The Agie Charmilles Form X, Form S, Form P and Form E series of die-sink EDM machines feature improved software and a range of technical innovations designed to give precision mould makers and component manufacturers a competitive advantage.
Whether the requirement is for a single, standalone machine for straightforward use or with full and integrated automation, Form machine tool solutions enable users to meet current and future challenges with greater flexibility, improved machining accuracy and reduced operational costs.
The machines provide customers with Econowatt technology to save energy, a variety of Industry 4.0-orientated connectivity features to help support manufacturers’ digital transformation, and e-Tracking software for EDM process monitoring and full traceability.
From faster rib machining to micro-machining, the Agie Charmilles Form family is the outcome of GF’s continued investment in advanced DSEDM research. The result is that users are able to achieve optimum machining performance with either graphite and/or copper electrodes.
The series allows for repeatable machining of micro-cavities and the machines’ onboard ‘iGAP’ technology guarantees the rigidity of plastic, injection-moulded end products with deep, plastic-reinforced ribs. It also ensures fast, accurate machining of rib cavities with respect to the required de-moulding taper and VDI homogeneity throughout the cavity surface.
Additionally, manufacturers requiring maximum performance can exploit the range’s eConnectivity features and MTConnect capability to stay informed of the machine’s status and machining process.
Specifically, Form X 400 and Form X 600 EDM die-sink machines help precision mouldmakers and component manufacturers control temperature fluctuations to guarantee confidence and right first time machining of complex high-precision parts.
In designing and manufacturing the new machines, GF’s R&D team focused its attention on temperature fluctuations occurring within the machining environment and/or within the machine itself, and its impact on delivering and maintaining high levels of accuracy.
The results of the research has led to the design of a sensitive and sophisticated thermo-control system that has been integrated into the Form X series, guaranteeing optimum performance irrespective of prevailing machine shop conditions.
The thermo-control system compensates for temperature variations by using thermally-stable dielectric to cool the machines’ X, Y and Z-axis glass scales, as well as the Z-axis ball screw mechanism. In addition, during assembly, care is taken to ensure that moving parts within the machines are isolated from both loading and machining areas to ensure they are not affected by temperature variations in the erosion area – nor by the extreme range in weight of the workpieces that can be accommodated by the Form X machines.
Moreover, the Form X machines’ structure has been specially designed with a frame of polymeric material that ensures constant positioning accuracy. The rigid and robust construction means that all the mechanical forces are absorbed so that an accurate gap between the part and the electrode is maintained.
The spheroidal cast iron X-, Y-, and Z-axes, located in the upper part of the machines are designed to reduce mass and at the same time meet requirements in terms of rigidity, precision and dynamic conditions.
Whether the user is machining a single cavity, a multi-cavity or micro-cavity mould for the production of small parts, the Form X 400 and 600 machines deliver excellent positioning accuracy. During build, the final alignment steps are verified via laser interferometer to ensure perfect 3D positioning. As with other GF Machining Solutions die-sinking EDM machines, the range features the Intelligent Speed Power Generator (ISPG).
With the machines’ new discharge circuit for spark erosion power modulation and the flexibility to maximise material removal, customers can achieve optimum levels of quality and efficiency, consuming fewer electrodes.
Form X 400 and 600 models also feature the latest generation advanced and ergonomic AC Form human-machine interface (HMI). Developed in conjunction with customers to streamline the mould making process, the AC Form HMI is organised on one menu level platform where all icons are arranged logically and in chronological order of use.
With integrated quality-enhancing and cost-saving intelligence, onboard software modules such as Tecform ensure that the EDM process is continuously optimised with each pulse calibrated to reduce electrode wear and ensure good surface finishes.
GF Machining Solutions www.gfms.com/uk
