Manufacturing Industry News

GF Machining Solutions, the EDM, milling and laser texturing machine tool manufacturer and automation and tooling systems specialist, has supplied leading precision subcontractor Thomas Brown Engineering with a new high-performance 5-axis machine.

 

The Mikron Mill P 500U was installed at the company's 20,000ft² facility in Huddersfield in January 2019 and is being used to machine precision components for customers operating in the aerospace, medical, automotive, robotics, food processing, oil and gas and steel manufacturing/processing sectors.

The components machined on the Mill P 500U are diverse and varied. Typical materials machined include aluminium, steel, stainless steel and Inconel, and batch volumes are mainly in the low to medium range.

The components machined on the Mikron are characterised by their accuracy and impressive surface finishes with a 20µm geometric tolerance and a Ra 0.2µm surface finish requirement being the rule rather than the exception.

“The sectors where we operate are competitive and demanding,” managing director Tom Brown begins. “Quality is non-negotiable and ever-stringent delivery times are increasingly prevalent. To meet customer demands and survive in these environments you need to be committed to continuous improvement and continually raise your game.

“By investing in the latest and most advanced machine tool technologies and by combining our manufacturing prowess with excellent customer service, we have found that we have been able to grow our business.”

Growth and change

Thomas Brown Engineering was established in 1983 the current owner. Over the last 35 years the company has grown steadily from being a one-man band to a business that now employs 20 members of staff. Other changes in the company have been even more noticeable – and dramatic.

“When the company was created it operated out of a couple of old garage units. Mr Brown continues. “As a fledgling engineering subcontractor, we were at that time, relying on a couple of used manual machines to machine parts and to make a living.”

Today, in stark contrast to these early days, the company has 14 CNC machine tools at its disposal and is looking to increase its floorspace (by the end of the year) by an extra 4,000ft².

The company's customer profile and customer base has also changed significantly.

“We are a Tier 2 supplier in the sectors where we operate,” Mr Brown explains. “The investment we have made in a plant, people, technologies, systems and processes has enabled us to consolidate our position in these sectors with existing customers, and also win new contracts and new customers.”

This is exemplified by the company's position in aerospace sector where its AS 9100 accreditation has been instrumental in achieving a number of new contract wins.

This increase in demand for the company's engineering services did, however, create some production issues resulting ultimately in the decision to invest in the new Mikron Mill P 500U.

“We audited and reviewed our machining strengths and weaknesses and identified where the pinch points existed,” Mr Brown comments. “The exercise helped determine that we needed to increase our 5-axis milling capacity and capabilities as a matter of some urgency.

“We had previously invested in a Mikron HPM 450U 5-axis machine some years earlier and the machine had served us well. We particularly liked the machine's built-in automation and the way in which its integrated automatic pallet changers have helped us increase our productivity and efficiency and reduce our operational costs.”

Meeting the standards

The company drew up a list of technical and performance requirements for the new machine and benchmarked these against the 5-axis machines in GF Machining Solutions' portfolio but it soon became clear that the Mill P 500U was the preferred choice.

The Mill P 500U is an ultra-high-performance, simultaneous 5-axis machining centre that offers powerful and dynamic material removal capabilities, thermal stability and high stiffness, to deliver excellent precision and surface finish on complex parts.

The machine features a thermo-stable and symmetrical design, so that even when machining at a fast pace and over long production runs, accuracy and process reliability remain high and consistent.

The machine delivers fast acceleration (1.7g) and is equipped with a formidable, high-torque 36kW Step-Tec motor spindle with fast acceleration. Productivity is enhanced by its in-built automation which comprises a 215 position ATC and possible 12 pallet APC.

Twists and turns

The company also wanted the machine to be able to perform interpolation turning operations. Interpolation turning is a machining technique developed for advanced machining centres and B-axis multi-task machines. It enables a turning operation to be carried out by interpolating the X- and Y-axis in a circular direction and rotating the machine spindle in time with the rotational contour.

The circular movement can either increase or decrease in diameter to produce facing operations or be combined with the Z-axis to produce a bore or outer diameter.

“The Mill P 500U is a great machine. It is accurate, fast and flexible. We mainly use the machine for 3+2 positional 5-axis machining operations as opposed to full simultaneous 5-axis machining and its performance to date, no matter what we've asked it to do, has been exceptional,” Mr Brown concludes.

 

Thomas Brown Engineering
https://thomas-brown-engineering.co.uk

GF Machining Solutions

Peak Machine Sales

 

 

_{Originally Published by Production Engineering Solutions: https://www.pesmedia.com/thomas-brown-engineering-mikron-5-axis-milling-gf-machining-solutions/}

To meet the demands of mold and die machining, GF Machining Solutions has unveiled the Mikron HSM 500 Graphite high-speed milling machine.

 

GF Machining Solutions offers the AgieCharmilles Cut C 350 and Cut C 600 wire EDMs for U.S. manufacturers that want higher performance with lower operating costs.

GF Machining Solutions offers the AgieCharmilles Cut C 350 and Cut C 600 wire EDMs for U.S. manufacturers that want higher performance with lower operating costs. The company says the machines provide optimized cutting speeds and reliable accuracy, while their AC Cut HMI 2 interfaces ease programming through efficient EDM expert modules.

Both models offer manual-mode setup for access to main functions, enabling operators to perform manual measurements and machining. A low-maintenance design reduces the number of components and consumable parts in order to lower operating costs. Along with an integrated anti-collision protection system, the machines include linear glass scales and encoders for high production accuracy.

Easily accessible wire spool holders enable fast and easy changes, the company says. Automatic threading systems thread hard, soft, coated or uncoated wire for reliable lights-out manufacturing.

Both the Cut C 350 and Cut C 600 operate with digital Intelligent Power Generators (IPG) for optimized cutting speeds. With the IPG, the machines can generate surface finishes of 0.25 micron Ra in carbide and 0.30 micron Ra in steel. Additionally, several Expert Intelligent technologies manage surface quality and part precision while streamlining overall operation, according to the company. For wire breakage prevention on variable-height parts, the Power-Expert intelligent function automatically selects power levels. Corner-cutting strategies automatically adjust machining parameters during changes of cutting direction to create accurate sharp angles and small radii.

 

File and project management features enable operators to configure and sequence jobs, follow job progress, manage digital project documents and access the AC CAM Easy programming system for autonomous operation.

 

_{Originally Posted in Modern Machine Shop 4/23/2019: https://www.mmsonline.com/products/agiecharmilles-cut-c-350-and-600-wire-edms-deliver-cost-effective-performance}

GF Machining Solutions offers Spark Track technology for wire-cutting EDM. Spark Track, powered by the company's Intelligent Spark Protection System (ISPS) module, prevents wire breakage that occurs when cutting irregularly shaped workpiece features. With Spark Track technology and the ISPS module, wire EDM users gain secure and uninterrupted EDM processing, improved machining efficiency and ease of use for operators.

 

Check out the machines here:

AgieCharmilles CUT E Series - High-Efficiency

AgieCharmilles CUT P Series - High Perfromance

The Spark Track technology, which won the 2019 Prodex Award that honors pioneering products, harnesses modern electronics – sensor signal, speed and effectiveness – to constantly monitor the spark distribution along the EDM wire. Based on the spark data gathered, the ISPS analyzes and automatically recognizes shape changes and adapts machining parameters accordingly to prevent wire breakage during roughing. As a result, irregular shapes such as cavities, varying heights, taper surfaces and sharp corners are roughed without the need for operator intervention to set up machining conditions in advance. As a result of the highly secure EDM process enabled by Spark Track, customers can benefit from 100% automation, which in turn reduces the cost per part.

Angled part surfaces are a prime example of where Spark Track and the ISPS module bring high efficiency to the wire EDM process. Such tapered surfaces can create non-homogenous flushing conditions at a wire EDM's upper nozzle, disrupting the machining process. The ISPS module eliminates the need for the machine operator to adjust the machining process to accommodate such difficult machining conditions since the technology analyzes the spark distribution data, automatically recognizes the shape change and adjusts the process to increase machining efficiency.

A strategy for machining details when the part geometry falls across multiple workpiece materials

 

“Can I die sink EDM two different workpiece materials at the same time?” is a frequently asked EDM question, especially in mold manufacturing where tool steels and copper alloys are often involved. Although plastic injection production molds are typically made from common tool steels, copper alloy inserts are common in detail areas to dissipate heat and improve molding cycle times. The challenge mold builders face is machining the details when the part geometry falls across both materials. Machining these materials separately requires multiple part setups (one for the tool steel and one for the copper alloy) and additional electrodes for separate burns with different EDM operations. This approach increases machining time for both electrodes' fabrication and EDM, which leads to higher manufacturing costs. Also, all this added effort could result in the two details not matching up in the mold correctly, causing a mismatch or an out-of-tolerance part that would then require additional machining, or possibly the remanufacturing of the detail inserts. The question becomes: What do EDM operators need to know to effectively and efficiently machine these materials at the same time?

 

Work Metal Properties

Work metal properties and characteristics will alter the EDM approach. Understanding the difference between the physical properties of the two work metals in use and the way each will affect EDM performance is the first step (Chart 1).

The melting temperature and thermal conductivity of the work metals may vary from one to another, and EDM operators may need to adjust parameters such as on-time, amperage and polarity. If the same EDM approach is used regardless of the work metal, the end result could be vastly different. Thermal conductivity is the physical property that makes the biggest difference in EDM for the same reason it helps reduce molding cycle time: higher thermal conductivity dissipates the heat of the spark during EDM.

 

Power Setting Parameters  

To overcome any disparity in the thermal conductivity of the work metals, three primary power setting parameters may need to be modified:

• On-time. The duration time of the EDM spark measured in

microseconds.

• Peak current (amperage). The maximum current available

from each pulse from the power supply/generator.

• Polarity. The designation of positive or negative electrical

potential to the electrode.

Typically, the EDM power settings for tool steel are positive polarity and an on-time value between 50-100 micro-seconds. These settings provide the optimal combination of speed and electrode wear. A higher on-time and positive polarity will yield lower electrode wear. This result is achieved with a “replating” process during which molten particles from the workpiece follow the electrical current flow to the electrode and plate themselves to the surface of the graphite electrode, reducing the amount of wear caused by the EDM process. When working with copper alloys, negative polarity and lower on-time values (12-20 micro-seconds) are most effective. “Replating” of the electrode does not occur because the flow of electrical current is reversed and now travels toward the workpiece. The molten metallic particles are not forced to the electrode surface. Graphite particles cannot replate the workpiece since graphite does not melt; it transitions from a solid to a gas. This is called sublimation.

 

The operator determines amperage by the size of the frontal surface area for the detail being machined. The amperage value will be higher when burning a copper alloy workpiece to maintain the same spark intensity. Spark intensity is the amount of energy in the spark that is controlled by the on time, peak current and voltage (on-time x peak current x voltage = spark intensity). For example, we are currently using 50 sec of on-time and 20 amps to burn a detail. We decide to lower the on-time down to 20 sec. In order to keep the same spark intensity, we need to increase the Amperage from 20 to 50.

 

Material Choice

The decision to use either a standard graphite or copperimpregnated graphite electrode requires a look at how each material will handle the conditions of both the machining of the electrode detail and EDM process. A few factors to consider include electrode size, detail and fabrication time, cost, performance during the EDM process, meeting job priority expectations (speed, wear and surface finish) and the number of cavities to burn. Traditionally, a standard graphite would be used when EDM tool steel in positive polarity to achieve lower electrode wear. When burning a copper alloy workpiece in negative polarity, a copper-impregnated graphite electrode is preferred. This is due to a lower electrical resistivity value that allows for a greater percentage of the amperage to penetrate through the electrode and into the burn area. The material decision is not as abundantly clear since more than one metal will be EDM at the same time. Operators must consider the aforementioned factors when selecting the most effective electrode material to optimize the EDM process and to improve overall performance.

 

Tool steel cavity with a copper alloy insert used in testing to mimic the   

mold manufacturing environment.  

Testing Matters

A team of application specialists performed a series of tests to validate the impact of materials and EDM parameters on the simultaneous die sinking of a tool steel and a copper alloy. The objective was to determine what power setting and electrode material would achieve the best metal removal rate (speed) and lowest electrode wear and identify any dimensional or surface finish variances from one metal to the other. The team performed initial tests using a 0.500-inch square electrode with both standard graphite and copper-impregnated graphite programmed with steel settings of 65 microseconds on-time, 20 peak amps and positive polarity. They used side flushing and a jump cycle to keep the cutting condition clean. The operator stopped each test after one hour and took measurements. Overall, the metal removal rate was lower and the electrode wear was higher than expected for steel machine settings (Chart 2). The team then conducted a second set of tests using the same testing parameters but programmed with machine parameters more applicable for a copper alloy: 12 microseconds on-time, 80 peak amps and negative polarity. Both the standard and copperimpregnated graphite showed improvement with these settings as compared to the steel settings in the first test (Chart 2). The combination of proper machine settings and the copper impregnated graphite electrode showed the best overall performance. The team's next step was to mimic a tool steel cavity with a copper alloy insert and EDM different details (Figure 1). Four details were burned into the top surface along the parting line of the two workpiece materials (Figure 2): • Rib: 0.040 by 1.000 by 1.000 inches deep 24 VDI (Figure 3) • Square pocket: 0.500 by 0.500 by .250 inches deep 20 VDI • Dowel pin hole: 0.375 dia by 0.500 inches deep 20 VDI • Cross shape: 0.500 by 0.500 by 0.520 inches deep. 27 VDI The EDM tests indicated that machine parameters for copper alloys provided the most optimum performance. The final end wear was slightly higher on the portion of the electrode EDM the tool steel section than on the copper alloy. Since the tool steel portion of the burn resulted in higher electrode wear, an additional electrode was required to ensure consistency between the tool steel and the copper alloy. Overall, the team used four electrodes to fully complete each detail. The final measurements of the test burn confirmed that dimensional integrity and surface finish was consistent for both materials.

 

Results Are In

In the end, the answer to the frequently asked question is, “Yes, you can die sink a tool steel and copper alloy at the same time.” Preliminary testing showed that both standard graphite and copper-impregnated graphite can be used to accomplish the part detail. The difference was in the overall performance during the EDM. Deciding which graphite to use requires a look at the full spectrum of the relative factors and will be unique to each company's objectives. The data presented are derived from feasibility testing, so an expanded investigation is planned to identify a more optimum means to EDM different metals at the same time. This investigation will include the most current machine technologies available and any industry input to assist this investigation is welcomed.

 

Originally posted in Moldmaking Technology, November 2019

How to EDM Steel and Copper Alloy Simultaneously.pdf

GF Machining Solutions

AgieCharmilles EDM

Mikron High Speed Milling

Laser Texturing

Additive Manufacturing

 

Trucks are ready: Get a real solution delivered to your door

Our new, used, and demo machines, as well as technical solutions, are loaded and ready for fast delivery to your door. Act today and take your business to the next level with real machining solutions supported by the expertise that only a technology pioneer like GF Machining Solutions can provide.

 

 

2019 Year End Rally Flyer

 

Updated 12/04/2019

GF Machining Solutions

AgieCharmilles EDM

Mikron High Speed Milling

Laser Texturing

Additive Manufacturing

 

Trucks are ready: Get a real solution delivered to your door

Our new, used, and demo machines, as well as technical solutions, are loaded and ready for fast delivery to your door. Act today and take your business to the next level with real machining solutions supported by the expertise that only a technology pioneer like GF Machining Solutions can provide.

 

 

2019 Year End Rally Flyer

Businesses have ongoing incentives to acquire and install capital equipment. The Tax Cuts and Jobs Act of 2017 made significant changes to both Section 179 and bonus depreciation. These changes continue to be in effect for 2019 and when used together may allow businesses to deduct up to 100% of capital purchases.

 

EF-Section-179-flyer.pdf

 

GF Machining Special Financing.pdf

Manufacturers' precision, surface finish and autonomy reach new levels with GF Machining Solutions' Mikron MILL P 500 U and MILL P 800 U and the scalable System 3R TRANSFORMER Automation solution with a six-axis FANUC robot or integrated pallet magazines for from five to 12 pallets

 

GF Machining Solutions' Mikron MILL P 500 U and Mikron MILL P 800 U high-performace machining centers deliver top accuracy on parts, process reliability, 100 percent flexibility in parts production, double users' business efficiency, and guarantee 100 percent uptime for maximum productivity. Whether the application is a complex precision part or mold, users achieve highest surface finish and precision with the Mikron MILL P U family.

 

 

With their powerful and dynamic material removal capabilities and high stiffness, the Mikron MILL P 500 U and MILL P 800 U enable continuous machining of complex shapes and tough materials while shortening process time. Their advanced thermal stability ensures reliable precision over long machining periods. Furthermore, they deliver exceptional competitiveness by integrating smart Automation and ensure the process reliability essential to precision parts manufacturing segments such as aerospace and machinery parts as well as automotive mold making.

 

±2 μm precision in X/Y plane

With the Mikron MILL P 500 U and MILL P 800 U, manufacturers of precision parts and molds experience top accuracy and uncompromising process reliability, thanks to the machines' thermostability and symmetrical design. Even when machining at a fast pace and over long production periods, accuracy and process reliability remain steadfast, so users achieve consistent dimensional precision and 24/7 process reliability.

365 days per year flexibility

Thanks to the Mikron MILL P 500 U's and MILL P 800 U's 1.7 g acceleration, 36 kW Step-Tec HPC190 Spindle with a large speed range up to 20,000 rpm, and rotary tilting table capacity of up to 800 kg and workpiece diameters up to 860 mm, manufacturers experience constant dynamic machining as well as 100 percent flexibility in their part production.

The rotary tilting table of the Mikron MILL P 500 U is available in several variations: T-slot and pallet tables accommodating payloads of 200 kg, 400 kg or 600 kg. Incremental, direct angle measuring systems are directly mounted on the swiveling and circular axes to guarantee very high positioning and repeatable accuracy.

 

Out of these machines' two tool Spindle choices, Step-Tec's 20,000 rpm HPC190 with HSK-A63 tool interface is manufacturers' first choice. This platform Spindle robustly and reliably delivers repeatable accuracy. Its carbon fiber mantle defeats deviations in accuracy related to hot spots and thermal tilt, and the carbon fiber acts as a heat barrier to ensure that the heat is taken out of the Spindle. Moreover, the outer sleeve's carbon fiber reduces Spindle weight by 6 percent, significantly increasing linear drive dynamics while reducing oscillation in the vertical axis. For the MILL P 800 U, a Step-Tec CoolCore Spindle with 28,000 rpm is also available. This Spindle is dedicated to high-end precision jobs and delivers repeatable accuracy.

For precision parts machining as well as for mold and die, the lighter but still powerful 36,000 rpm Step-Tec HVC150 Spindle with HSK-E50 tool interface supersedes its predecessor. An all-aluminum integral structural part on the rear end reduces the Spindle weight by 17 percent, making it a great choice in power-to-weight ratio. In addition, Step-Tec's well-proven OptiCool Principle (OCS) delivers excellent polar thermal stability which is ideal for precision machining but also offers best surface finish for mold and die components. Both Spindles feature integrated sensors for total process control such as vibration monitoring along with many other Spindle parameters.

250 percent higher productivity with integrated automation

Precision parts producers and mold makers can more than double productivity with the 12-square-meter Mikron MILL P 500 U's and MILL P 800 U's accommodation of limitless integrable Automation solutions through the back.

For example, a scalable System 3R TRANSFORMER Automation solution with a six-axis FANUC robot can be added to the Mikron MILL P 500 U to advance productivity, flexibility and autonomy. Both stationary and rail versions of System 3R Automation solutions with FANUC industrial robots are available. Customizable to users' needs, these solutions cover a wide range of applications and requirements, from 70–600 kg transfer weight and up to 3,400 mm radial reach to complex transfer movements and parts handling.

 

The direct benefit of the System 3R TRANSFORMER with a six-axis FANUC robot is cost-effective yet flexible Automation through state-of-the-art technology and smart technical solutions using standardized modules. Moreover, with System 3R's user-friendly WorkShopManager cell management software, complex Automation is made easy to use.

MSP: full production within 10 minutes of a crash

 

Mikron MILL P 500 U and MILL P 800 U users pare their downtime from hours to mere minutes, thanks to GF Machining Solutions' Industry 4.0-supporting smart modules such as Machine Spindle Protection (MSP). MSP prevents Spindle breakdowns while protecting the machine geometry and maximizing machine uptime to reduce costs associated with unexpected Spindle collisions. MSP makes it possible to absorb axial and lateral collisions and then restore perfect accuracy: The Spindle returns to normal operations without any specific maintenance or recalibration, ensuring almost no downtime or collision-related costs.

 

Learn More: https://www.peakedm.com/59m7/mikron-high-speed-3-5-axis-milling/performance.html

 

Originally published by MachiningNews.com April 25, 2018 -

Source:http://www.machiningnews.com/2018/04/gf-machining-solutions-mikron-mill-p-500-u-and-mill-p-800-u-with-scalable-automation-advance-manufacturers-agility-and-autonomy/