GF Machining Solutions. AgieCharmilles DRILL 300

Transcription

1 GF Machining Solutions AgieCharmilles DRILL 300

2 GF Machining Solutions : all about you When all you need is everything, it s good to know that there is one company that you can count on to deliver complete solutions and services. From world-class Milling, electrical discharge machines (EDM) and Laser texturing machine tools through to first-class Automation, Tooling and software systems all backed by unrivaled Customer service and support we, through our Mikron, Liechti, AgieCharmilles and System 3R technologies help you raise your game and increase your competitive edge. Swiss design and quality 2 AgieCharmilles DRILL 300

3 Contents The winning solution High-speed EDM drilling Fine hole quality Powerful control Quick preparation High degree of autonomy and Automation GF Machining Solutions DRILL 300 The winning solution for cooling hole machining of components in aircraft engines In today s aircraft engines, the temperature in the combustion chamber can be close to the melting point of the nickel alloy used. In order to create a film of cooling air on the surface of components to prevent the nickel alloy from melting, cooling holes are needed on the curved surface of components such as turbine blades, vanes, and shrouds. Machining these cooling holes with high quality and productivity is always the main concern for aircraft engine component manufacturers.

4 The GF Machining Solutions answer The DRILL 300 is equipped with GF Machining Solutions latest digital generator, allowing the drilling process to be continuously optimized with every pulse. As a result the machining speed has been increased significantly compared to conventional EDM drilling. Technology is chosen according to the desired results. For example, by selecting quality technology, the electrode wear will automatically be reduced and the heat-affected layer is reduced to a few microns. Conversely, the operator can select speed technology to produce holes with the fastest possible erosion rate. With six-axis configuration, holes with different positions and angles can be freely programmed and machined, allowing for greater part flexibility and design. Single setup machining reduces unproductive time. By using the automatic electrode/guide changer (AEC/AGC), multiple holes with different diameters can be machined automatically and the machine attains longest autonomy. Due to wide range of optimized technologies for electrically conductive material like Inconel, steel and hard metal, the DRILL 300 is a winning solution for cooling hole machining in aerospace as well as other industrial applications such as cutting tools, automotive, medical and die plates. 4 AgieCharmilles DRILL 300

5 5 AgieCharmilles DRILL 300 With 60 years of experience building Electrical Discharge Machines, GF Machining Solutions has developed a new EDM drilling machine, the DRILL 300. This machine is manufactured in Switzerland to deliver top performance in machining cooling holes for aircraft engine components.

6 High-speed EDM drilling Increasing your productivity The EDM generator has state-of-the art powerful electronics to increase production output by utilizing efficiently controlled EDM processes that include FPGA technology, digital data recording and fully digitized pulse control. The drilling process is continuously optimized with every pulse, thus the fastest drilling speed is achieved. Fast and reliable breakthrough Without breakthrough detection, the machining time at breakthrough is even longer than the entire hole drilling time when the flushing process breaks down. With advanced breakthrough detection on the DRILL 300, the process is monitored in a real time; the technology is adapted automatically to exit technology; the reliable process is attained and the breakthrough time is shortened by percent. Depth mm 0 mm Conventional drilling time 48 s 280 s DRILL 300 drilling time 28 s 170 s With advanced breaktrough detection Electrode: brass, Ø 1.0 mm Workpiece: steel Speed technology Drilling time Conventional EDM drilling DRILL 300 DRILL 300 up to % faster 60 mm 0 mm Without breaktrough detection 6 AgieCharmilles DRILL 300

7 Steel Copper Hard metal Brass Carbide Inconel Aluminium 1.0 Copper Optimal technologies One type of technology cannot meet all of your requirements. According to the workpiece material and your stringent metallurgical requirements, the DRILL 300 has the optimized technologies to focus on either quality or speed. The quality technology achieves minimum heat-affected layer and better hole integrity, while the speed technology focuses on short drilling time. 7 AgieCharmilles DRILL 300

8 Fine hole quality The new standard in hole-drilling EDM Minimum heat-affected layer Heated-affected layer has significant influence on the fatigue lifetime of components and the safety of aircraft engines. The DRILL 300 is designed for achieving the best result in terms of heat-affected layer and avoiding cracks in the components. The DRILL 300 digital generator allows the finest pulse duration of a few microseconds. When quality technology is used, the heat-affected layer can be dramatically reduced to a few microns with a reasonable machining speed. 8 AgieCharmilles DRILL 300

9 without FirstSpark with FirstSpark Consistent hole dimension When machining cooling holes with conventional EDM drilling, the spatters at the hole entrance are always a problem, especially if there is a small angle between the hole and surface of components. The DRILL 300 has a fine pulse applied with the first spark function, then the technology is automatically adapted to the standard parameters. Therefore, the spatters in the hole entrance are avoidable and a perfect profile is achieved. Electrode: brass, Ø 1.0 mm Workpiece: steel, mm height Quality technology In order to optimize the machining of the most complex holes, the DRILL 300 provides the way of programming parameters corresponding to the machining depth. Multiparameters can be used in the same hole. With advanced breakthrough detection Breakthrough Strategy on the DRILL 300, the hole exit technology is optimized and the exit electrode length is programmable, and backstriking can be prevented. Meanwhile the quality technology also helps attain the right hole dimensions at the bottom of the hole. 9 AgieCharmilles DRILL 300

10 Powerful control To manage sophisticated hole machining CNC control In order to meet the demands of different applications, the DRILL 300 can be configured with different kinematics: XYZW, XYZWBA, XYZWAB, XYZWB1C1, XYZWB1, XYZWAB1. With single setup the holes with different diameters, positions and angles are freely programmable and machined. Control unit The graphical user interface is based on the Windows operating system and allows real time control of the EDM process. The system works with descriptive picture symbols and conversational screen pages following one after another in a logical way. This allows even new users to understand the EDM principle quickly and means time to production is very short. AgieCharmilles DRILL 300

11 Manual operation Easy Drill Main functions include all setup cycles, easy and fast programming for single hole machining (one hole on one page) as well as electrode and guide management. Work execution This page activates the work and executing measuring cycles. All machining, parameters and hole positions are monitored on this page. Work preparation The machine can import the entire work in the format of XML.NCC, ISO.NCC and PAT.NCC (compatible with AC CAM DRILL) directly or prepare the work manually with TEACH function. The parameters of every machining can be modified with Edition. The work can be graphically checked. 11 AgieCharmilles DRILL 300

12 Quick preparation Reducing the un productive time Fast setup cycles The universal console is equipped with the touchscreen based on the Windows operating system. The setup cycles probe, edge finding, corner finding, center finding, etc., help to prepare the job in a convenient way. Single setup machining With different kinematics of six axes, holes with different diameters, positions and angles can be freely programmable and machined even with single setup, allowing for greater part flexibility and design. Single setup machining eliminates the need for additional expensive fixtures and avoids multiple setups to reduce unproductive time. Less down time To ensure the longest life and reliability of the electronics, a closed water-air cooling circuit is contained within a dustproof cabinet, in which the temperature is also monitored and stabilized with multi-sensors. With this design, the lifetime of the electronics is guaranteed even in the most difficult conditions. 12 AgieCharmilles DRILL 300

13 High degree of autonomy and Automation For maximizing productivity Automatic electrode/guide changer The optional linear 16/4 electrode/guide changer and 50/8 rotary electrode/guide changer are available on the DRILL 300. AEC/AGC 16/4 is affordable solution and AEC/AGC 50/8 is a solution with the longest autonomy for max productivity. Automatic filtration and conductivity control With the 0-liter water tank and a -liter resin bottle in a standard configuration, the water filtration and conductivity are automatically controlled and cycled. 13 AgieCharmilles DRILL 300 Automatic part changer With the optional Automation kit, the DRILL 300 can connect to external robot to automatically manage part changing.

14 Technical data DRILL 300 DRILL 300 Machine Machine dimensions (L x W x H) mm (in) Without tilting head: 23 x x 2180 (91.34 x x 85.83) With tilting head: 23 x 1900 x 2180 (91.34 x 74.8 x 85.83) Net weight kg (lbs) 2500 (5512) without variants and options Machining area Electrode diameter mm in 0.3 ~ 3.0 (option: 0.1, 0.2, 4.0, 5.0, 6.0) ~ 0.12 (option: 0.004, 0.008, 0.16, 0., 0.24) Max. workpiece dimension mm (in) 00 x 700 x 500 (39.37 x x 19.69) Max. workpiece dimension mm (in) Ø x L = 350 x 3 (13.78 x 12.60) with tilting/rotary axes Max. workpiece weight kg (lbs) 00 (25) Max. workpiece weight kg (lbs) 25 (55) including clamping weight with tilting/rotary axes Worktable dimension mm (in) 800 x 600 (31.50 x 23.62) Worktable type 4 bars (2 stationary, 2 adjustable) Distance from table surface to floor mm (in) 850 (33.46) Accessibility Front Axes Travel X x Y axes mm (in) 600 x 0 (23.62 x 15.75) Travel W x Z axes mm in 450 x 450 (650 optional) x (25.59 optional) Tilting/rotary axes (option) º ± 0 / 0~360 Max. axis motion speed m/min. (ft/min) 4 (13.12) Measuring system for Z, W axes Encoder Measuring system for X, Y axes Encoder (linear glass scales optional) Lubrication Manual Dielectric unit Dielectric type Industrial water or civil water Dielectric capacity l (us gal) 0 (53) Max. flushing pressure bar (psi) 80 (1160) Filter accuracy µm 5 Capacity of deionizing bottle l (us gal) (2.6) Cooling system Water/water heat exchanger 14 AgieCharmilles DRILL 300

15 DRILL 300 Generator Generator type ISPG Max. mean working current A 60 Cooling system inside cabinet Air/water heat exchanger Numerical control Flat screen 17 flat touchscreen Keyboard Standard Mouse Standard Storage capacity > 230 GB HD, 24 MB Ram Interface port USB and Ethernet Measurement unit Metric/inch Command format Absolute/incremental Coordinates system Machine, part Max. number of machining in the program 500 Servo controlled axes X, Y, Z, W, A, B Import files XML.NCC, ISO.NCC, PAT.NCC Onboard CAD/CAM AC CAM DRILL as standard First spark detection Standard Electrode wear compensation Standard Breakthrough detection Standard Onboard documentation Standard Electricity supply Three-phase input voltage V 380 or 0 Permissible variations from +% to -% Main frequency Hz 50 or 60 Power consumption kva 4.2 Nominal current A 6 Cooling water when heat exchanger used Flow minimum required l/min (gal/min) (5.2) Temperature C F < Tworkshop 9 C < Tworkshop 18 F Compressed air Pressure range between bar (psi) 6 to 8 (85 to 113) Flow minimum required m 3 /h (yd 3 /h) 5 (6.54) Connection pipe external diameter mm (in) (0.4) Main options Automatic electrode/guide changer AEC/AGC 16/4, AEC/AGC 50/8 Tilting head Max. ~ ± 45 Large travel of Z axis mm (in) 650 (25.59) Rotary/tilting table 15 AgieCharmilles DRILL 300

16 2375/ /89.76 / / DRILL / / / / / / /15.75 /1.57 Max. workpiece 00 x 700 x x x / / / /93.5 / DRILL 300 tilting head 730/ / / AgieCharmilles DRILL / / / / / /23.62 /1.57 Max. workpiece 00 x 700 x x x19.68

17 17 AgieCharmilles DRILL 300 The DRILL 300 easily drills cooling holes in turbine blades. For this demo blade, 180 through holes and blind holes (Ø 0.5 mm and Ø 1.0 mm) were machined in only 75 minutes, using a single setup with the automatic electrode and guide changer.

18 GF Machining Solutions EDM (electrical discharge machining) AgieCharmilles wire-cutting, die-sinking and hole-drilling machines. For over 60 years we have been at the forefront of every EDM development: designing and refining the EDM process and building machine tools that deliver peerless part accuracies, surface finishes, cutting speeds and process reliability. Today, our AgieCharmilles wire-cutting, die-sinking and hole-drilling machines are recognized throughout the world as the best in the business. Our continuous research and development in digital generator technology, control systems and integrated Automation systems are evidence of our commitment to keeping your EDM operations on the leading edge of technology. Milling Mikron high-speed (HSM), high-performance (HPM) and high-efficiency (HEM) Milling centers. Customers operating in the mold, tool and die and precision component manufacturing sectors stake their reputations on being able to quickly and cost-competitively meet their customers demands. That s why they invest in Mikron machines. Incorporating the latest and most advanced technologies and premium-performance components, Mikron HSM, HPM and HEM machines help you increase your production capabilities and improve your productivity. Designed and built for speed, accuracy and reliability, the machines, like you, are proven performers. Laser AgieCharmilles Laser texturing machines. Laser texturing is a fully-digitized surface engineering process that has huge potential. The technology enables precise 2D and 3D textures or engravings to be machined accurately and directly onto complex parts or molds to improve and alter their aesthetic appeal, functionality and performance. The process is infinitely repeatable and offers many distinct environmental and economic advantages over conventional texturing processes. Laser Additive Manufacturing (AM). GF Machining Solutions has partnered with EOS, the global leader for high-end AM solutions, to integrate this innovative technology and further develop it into its current solutions to fully benefit the mold industry, by focusing on injection efficiency : optimized cooling design to reduce cycle time, lower energy consumption, higher quality of plastic parts. Liechti Dedicated Aerospace and Energy machining Centers. Aerospace and power generation turbine manufacturers increasingly turn to Liechti dedicated five- and six-axis machining centers to machine complex, high-precision airfoils on blades, disks, blings, blisks / IBRs and impellers. It s easy to see why because these machines, with their specific profile machining technology, specialized CAD / CAM software and engineering competence for ultra-dynamic machining in titanium, Inconel, nimonic, titanium-aluminide and high-alloy steels, yield productivity gains as much as 30 percent, thanks to reduced machining times. In the globally competitive aerospace and power generation manufacturing sector, that s definitely worth shouting about. Step-Tec Spindles. At the heart of every Mikron machining center is high-performance Step-Tec Spindle. Step-Tec Spindles are essential core components of our machining centers. Highly accurate and thermally stable Step- Tec Spindles ensure that our machines can handle everything from heavy-duty roughing to fine-finishing operations. Automation System 3R Automation, Tooling and software. Productivity is the key to manufacturing success, and automating a manufacturing process is a proven method of increasing its efficiency, effectiveness, quality and reliability. System 3R s integrated Automation, Tooling and software solutions simple workpiece pallet and electrode changers and flexible manufacturing and robot handling systems increase your competitive advantage. Customer Services Operations Support, Machine Support and Business Support. To help you get the most and the best from your machine tools and equipment, we offer three levels of support. Operations Support covers our range of original wear parts and certified consumables (EDM wires, filters, resins, electrodes etc.) to ensure that your machines are performing at the highest levels. Machine Support maximizes, through our best-in-class technical support, preventive services and quality spare parts, your machine tool uptime. Business Support is designed to help you make a real step-change in your productivity and performance with solutions tailored to your specific needs. 18 AgieCharmilles DRILL 300

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20 GF Machining Solutions EN At a glance We enable our customers to run their businesses efficiently and effectively by offering innovative Milling, EDM, Laser, Spindle, Automation and Tooling solutions. A comprehensive package of Customer Services completes our proposition. GF Machining Solutions Management SA, 15 The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change.