machines, electrodes, and electrodes per machine increases, so does the chance of an error.

Modern software and the elimination of manual inputs helps ensure that errors are reduced.

“It's easy to feel overwhelmed when you have 20 or 30 electrodes sitting on the workbench and you have to figure out where they all go,” said Ostini. “Following the CAD/CAM model really does help with this.”

A new addition to GFMS's software, the True Response to User Expectation (T.R.U.E) system, also aims to improve productivity by optimizing the entire process from electrode creation to cavity creation and even measurement.

According to Ostini, the CAD/CAM system analyzes the part's form and designs an electrode for which the ideal undersize (how much smaller the electrode is than the cavity it is creating) has already been automatically calculated.

During the job preparation sequence, the data gathered in CAD/CAM preparation is transferred for work order data generation, including manufacturing order and part identification. In the execution sequence, either for a stand-alone machine or for an entire production cell, the software ensures that the EDM process always uses real data based on the true geometry of the electrode and part.

The dielectric fluid's role is to help control the spark by maintaining a precise conductivity. The fluid also flushes away burnt metal from the erosion zone. Photo courtesy of GF Machining Solutions.

“What is being demanded more and more worldwide is to reduce the number of electrodes you need in order to produce the cavity,” said Ostini. “This means you need a generator that can adapt between speed and finish. You can program the generator for more accuracy than speed or finish. And today the need has been more towards low wear because if you do this, you can either use the same electrode over and over and over for cavities or use fewer electrodes per cavity.”

Using a CAD model reduces human error because there are fewer manual inputs as well.

“It's less likely that somebody types something in wrong like depth or the undersize if all the data involved in the process is already part of a CAD file,” said Pat Crownhart, national sinker EDM product manager, MC Machinery Systems, Elk Grove Village, Ill. “It speeds up the process and avoids errors.”

Once a part is set up on the machine, it's time to start producing the cavities.

Generator Technology

The EDM's generator technology creates sparks while controlling electrode wear and optimizing cutting speeds. On certain die-sinking EDM equipment, the technology manages the electrical current between the fronts and sides of electrodes and controls its delivery to minimize lateral sparking that disrupts effective machining of areas such as the sides of mould cavities. The system allows the electrode to have maximum power in the front of the cavity without destroying or creating oversize gaps on the cavity side walls.

“Spark size and shape is very important to the process,” said Crownhart. “There is a direct relationship between spark size, shape, and number of sparks and cut speed and quality. If you are generating a big spark, you may be generating 8,000 sparks per second, but if you're talking about a small spark, you're up to 40,000 sparks a second or more. Big sparks will remove larger amounts of material than small sparks, so it's important to be in control of these functions.”

The number of sparks and their shape are controlled by the EDM's amperage and on-time. These are adjusted to control speed and are also based on material type.

The right spark has to be tailored to the material being eroded, said Crownhart.

“Think of a spark like a tiny shovel removing material. The size and shape of your shovel is determined by what you are shovelling,” said Crownhart. “It's the same in this process. The size and shape of the spark also determines how much material you are removing, so it also determines the roughing and finishing of a part.”

Gap Distance

The material and size and depth of a cavity also affect the gap distance, which is the distance between the electrode and the part. Typically, this distance is around eight or nine thousandths of an inch. This gap distance during final fine finishing, however, can be as little as a 10 thousandths.

Multiple electrodes are used to create parts on a die-sink EDM. Photo courtesy of GF Machining Solutions.

Before the cavity is finished, an orbiting cycle is performed. This cycle uses small, weak sparks in combination with movement of the electrode to make the final part form. Electrodes are manufactured slightly smaller than the form to take this step into account.

On-machine Measurement

Today an EDM can use a touch probe system or use its electrode as a probing system to check for part location and dimensional accuracy. A part can be probed before it is machined to determine its exact orientation in the work tank and during the machining process to verify that the cavity has been burned to the proper size.

“A touch probing system is not as accurate as using the electrode to touch the part, but the benefit of touch probe is that, because electricity isn't being used, it won't mark the part,” said Ostini. “So, if I'm touching off on a shiny surface with an electrical touch, I will mark it with the spark that comes from the electrode.”

Using either a touch probe system or an “electrical touch,” you get some of the benefits of measuring on a CMM without removing the part from the machine.

“The measuring process can be automatic, meaning that it measures immediately after it's done producing the cavity. If it finds that it is still not the right size, it tells the machine to go back into the cavity with the electrode and do some more work,” said Ostini.

Originally published by Canadian Metalworking: https://www.canadianmetalworking.com/canadianmetalworking/article/metalworking/die-sink-edm-forms-complex-parts?utm_source=hootsuite&utm_medium=social_media&utm_term=&utm_content=&utm_campaign=post

For More Information on AgieCharmilles Sinker EDM Machines: https://www.peakedm.com/AgieCharmillesEDM.html#AgieCharmilles_SINKER_EDM

Editor Joe Thompson can be reached at jthompson@canadianmetalworking.com.

GF Machining Solutions, www.gfms.com

Featuring nine lasers and a large format build chamber measuring 1m x 1m x 600mm, the metal system will be used to address the ammunition, ground vehicle, helicopter, and missile defense needs of the Armed Forces. Alongside the system itself, 3D Systems is also developing complementary materials, software, and services to provide a more comprehensive product. Following Army installation, the machine will then be made available to select aerospace and defense companies, provided they benefit the U.S. Army in some way.

Stephanie Koch, ARL's Advanced Manufacturing, Materials, and Processes Program Manager, states: “When we embarked on this project, we needed a faster way to produce critical components for major ground combat subsystems. The progress that has been made on this project to date is monumental. We look forward to the coming months as we progress to a full-scale production solution that will enable innovative new capabilities for transformational overmatch.” 

The nine laser system will be used to fabricate metal parts for the Army's weapons systems. Photo via Dave McNally/U.S. Army.

Advanced optics for an advanced system

October 2020 saw the completion of the first test print on the new system. The machine features key components based on the ones found in the company's well-established Direct Metal Printing (DMP) series of 3D printers. This includes the optical train, which gives each of the nine lasers its own melt pool monitoring system, resulting in improved part quality control. Since a near identical optical system is employed, the new machine is also able to make use of the company's existing extensive qualified materials library.

3D Systems has also integrated six high contrast single-lens reflex (SLR) cameras into the machine's build chamber, allowing for in-situ monitoring. The cameras provide a top-down view, meaning the user does not need to go through an image manipulation process. Alongside the powder bed images, the system's firmware captures sensor data, positional data, and melt pool data and collates it all into an SQL database, enabling full part insight.

Chuck Hull, Co-founder and CTO of 3D Systems, adds: “3D Systems was founded on a spirit of innovation, and our customers play a key role in catalyzing this process. Our collaboration with ARL is allowing us to elevate our research and development efforts, achieving many industry firsts on our way to empowering the ARL to meet their goals. Our accomplishments through the first phases of this project will fuel the next, on our way to helping ARL scale their capabilities and bolstering their supply chain.”

The new system features parts based on this DMP Factory 350 metal 3D printer. Photo via 3D Systems.

Improved material efficiency

Unlike conventional PBF 3D printers, 3D Systems' machine operates on a selective powder deposition process, meaning it limits powder use by depositing material only where it is needed. The system's build chamber also features a heated plate, which serves to reduce thermal stresses and improve deposition quality.

Furthermore, the company's previously developed vacuum chamber concept has been integrated, whereby oxygen levels remain below 25ppm (as opposed to 500 – 1000ppm). As such, the machine consumes about a tenth of the argon comparable metal 3D printers may use, resulting in parts with high chemical purity, a higher proportion of reusable powder, and a lower cost of operation.

This is not the first instance of the Armed Forces having turned to 3D printing technology. Researchers from the US Army Aeromedical Research Laboratory have previously used 3D printing to produce and test customizable earplugs for its soldiers. The army scientists' novel technique for producing ear protection could be deployed to prevent hearing loss among soldiers on the battlefield.

More recently, the Army extended its digital twin teardown project, which originally involved disassembling a UH-60 Black Hawk helicopter to 3D scan each of its individual components. Announced in October, the project will now be used to fabricate spare parts for aircraft, tanks, and even provide VR training for members of the Armed Forces.

Learn more about the 3D Systems/GF Machining Solutions co-developed DMP Series of Metal 3D Printers Here: https://www.peakedm.com/AdditiveManufacturing.html

Originally published by 3DPrinterIndustry.com: https://3dprintingindustry.com/news/3d-systems-update-on-arl-funded-nine-laser-worlds-largest-metal-3d-printer-179086/

In the manufacturing industry, different production methods are used depending on the type of part created. While additive manufacturing has proven its worth, whether for rapid prototyping or end-use part applications, it is still a method that is often complementary to subtractive manufacturing processes. Indeed, current technologies do not yet allow for the design of large volumes and are often too slow. Additive manufacturing is preferred for parts with very complex geometries, small series, prototyping or tooling. However, it can be seen that more and more manufacturers are looking to combine the two production processes: known as “hybrid manufacturing”, it offers a number of advantages and is, in some cases, more viable from an economic view point.

Nevertheless, combining these two processes can generate some challenges. In most cases, the part is 3D printed and then post-processed and machined to obtain the final geometry or a better surface finish. This is often the case for very complex components that incorporate internal geometries, such as cooling channels, or anything that cannot be machined directly from a metal block. These geometries require steps such as supports removal, heat treatment, milling or even manual polishing to achieve a better finish. These are often time-consuming and expensive and should be kept to a minimum.

 

Hybrid cutting tool | Image via GF Machining Solutions

Therefore, the hybrid manufacturing process has been increasingly employed to create these so-called “hybrid” parts. This process consists not only of combining additive and subtractive technologies, but more precisely of printing directly onto a conventionally pre-machined preform. Indeed, metal 3D printing is a process that can be time consuming and costly. Therefore, industrialists are able to machine their preform and then create or add, thanks to additive manufacturing, characteristics that would be impossible to obtain using conventional processes. The result: reduced production time, limited costs, and retained technological benefits.

One of the limitations of this approach is the positioning of the preform in question. This is because the position of the preform, fixed on the printing plate, is difficult to identify. There is no mechanical link between the preform and the optical system, as can be the case in a milling machine, for example. So how can you print accurately on this preform? Many manufacturers rely on visual alignment or external coordinate measuring machines (CMMs). These methods are far from perfect, with a high risk of error and a significant lack of precision – the accuracy is only within 100 microns. What's more, it's a fairly time-consuming operation.

 

Preforms inside the DMP Flex 350 | Image via GF Machining Solutions

DMP Calibration Tool: a tool to facilitate hybrid manufacturing

To overcome this problem, GF Machining Solutions, an expert in metal additive manufacturing, has developed a tool with its partner 3D Systems, one of the pioneers in the market. Known as the DMP Calibration Tool, it reduces the number of errors made by operators, saving them a considerable amount of time. It is a software solution based on the monitoring functionality of the melting tank integrated into the DMP machine range, DMP Monitoring. This feature was originally designed to detect potential defects during the manufacturing process. However, GF Machining Solutions has diverted its main function. Dogan Basic, Product Manager at GF Machining Solutions explains: “The DMP Calibration Tool uses this light-sensing monitoring equipment for another purpose: scanning preforms to identify pre-machined positioning holes in the workpiece surface.” In practice, the laser scans the holes in the preform and sensors analyze the differences in light reflection. Thus, by triangulation and after correction of the orientation of the x, y and z axes by the software, the positioning of the preforms is known precisely. This process can be carried out very quickly and on several preforms at the same time. The risk of human error is also eliminated. This allows the user to additively add material to an already machined workpiece in a much more optimized way.

 

Diagram of the process described by GF Machining Solutions

On the application side, GF Machining Solutions says that this hybrid manufacturing approach will be of use to many industries including aerospace and medical, which produce complex parts in terms of internal structure, but also in the creation of tibial tray-type implants. These could be more geometrically accurate while being more suitable with each patient's body. Finally, the tool should be of particular benefit to manufacturers of mold inserts and dies.

Dogan concludes: “Cutting tools are another application example. Increasingly they are produced by hybrid manufacturing, involving a machined preform on which an additive section is printed. Hybrid methods are preferred because the preform has a geometry that is very simple to produce by conventional methods. The use of additive manufacturing on such tools creates complicated lubrication and cooling channels that would be difficult to produce with conventional machining. A lack of precision in additive manufacturing can lead to a large deficit in tool performance. This is why our unique reference solution is highly appreciated.” More information can be found on the GF Machining Solutions website HERE.

 

A mould designed through different manufacturing processes, including additive manufacturing | Image via GF Machining Solutions

 Originally published: https://3d-prints.com/2020/10/01/gf-machining-solutions-facilitates-the-manufacture-of-hybrid-parts/?utm_source=hootsuite&utm_medium=social_media&utm_term=&utm_content=&utm_campaign=post

GF Machining Solutions offers a complete AM solution for medical device manufacturers. PES hears about some of its latest additive advances.

Metal Additive Manufacturing (AM) – also known as metal AM or 3D metal printing – is becoming a driving force in the production of many of today's medical devices.

In fact, orthopaedic implants with porous surfaces and lattice structures mimicking the behaviour of normal bone, have led to significant improvements in patient outcomes – and implants with these features simply cannot be made without AM.

Moreover, it is not just implants that have new designs; surgical tools and instruments also benefit from simplified manufacturing processes, weight savings and ergonomic features that can only be made with AM. Not surprisingly, it is estimated that as much as 10% of all orthopaedic implants being introduced have at least one component made by AM.

As metal AM grows in importance, OEMs and subcontract manufacturing organisations of all sizes are investigating how to best integrate this technology in order to better meet their customers' needs.

With a complete end-to-end solution that brings customers high quality together with low running costs, GF Machining Solutions and 3D Systems recently launched the DMP Flex 350 to help ensure success when adopting this new technology.

Powder melting

There are various technologies for printing metals, but the dominant approach today creates solid material through the targeted melting of very fine metal powder. DMP Factory and Flex systems from GF Machining Solutions and 3D Systems use a laser-based process (selective laser melting) which can produce high-quality surface finishes and small features down to 0.1mm.

A key consideration when investigating metal AM technologies is the range of materials the respective systems can print, as well as the ability and speed to change (or not change) materials if necessary. For example, surgical instruments are most often made of stainless steel, while surgical implants usually require titanium.

If the manufacturing objective or priority is to fully load a 3D printer with different types of jobs, a flexible system allowing efficient material changes will be the natural choice.

The DMP Flex 350 has been engineered to allow a user to change the metal being printed in only a few hours. On the other hand, the DMP Factory series is designed for use with a single metal.

With the DMP Factory and DMP Flex versions of the system, manufacturers can invest in the technology that is right for them.

New innovation

When it comes to 3D metal printing, oxygen is the enemy. When metals such as titanium are in its presence, they degrade through oxygen uptake. GFMS' innovative design makes use of a sealed build chamber to create the optimal printing environment by evacuating all air from the chamber and replacing it with argon. This cycle is repeated three times before the build begins, removing both oxygen and any trace of humidity from both the chamber and the powder reservoir.

With this approach, GFMS says the oxygen level present during operations is around 25ppm (parts per million) compared to 300 to 700ppm of oxygen in other systems' build chambers (which most often have a continuous flow of argon entering the chamber). The results with this system are said to be better and more consistent product quality – build after build –with lower operating costs through both reduced argon consumption and a longer useful life for the metal powder.

A complete solution

Even with its many advantages, the DMP Flex 350 is just one part of the metal AM printing puzzle. Success also requires a product design adapted for 3D printing, a validated process, and the ability to integrate downstream operations. GF Machining Solutions and 3D Systems provide a full range of technologies, including both machines and automation systems for downstream processing.

One of the keys to GF Machining Solutions' approach is the use of System 3R pallets as a base within the DMP Flex 350.

Printed products can be transferred to secondary processing such as milling without the need for re-clamping or re-referencing, and with product manufacturing data secured via System 3R's radio frequency identification (RFID) chip.

GF Machining Solutions and 3D Systems have also introduced a wire-cutting Electrical Discharge Machining (EDM) system designed specifically for AM: the AgieCharmilles Cut AM 500 is claimed to be unique by the manufacturer in that it allows removal of product from the build plate cleanly and without cutting forces.

Taking a product from idea to design 3D print requires both experience and the appropriate software. 3D printing is a vertical process. The powder present in the bed cannot support the weight of the printed metal, so designs must be adapted to include support structures which can also prevent deformation due to thermal stresses arising during the melting process.

Build simulation software allows for the verification of the size and geometry of support structures; at the same time, training and design experience are also valuable assets.

GFMS' 3DXpert software offers simulation tools that consider wall thicknesses, weight and powder behaviour to ensure that supports are minimised and not obstructive, but still of sufficient size and strength to do their job.

As an advanced software package, 3DXpert also links the printer design, its Laser, and its powder characteristics. The result is a printing process that optimises the Laser path and the build strategy to ensure that the desired mechanical properties of the product can be achieved.

3DXpert is the key to both product design and defining the optimal printing strategy; it is a complete solution from CAD to the finished product.

In highly regulated, risk-averse sectors like medical device manufacturing, qualification and validation can represent big hurdles for a manufacturer. A validated AM process includes the entire ecosystem, from quality control processes for incoming powder to software, post-processing, and process controls on finished products.

Companies looking to bring AM into their production portfolio should carefully consider which supplier/partner has the level of experience and expertise.

As experts in metal AM as well as a broad range of other manufacturing technologies and with expert customer training and first-class customer services and support, GF Machining Solutions and 3D Systems are well qualified to help manufacturers integrate AM into a factory and master every step, from machine installation to manufacturing of AM devices.

Additive choices

The products end users plan to make will inform the choice of printing technology and the make and model of the printer will increase (or limit) flexibility in terms of materials and the products that can be made.

The technology and the printer design selected will also drive running costs up or down and influence the quality of the products made. In the final analysis, oxygen management in the system chosen will likely be the single biggest driver of both running costs and product quality, and it should be high on list of priorities when deciding which system to purchase.

Managing the changes metal AM brings to product design and understanding validation of the complete value chain – including post-processing steps – are also key. Training staff or hiring people with relevant experience and adapting internal processes are also important starting points.

As 3D printing continues to cement its place in medical device manufacturing, GF Machining Solutions and 3D Systems bring together the elements essential to a streamlined integration of the technology while delivering not only the system with the lowest running costs but an end-to-end solution that includes powder, software, expert application support, operator training, and customer services.

Originally published by Production Engineering Solutions: https://www.pesmedia.com/3d-printing-gf-machining-solutions-140420/

In industries where components are used in extreme environments, manufacturers have historically relied on investment casting processes to produce parts. However, with the advent of metal additive manufacturing (AM), those same manufacturers have discovered that many cast parts are more efficient to create with metal AM processes.

But how do shops determine whether investment casting, AM, or a combination of both processes will be the most efficient for their part-production operations? Both have advantages, but manufacturers around the world must consider a wide range of factors to determine which process best fits their needs.

Turbine rear vane built in 48 hours at AMotion Center, Stabio

In deciding between investment casting and additive manufacturing, the size of the part has generally been the deciding factor. The initial generations of metal AM technology featured relatively restrictive build areas, but this is changing. New, high-performance powder-based AM machines now feature much larger working envelopes, which makes the technology more competitive with investment casting processes by allowing for building much larger parts.

All shapes and sizes

Part materials also tend to determine what kind of process a manufacturer can use. Metal AM processes require rapidly heating and cooling materials, which generates an extremely refined grain structure. Casting, on the other hand, is capable of producing a single crystalline structure, which can be crucial to the integrity of high-temperature superalloys common in aero engines.

If a part can be built in an additive machine and will not be used in an extremely high-temperature application, metal AM should be considered as a cost-effective solution. This is particularly true when compared to investment casting, given that AM processes require no tooling. For the large, geometrically-complex parts, such as aerospace turbine rear vanes, casting tooling can quickly become expensive due to its size and precision.

The AMotion Center AM expert team, Stabio [Team]

Adding to the expense of investment casting are the long lead-times involved. Many shops rely on outside suppliers for castings, but even when they perform the work in-house, investment casting requires several time-consuming steps to prepare a mould for pouring. Conversely, metal AM part production is now as simple as programming the part with dedicated software, determining necessary supporting structures and launching the job. Although parts may take longer to build with this powder-based AM technology, machines can do so completely autonomously, meaning that large, seamless parts like turbine rear vanes can be completed more efficiently.

However, many manufacturers still believe metal AM technology is out of reach, as the initial or ongoing material costs and cost per part are thought to be too high. Others are concerned about the limited knowledge of AM technology or safety concerns regarding sensitive powdered metals. And while manufacturers recognise that AM represents the future of production, shops still need a partner that understands how to profitably integrate that futuristic technology into their existing workflow.

A sum of the parts

Fortunately, today's AM machines, such as GF Machining Solutions' DMP Flex 350, DMP Factory 350 and DMP Factory 500 significantly lessen or eliminate the concerns about AM technology. Designed to operate as a complete, integrated solution, the DMP series of AM machines, as well as part-separation solutions like the AgieCharmilles CUT AM 500 and software, such as 3DXpert, allow shops to overcome a wide array of manufacturing challenges, including control of part quality, cost, workflows and scalability. In doing so, it enables manufacturers to build higher quality parts, reduce total cost of ownership, simplify process workflows, and scale up production in a factory environment. High-performance laser solutions allow for fine-grained control for additive processes, even for parts built within the large 500 x 500 x 500mm build area of the DMP Factory 500.

GF Machining Solutions' AM technology also includes a suite of software designed to make additive part production accessible for all manufacturers. The 3DXpert software, developed by GF Machining Solutions' partner, 3D Systems, handles the entire AM workflow, from part design to post-processing, while DMP Monitoring enables real-time process optimisation. This helps shops quickly redesign parts to be ‘AM-friendly', setting them up to have the fewest possible support structures while maintaining the part's mechanical functionality and integrity.

Of course, the complex geometries and lightweight part features available with metal AM present difficulties when separating parts from the build plate. For example, when parts are separated using vertically-configured cut-off methods, such as conventional wire EDM or bandsaws, there's greater risk for the first part that is cut off among the group to fall in a way that damages the other parts around it. Therefore, GF Machining Solutions has also developed a way to handle AM part separation: the CUT AM 500 horizontal wire EDM machine.

Despite these advances in AM technology, there are still many applications that are more efficiently accomplished with investment casting, particularly as production volume increases even further. This casting method also allows for sophisticated part geometries and smooth part finishes that would be difficult or otherwise impossible with other types of casting.

When compared to AM, casting stands out for its material variety and vast size range. Even as additively manufactured parts get bigger, castings can be made as big as the available tooling, in theory. Likewise, it's ideally suited for nickel-based superalloys and other high-temperature applications. But this process requires significantly more expertise than today's simple AM systems, and most shops continue to have outside suppliers run their part production with finished tooling for a casting operation.

Whether casting or AM, shops must realise that both processes do not exist in isolation; they are part of a larger manufacturing workflow. So, whether incorporating an investment casting, AM or both processes, shops benefit greatly when they work with a supplier that can provide complete solutions to support both the upstream and downstream processes.

Typically, suppliers such as GF Machining Solutions and GF Casting Solutions, will provide support for a range of technologies, from high-speed milling, EDM and micro laser machining to laser texturing, automation, AM and casting. Their experts can work together with shops to construct turnkey systems designed to the customer's exact specifications.

A bedrock of knowledge

These services can be useful for shops inexperienced with AM technology or investment casting techniques, but even experienced shops can benefit from a partnership with an OEM like GF that offers assistance based on its extensive casting and AM knowledge. At the company's Centres of Competence, particularly its AMotion Center in Stabio, Switzerland, customers work collaboratively with company experts. These specialists assist with simulating processes and developing prototypes – and for challenging AM or investment casting processes involving novel materials or complex part geometries, even the most experienced shops can benefit from assistance with testing and optimising various part-production strategies.

Effective OEM partners will also be able to ensure the highest level of part quality. Both GF Precicast, its precision casting division, and the AMotion Center have Nadcap accreditation. When combined with the company's dedication to quality across its entire technology portfolio, this ensures customers will have access to the support they need to build or cast complete parts.

Whether the optimum process turns out to be additive manufacturing or investment casting, OEMs like GF offer support for both in terms of evaluation, technology and full part production as well as provide casting tests and certification. As a result, no matter whether a part is best handled with investment casting or metal AM, shops can receive the support they need from the earliest stages of an application to part validation and delivery.

www.gfcs.com

www.gfms.com 

Originally published Aerospace Manufacturing Magazine: https://www.aero-mag.com/pick-and-choose/

Cell 1 – Additive and subtractive manufacturing workflow
As additive manufacturing (AM) and laser micromachining become increasingly common, manufacturers need a way to easily integrate these technologies with their conventional subtractive machining operations. GF Machining Solutions has an example of just this form of integration: a three-machine cell comprised of the DMP Flex 350, AgieCharmilles CUT AM 500 and Mikron MILL S 400 U for fast, optimized hybrid part-production operations. 

The robust, flexible DMP Flex 350 enables the efficient 24/7 production of very dense, pure metal AM parts from tough-to-machine alloys, including Inconel, titanium, cobalt chrome, aluminum and steel. Short changeover times and streamlined 3DXpert® all-in-one parametric software allow shops to move quickly from 3D modeling to successful part printing, while the innovative CUT AM 500 uses an innovative tilting table and horizontal wire EDM to separate parts from build plates with lower running costs and higher part quality than conventional EDMs and band saws. 

To complete parts produced with metal AM as quickly as possible, even when unattended, GF Machining Solutions has included the MILL S 400 U in the cell, a high-speed full simultaneous 5-axis milling machine with an integrated 18-pallet changer, automatic table and workpiece cleaning system and a range of smart machining modules for advanced in-process monitoring. Both the additive and subtractive processes utilize the same type of System 3R tooling to expedite moving parts between machines and ensure the highest repeatability. 

Cell 2 – Lights-out automation
For the most demanding part-production applications, accuracy must be maintained over long periods of machining, even when left unattended overnight. In this second model cell, GF Machining Solutions highlights the long-term precision machining capabilities of three high-performance machine tools: the AgieCharmilles FORM S 350 die-sinking EDM, AgieCharmilles LASER S 1000 U laser texturing platform and Mikron MILL P 500 five-axis vertical machining center.

All three of these machines are capable of achieving micron-scale precision for the highest quality surfaces even during the longest machining cycles thanks to features such as integrated thermostabilization, rigid polymer concrete machine bases and software solutions such as Intelligent Spindle Monitoring (ISM), Smartpatch and Intelligent Speed Power Generator (ISPG). Even for exceptionally precise parts, these machines can deliver perfect repeatability all night long, every night, for lights-out automation that manufacturers can trust. 

Cell 3 – Standalone robot
To make the most of advanced manufacturing technology, even a single machine's productivity can be enhanced with the appropriate automation. In this model cell, the AgieCharmilles CUT P 550 Pro wire EDM solution is made even more productive with the addition of a System 3R WorkPartner 1+ (WPT1+), an automation solution that offers maximum magazine capacity in minimal floor space for unprecedented flexibility, making it easy for manufacturers to start with a single magazine and add one or two as required. 

This is ideal for the high-speed productivity of the CUT P 550 Pro, which provides 20 percent faster cutting speeds with 25 percent less wire consumption thanks to its Intelligent Power Generator (IPG) technology. To maximize its productivity during unattended machining – and leverage the flexible capacity of the WPT1+ – the wire EDM solution also features new Spark Track technology with Intelligent Spark Protection System (ISPS) for the most secure processes available in the EDM sector today. 

For even greater part-processing speeds, the CUT P 550 Pro will be compatible with the company's new Uniqua control. First previewed at the grand opening of GF Machining Solutions' new Biel, Switzerland-based milling machine factory in 2019, this innovative human-machine interface builds on the dynamic programming potential of the company's VISION Controls with EIA/ISO code compatibility, as well as a range of features designed to improve wire cutting speeds from 14-28 percent on CUT P series machines. The new control will be available in June. 

About GF Machining Solutions
GF Machining Solutions is the world's leading provider of machine tools, diverse technical solutions and services to manufacturers of precision molds and tooling and of tight-tolerance, precision-machined components. The key segments we serve include the aerospace, automotive, medical, energy, information and communications technology (ICT) and electronics industries. Our extensive portfolio ranges from Electrical Discharge Machining (EDM) solutions, three- and five-axis Milling machines and Spindles, 3D Laser texturing machines, Additive Manufacturing and machines for Laser micromachining to solutions for Tooling, Automation, Software and Digitalization – all backed by unrivaled Customer Services and support. GF Machining Solutions is a globally acting Division of the Georg Fischer Group (Switzerland) and maintains a presence at 50 locations worldwide. Its 3,358 employees generated sales of CHF 972 million in 2019.

Originally published on ThomasNet: https://news.thomasnet.com/fullstory/achieve-optimized-manufacturing-workflows-with-gf-machining-solutions-40037344

Spark Track is GF Machining Solutions latest EDM software monitoring system that adjusts the rate and intensity of sparks along the length of the wire and, in doing so, prevents heavy wear from occurring at any point on the wire – extending its life and preventing breaks.

At the heart of the innovation is GF's generator technology – specifically its high-performance ISPS (Intelligent Spark Protection System) module – which accurately identifies the intensity and location of sparks along the wire and, when necessary and required, adjusts current and voltage rates to prevent concentration of wear on the wire.

Spark Track provides comprehensive and real-time spark distribution information to manufacturers, enabling them to push their EDM machines to the limit.

Martin Spencer, managing director at GF Machining Solutions UK says: “The ISPS module eliminates wire breakage regardless of machining conditions and, as such, makes manufacturers' wire EDM processes more reliable and secure.

Spark Track solves problems such as wire oscillation which can occur when machining different heights and tapered surfaces, and can lead to wire breaks and damaged workpieces.

“Superior wire cutting performance is achieved when discharge distribution, along the wire, is as uniform as possible. Spark Track enables this to occur,” Mr Spencer continues.

ISPS and Spark Track, working in combination, not only prevent wire breaks they also, as a consequence, eliminate time intensive resets and reduce the amount of time an operator has to devote to a given job. They also help extend wire life.

Other recent developments introduced by GF Machining solutions to better regulate the spark output of its machines include: the standardisation of high-performance generators across all of its EDM machines; and the redesign of its machines and the positioning of its generators to place them as close to the wire as possible.

This makes the machines more responsive and able to react quickly to inputs from the control by reducing the distance computer signals and sparks need to travel.

Originally published by PESMEDIA.com - July 13, 2020 - https://www.pesmedia.com/gf-machining-solutions-wire-edm-13072020/

True, wire and sink EDM does generate a storm of electrical activity, as well as temperatures that rival those found in the sun's atmosphere, but this volatility occurs beneath the surface of the water or oil-filled tank, or deep inside a workpiece. As a consequence, determining what is going on in the EDM process in real time, or at any given time for that matter, has always been open to speculation.

This situation has changed with GF Machining Solution's Live Remote Assistance (LRA) facility – a machining solution that incorporates the Industrial Internet of Things (IIoT) and part of the company's rConnect central communications platform – which not only gives customers the ability to observe and record every minute detail of the EDM process, but enables them to initiate maintenance operations remotely from the machine's control.

Martin Spencer, managing director at GF Machining Solutions UK explains: “LRA gives us direct access to the machine's control. A customer, when they want to access the service, pushes a button on the user interface and this sends a message to our support center. Once we have confirmed our credentials – essentially confirming who we are – and given access to the machine's control, we are able to perform a range of diagnostic and preventive maintenance operations remotely.”

These operations include a whiteboard facility where a service engineer can pull up and access a service document, and then highlight a specific area of interest or concern for the customer to review.

The system enables the customer, via a plug-in headset, to talk directly to the service engineer and, if a Windows-based tablet is available, its camera can be activated to provide the engineer with eyes on the ground, allowing them to inspect the machine virtually e.g. peek inside the machine's electrical cabinet or to check the status of the machine's various LED indicators.

For more complex repair and maintenance situations the GF Machining Solutions rConnect facility can be used by onsite service engineers to liaise directly with engineers at the support centre. The result being faster and more efficient and effective customer support.

LRA also provides a user interface that the customer can use internally to check the machine's status from the front office (instead of the machine shop), or review upcoming maintenance activities.

There is more to IIoT than maintenance, and GF Machining Solutions uses it to provide real time monitoring of the EDM machining process, allowing customers to record and access the resulting data.

Mr Spencer says: “This is an important development for aerospace and medical customers where traceability is critical.”

IIoT functionality has also made inroads into wire EDM consumables.

“We've created a system that can read RFID tags placed inside the wire spool,” says Mr Spencer. “When you place the spool in the machine it is constantly reading and updating the information stored there. This facility has a number of benefits. For example, you can tell how much wire is left on a spool, when the wire was manufactured and where it was purchased. This eliminates the possibility of running out of wire during a job or that the wrong spool or type of wire gets used.”

As IIoT gains more acceptance and traction it's clear that more enlightened manufacturing companies will see it as a ‘need to have rather than a ‘nice to have' technology.

Production managers can see what assets are running, what is being worked on and what is next in line. Machine tool operators and programmers have easy access to everything needed to do their jobs, and can take the proper corrective action if something goes awry. And when such an action is taken, the steps are recorded so there are no more knowledge silo issues.

Best of all, management has a clear view of the operating costs. Taking on a rush order is no longer a nail-biting experience. Scheduling is more accurate, uptime increases, and quality improves. The company becomes a data-driven organisation, one that uses facts to make continuous improvement decisions, rather than assumptions or best guesses.

Mr Spencer concludes: “It won't be too long before, using sophisticated sensor technology, that variables such as a dielectric's pH and temperature (as well as other parameters that affect quality and productivity) will be recorded in real time giving manufacturers the ability to access and analyse data, and make changes and improvements to their processes. The IIoT is here to stay and GF Machining Solutions is at the forefront of its development and use.”

GF Machining Solutions

Originally published by Production Engineering solutions - January 2019: https://www.pesmedia.com/edm-gf-machining-solutions-internet-of-things/

The Microlution ML-5 is optimized for micro-scale holemaking and fine cutting without creating heat-affected zones. The machine's compact, high-performance femto laser is engineered to reduce cycle times and tooling costs to enable the production of precision parts in seconds.

"The combination of quick acceleration, enhanced stability, precise part handling and motion control with integrated part characterization and measurement provide precise machining with increased accuracy, speed and quality," said the spokesperson. "The Microlution ML-5 brings new designs and products to life-from more efficient automotive fuel injectors and complex watch parts to highly precise medical catheter tips and micro-crack-free holes for mobile devices' hardened glass screens."

The platform offers up to five axes of motion and supports multiple laser types for ±1 µm positional accuracy and ±0.5 µm repeatability. Its high-precision beam delivery system is supported by a precision-ground natural granite base and granite-mounted ironless rails. The Microlution ML-5 also features high-precision linear motors and high-resolution Heidenhain glass scale encoders along with an in-line workpiece touch probe, integrated power meter and high-speed optical camera.

Learn More or Request Quote Here: https://www.peakedm.com/m7/Microlution%20ML-5--microlution-ml-5.html

_{Originally Published by Manufacturing News: https://mfgnewsweb.com/archives/1/56493/Drilling-Tapping-Threading-apr20/Fast-Laser-Micromachining.aspx}

_{Published April 21, 2020 - 10:30am - https://www.ctemag.com/news/articles/magnets-save-spindle-life}

A spindle protection system based on magnetic force could exert a pull on part manufacturers experiencing costly machine crashes.

If a collision occurs during heavy-duty cutting, a machine spindle can be subjected to tons of force. Besides breaking a spindle, a crash can damage a tool and workpiece and result in significant machine downtime.

The chances of a collision are greater than normal during the initial phases of a machining process. At these times, crashes can be caused by setup mistakes and programming errors in tests of new CNC programs.

“Programs for CNC mills are made up of thousands of instructions, and there is a high risk of something not being perfect,” said Dante Payva, New England sales manager for GF Machining Solutions LLC, Lincolnshire, Illinois. “If something is not correct and the machine makes an unexpected move, it could damage the spindle.”

Preventing damage caused by collisions is the aim of the Machine and Spindle Protection system developed by GFMS. The self-contained MSP system relies on permanent magnets in the spindle housing. During standard machining operations, the strong magnets hold the spindle in position. In the event of a collision that generates sufficient force, however, the magnets disengage, allowing the spindle to deflect either to the side or into the machine's z-axis housing. At the very outset, he explained, this disengagement is detected by location sensors that trigger emergency braking action within nanoseconds, bringing the machine to a stop. The idea is to halt the machine before the spindle moves far enough to break, as illustrated below.

A crash involving a machine spindle (left) can cause costly damage and downtime. The MSP system, however, allows a spindle to deflect after a collision, giving the system extra time and distance to take emergency braking action before a spindle breaks. V is the linear spindle velocity during a machining operation. Breaking distance is the amount of spindle movement after a collision that causes breakage. Image courtesy of GF Machining Solutions

The system normally activates when a machine is operating in a setup or safety mode that lowers the maximum feed rate.

“Typically, you'd have the system on during the testing or prove-out phase of your new program or process,” Payva said. “Once you have run it once or twice and feel confident about it, the risk decreases substantially. Then you can turn the system off, and the machine would go back to its max feed rate.”

However, some shops always leave the system on for constant protection, he said, at the cost of a small amount of the feed rate they otherwise could achieve.

If a collision occurs, the system can reduce the resulting force on a spindle by 90%, according to GFMS. The system protects spindles in all five axes of machine motion.

“Many other systems protect the machine and spindle from a crash in the direction of the spindle axis,” Payva said. “But with our system, you can crash in any direction, and it has the same safety impact.”

He said other protection systems take the brunt of collision energy and thereby damage themselves to prevent a spindle and other machine components from being damaged. So even if they do their job, those systems need to be replaced after a crash, resulting in machine downtime and added costs for users.

By contrast, the MSP system doesn't need to be replaced after a crash.

The magnets and spring action bring the system back to its original position, “and it's ready for another crash immediately,” Payva said.

In addition, the system does not wear and requires no maintenance.

The system is currently an option for three GFMS mills.

“The option pays for itself after the first crash,” Payva said. “Spindles cost between $20,000 and $40,000, so you could easily have at least $20,000 of damage” in the event of a crash.

Adding to the risk of spindle crashes is the shortage of skilled machine operators.

“Companies are investing in high-performance machine tools and then handing them off to people who may not have all the capabilities needed to operate them,” Payva said.

Under such circumstances, opting for the system “is a nice way to protect yourself,” he said.  

Learn more about the machines that feature MSP: https://www.peakedm.com/Performance5AxisMilling.html

GF Machining Solutions offers a complete AM solution for medical device manufacturers. PES hears about some of its latest additive advances.

Metal Additive Manufacturing (AM) – also known as metal AM or 3D metal printing – is becoming a driving force in the production of many of today's medical devices.

In fact, orthopaedic implants with porous surfaces and lattice structures mimicking the behaviour of normal bone, have led to significant improvements in patient outcomes – and implants with these features simply cannot be made without AM.

Moreover, it is not just implants that have new designs; surgical tools and instruments also benefit from simplified manufacturing processes, weight savings and ergonomic features that can only be made with AM. Not surprisingly, it is estimated that as much as 10% of all orthopaedic implants being introduced have at least one component made by AM.

As metal AM grows in importance, OEMs and subcontract manufacturing organisations of all sizes are investigating how to best integrate this technology in order to better meet their customers' needs.

With a complete end-to-end solution that brings customers high quality together with low running costs, GF Machining Solutions and 3D Systems recently launched the DMP Flex 350 to help ensure success when adopting this new technology.

Powder melting

There are various technologies for printing metals, but the dominant approach today creates solid material through the targeted melting of very fine metal powder. DMP Factory and Flex systems from GF Machining Solutions and 3D Systems use a laser-based process (selective laser melting) which can produce high-quality surface finishes and small features down to 0.1mm.

A key consideration when investigating metal AM technologies is the range of materials the respective systems can print, as well as the ability and speed to change (or not change) materials if necessary. For example, surgical instruments are most often made of stainless steel, while surgical implants usually require titanium.

If the manufacturing objective or priority is to fully load a 3D printer with different types of jobs, a flexible system allowing efficient material changes will be the natural choice.

The DMP Flex 350 has been engineered to allow a user to change the metal being printed in only a few hours. On the other hand, the DMP Factory series is designed for use with a single metal.

With the DMP Factory and DMP Flex versions of the system, manufacturers can invest in the technology that is right for them.

New innovation

When it comes to 3D metal printing, oxygen is the enemy. When metals such as titanium are in its presence, they degrade through oxygen uptake. GFMS' innovative design makes use of a sealed build chamber to create the optimal printing environment by evacuating all air from the chamber and replacing it with argon. This cycle is repeated three times before the build begins, removing both oxygen and any trace of humidity from both the chamber and the powder reservoir.

With this approach, GFMS says the oxygen level present during operations is around 25ppm (parts per million) compared to 300 to 700ppm of oxygen in other systems' build chambers (which most often have a continuous flow of argon entering the chamber). The results with this system are said to be better and more consistent product quality – build after build –with lower operating costs through both reduced argon consumption and a longer useful life for the metal powder.

A complete solution

Even with its many advantages, the DMP Flex 350 is just one part of the metal AM printing puzzle. Success also requires a product design adapted for 3D printing, a validated process, and the ability to integrate downstream operations. GF Machining Solutions and 3D Systems provide a full range of technologies, including both machines and automation systems for downstream processing.

One of the keys to GF Machining Solutions' approach is the use of System 3R pallets as a base within the DMP Flex 350.

Printed products can be transferred to secondary processing such as milling without the need for re-clamping or re-referencing, and with product manufacturing data secured via System 3R's radio frequency identification (RFID) chip.

GF Machining Solutions and 3D Systems have also introduced a wire-cutting Electrical Discharge Machining (EDM) system designed specifically for AM: the AgieCharmilles Cut AM 500 is claimed to be unique by the manufacturer in that it allows removal of product from the build plate cleanly and without cutting forces.

Taking a product from idea to design 3D print requires both experience and the appropriate software. 3D printing is a vertical process. The powder present in the bed cannot support the weight of the printed metal, so designs must be adapted to include support structures which can also prevent deformation due to thermal stresses arising during the melting process.

Build simulation software allows for the verification of the size and geometry of support structures; at the same time, training and design experience are also valuable assets.

GFMS' 3DXpert software offers simulation tools that consider wall thicknesses, weight and powder behaviour to ensure that supports are minimised and not obstructive, but still of sufficient size and strength to do their job.

As an advanced software package, 3DXpert also links the printer design, its Laser, and its powder characteristics. The result is a printing process that optimises the Laser path and the build strategy to ensure that the desired mechanical properties of the product can be achieved.

3DXpert is the key to both product design and defining the optimal printing strategy; it is a complete solution from CAD to the finished product.

In highly regulated, risk-averse sectors like medical device manufacturing, qualification and validation can represent big hurdles for a manufacturer. A validated AM process includes the entire ecosystem, from quality control processes for incoming powder to software, post-processing, and process controls on finished products.

Companies looking to bring AM into their production portfolio should carefully consider which supplier/partner has the level of experience and expertise.

As experts in metal AM as well as a broad range of other manufacturing technologies and with expert customer training and first-class customer services and support, GF Machining Solutions and 3D Systems are well qualified to help manufacturers integrate AM into a factory and master every step, from machine installation to manufacturing of AM devices.

Additive choices

The products end users plan to make will inform the choice of printing technology and the make and model of the printer will increase (or limit) flexibility in terms of materials and the products that can be made.

The technology and the printer design selected will also drive running costs up or down and influence the quality of the products made. In the final analysis, oxygen management in the system chosen will likely be the single biggest driver of both running costs and product quality, and it should be high on list of priorities when deciding which system to purchase.

Managing the changes metal AM brings to product design and understanding validation of the complete value chain – including post-processing steps – are also key. Training staff or hiring people with relevant experience and adapting internal processes are also important starting points.

As 3D printing continues to cement its place in medical device manufacturing, GF Machining Solutions and 3D Systems bring together the elements essential to a streamlined integration of the technology while delivering not only the system with the lowest running costs but an end-to-end solution that includes powder, software, expert application support, operator training, and customer services.

GF Machining Solutions

_{Originally Published by Production Engineering Solutions: https://www.pesmedia.com/3d-printing-gf-machining-solutions-140420/}

 

The HSM 200U LP machining center from GF Machining Solutions is available in three- and five-axis versions bringing speed, efficiency and precision to the machining of small medical components.

The HSM 200U LP machining center from GF Machining Solutions is available in three- and five-axis (full simultaneous) versions for machining small, complex medical components such as stainless steel denture bars and orthopedic implants. Its compact size allows the machine to fit into facilities such as dental labs and other shops where floor space is at a premium, the company says.

The machine is said to generate part surface finishes as fine as 0.05 µm Ra thanks to linear motor technology in its main machine axes and direct-drive motors for the B and C axes. The 50,000-rpm, 11.4-hp Step-Tec spindle also contributes to precise part details and smooth surface finishes, according to the company.

Paired with optional Mikron pallet magazines with System 3R and Erowa interfaces, the HSM 200U LP can provide unattended 24/7 machining for increasing the output of existing workforces. 

A Heidenhain iTNC 530 control system and smart machining modules provide advanced machine monitoring. The system automatically checks and evaluates tools and workpieces, inspects tools for breakage, and performs measurements of the workpiece. 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 3D geometry errors caused by inaccurately measuring those tools, the 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 micron range.

_{Originally published by Modern Machine Shop: https://www.mmsonline.com/products/gf-machining-solutions-mikron-hsm-200u-lp-designed-for-small-medical-shops}

Wire EDM - productivity increase of up to 25% thanks to the absence of wire breaks (reliability); Time savings through higher cutting speed, constant and optimal eroding performance.

What is the degree of innovation of the nominated procedure?

Breakthrough in EDM wire cutting technology

How important is the nominated process for industry?

Significant increase in process performance in terms of speed, precision and surface quality

What are the economic successes of the nominated procedure?

Productivity increased by up to 25% thanks to the absence of wire breaks (reliability); Time savings through higher cutting speed, constant and optimal eroding performance.

What is the WOW effect of the nominated procedure?

Real-time control of the energy density on the wire, when a deforestation concentration takes place, the energy is reduced.

Real-time display of the discharge position in the workpiece. 3D representation in color of the power density (heat-affected zone) of the cut web (Industry 4.0: traceability).

Description of the nominated procedure:

The spark erosion process is a stochastic process because discharges occur in the gap between the electrode points where there is the least electrical resistance. A lot of research has been done in the past to optimize this process. Since wire discharge erosion (WEDM) takes place on a wire, it is in principle possible to determine the location of the discharge in real time if the machining current pulses are measured from two sides of the workpiece (wire input, wire output). This theory has been proposed by several authors in the past. Since the required control systems were not available at the time, implementation has so far been impossible. Due to the recent improvement in electronics, GF Machining Solutions AgieCharmilles has managed to to realize this utopia. Reliable detection of the place of unloading is possible!

How it works: The current from the generator is led to the wire through 2 cables, an upper and a lower feed path. The total current is divided into two partial currents I20 and I30. Both currents are measured separately and then subtracted. The current difference signal is assigned to a discharge position on the wire.

For example, if the discharge occurs at medium level, the current divides evenly between the upper and lower currents and their subtraction is zero. In practice, we know in real time where each discharge along the wire (and also on the workpiece according to the x, y, z coordinates) takes place. This functionality has many interesting effects:

• Cutting speed increase, reduction of wire consumption
• Create a model of wire shape and wear in real time and adjust the feed speed of the wire

Use of the wire as a geometry
measuring device : If the discharge distribution is known, the workpiece curvature can be derived. This makes it possible to detect the curvature of the workpiece and to improve the straightness by adjusting the generator parameters in order to adapt the electrostatic and electromagnetic forces acting on the wire.

Converting a stochastic process (EDM) into a deterministic process, i.e. active discharge control, by distributing the discharges according to a predefined pattern, by observing the position of a pilot discharge using the Spark Track and releasing the main discharge only if this is desired.

Creation of a three-dimensional model of the thermal stress caused by the process due to the discharges and prediction of the heat affected zone on the workpiece.

Originally posted:https://www.visit.prodex.ch/de/showcase/de/spark-track-von-gf-machining-solutions-international-sa-ca-design

This technology is available on the AgieCharmilles CUT P and CUT S/X Series of Wire EDM Machines. Learn More about them here: https://www.peakedm.com/AgieCharmillesEDM.html

Bill Berry, President and Owner of Die-Tech & Engineering (DTE) in Wyoming, Michigan, took on a complex die project from in Minneapolis, Minnesota, for a component that is critical to current ventilator production.

Die-Tech and Engineering and Twin Cities Die Casting are just two of the many American manufacturers coming together to help our nation through the COVID-19 crisis. Die Tech and Twin Cities Die Casting are working to help Ventec, a leading supplier of ventilators, to quickly ramp up production. Die-Tech is currently working on tooling for 10 more parts. While quoting the job on Friday, March 20, 2020, Berry was already arranging to get the steel for the die. It was delivered overnight and in production by 2 AM Saturday morning. His team continues to work through the night to get the job done--including last-minute mold design changes! The job is completed and delivered as of March 25, 2020. And, it's important to note that a job of this scope is normally 8 weeks or more. Berry believes that the combined creativity and innovation of American manufacturers is pivotal to the quality of life and security we enjoy today.

_{Originally Published by MoldMaking Technology: https://www.moldmakingtechnology.com/blog/post/moldmakers-stand-and-deliver-during-coronavirus-outbreak-}

At this year's Medical Design & Manufacturing (MD&M) West 2020, GF Machining Solutions demonstrated its MIKRON HSM 200U LP (linear performance) milling machine with pallet changer (PCH) and AgieCharmilles CUT E350 wire EDM. Both high-productivity, high-precision machines represent two key operations within GF's complete line of medical component processing solutions that provide medical manufacturers with a single source for all their part production needs. Also included in GF's medical solutions are laser texturing, additive manufacturing, micro laser machining, and modular pallet technologies.