Forces joined to master a full process chain

With the 3D measurement expert Alicona, GF AgieCharmilles has a partner that enables the leading supplier in precision machining to operate as a one complete solution provider. Initiated in the field of laser texturing, this collaboration will also be continued in the business divisions EDM and Milling Technologies. This makes Alicona to GF AgieCharmilles’ worldwide partner in all 3D measurement issues.

Alicona´s measurement systems are based on the principle of Focus-Variation. This optical technique combines the functionalities of a 3D micro coordinate measurement system and a surface measurement device. Users measure both surface roughness and form with only one system.

GF AgieCharmilles (GF AC), leading supplier of high precision machines and automation services, and Alicona, expert in high resolution optical 3D measurement, have combined their key competences and established a worldwide collaboration. Within this association, Alicona is the worldwide partner for all 3D surface measurement issues. With the optical 3D measurement system InfiniteFocus, GF AgieCharmilles is able to offer a solution that allows their customers to master a full process chain.
The partnership was founded in GF AgieCharmilles’ business field 3D laser texturing and will be continued in all technology areas of the Swiss machining and automation supplier. This includes EDM (Electrical Discharge Machining), HSM (High Speed Milling) as well as HPM (High Performance Milling).

InfiniteFocus in GF AC EDM and Milling Technologies
GF AgieCharmilles has complemented existing measurement equipment with the high resolution optical system by Alicona as it moves continuously into micro, eventually nano applications. “And it is almost impossible to go to this level without InfiniteFocus when operating in these dimensions”, states Jean-Paul Nicolet. For GF AC the system is a valuable tool as it delivers high resolution form and roughness measurements even at complex forms including steep flanks and varying reflection properties. This opens up new possibilities in tool optimization and makes research and development processes more efficient. “For our customers, I am convinced that at the moment there is no better instrument available. It offers the opportunity to verify the micro-geometry of their machined parts and components, which shows in return our competences in manufacturing high precision machines”, states GF AC. Nicolet: ”Another benefit that is offered by the system is the possibility to verify form deviations. It is a real interest to understand the deviation between two sets of data and further to take measures to increase process reliability for process optimization. This in combination with other measurement possibilities from Alicona is opening up other opportunities with EDM and Milling Technologies for 3D surface and micro shape measurement.”

Mikron Agie Charmilles AG
Ipsachstrasse 16, CH-2560 Nidau, Switzerland
Phone: +41 (0) 32 366 12 10, Fax: +41 (0) 32 366 12 39
www.gfac.com

Alicona
Teslastraße 8
8074 Grambach/Graz
phone +43 316 4000 742
www.alicona.com

Reach the top of efficiency!

OPS-Ingersoll, located in Burbach/Germany, operates world-wide as a leading technology partner for the mould- and die-industry at the highest stage. At EMO the company presented a lot of novelties and it’s time to present the Eagle MultiChangelinear automation concept: nonstop operation, error-free during constant operation.

As a full-range supplier, OPS-Ingersoll offers the new concept, where the advanced technology combination is perfectly joined with a well-engineered automation solution. The production capacity can be increased by the optimisation of the production cycle and the standardisation of all processes. The company develop customised solutions for highest efficiency with complete responsibility all from one source.

Modular and flexible for everyone
With the Eagle MultiChangelinear everything can be realised, a proven and reliable SICOM-guide rail assures in the standard version, that a transfer-load of 130 kg can be handled practically.
The system can be completed with a rotary-magazine with individual positioning and the integration of a measuring machine. OPS Ingersoll’s complete range of EDM and HSC machines can be connected. It is also possible to connect machines from other manufacturers or even other technologies.

Open to the future
The system can be expanded at any time. It is possible to add more machines, additional magazines or extend the guide rail. On the EMO, OPS-Ingersoll presented the line-automation Eagle MultiChangelinear with the EDM machine GANTRY Eagle 500, the HSC machine SPEED HAWK 550, the EROWA measuring machine PreSet 3D CNC and a rotary-magazine.

Proven software system
Our high-performance job management-system Eagle MultiCell is a proven software-system, which guarantees stable processes and is a clear interface to higher-level systems. The automatic production process causes definite shortened cycle times with more flexibility in the workflow and brings additional capacities.  Standardised applications increase the accuracy significantly and bring many advantages as far as precision and quality is concerned.

OPS-Ingersoll Funkenerosion GmbH
Daimlerstrasse 22
57299 Burbach
Fon: +49 27 36 / 4 46 – 282
Fax: +49 27 36 / 4 46 – 510
Info@ops-ingersoll.de
www.ops-ingersoll.de

A new dimension in structuring surfaces

Lasering brings a new dimension in structuring surfaces3D, for instance for mould construction surfaces. “Laser ablation“ is the name for the new manufacturing process for which GF AgieCharmilles builds controlled three to five axes machine tools. This technology offers users unimagined possibilities for the design and production of usual and spectacular surface effects on any shape of furnace.

New way to produce
Experts know that milling textures are unwanted for injection-molding or molding of exposed surfaces on die-cast and pressure-cast parts. Companies looking for new ways of shaping surfaces in mould construction were surprised at the EMO 2009 in Milan. In addition to and complementing its range of high-performance machine tools for milling, erosive sinking and cutting (wire cutting), GF AgieCharmilles now offers new machine tools under the name Laser 500, Laser 600, Laser 1000 and Laser 1200 for machining level or randomly arched surfaces by lasering on three or five axes. The material to be ablated evaporates in the laser beam. Even and reproducible 3D structures can thus be produced. This offers unimagined possibilities for labeling and marking, structuring and texturizing, by far exceeding the possibilities of the etching technology. Synergies are, in particular, gained where HPC and HSC milling, erosion milling and lasering are combined.

Success stories
J. & F. Krüth GmbH, Form-Ätz-Technik, Solingen, Germany have acquired and recently installed a Laser 600 5Ax and a Laser 1200 5Ax. During a Technical Forum organized by GF AgieCharmilles Germany in November 2009 in Schorndorf, the company’s Managing Director Stefan Krüth answered a question about the technology and his reasons for investing in the machines.

Mr. Krüth, what motivated you to use the laser as a tool for structuring the surfaces of  moldings – and how does the process work?

Stefan Krüth
A few years ago I would not have been able to imagine that laser’s would be suitable for shaping surfaces in production processes within such a short period of time. In 2006 we made first enquiries with a French start-up company who supplied us with a first machine in 2007. We demonstrated the technology to our customers who showed considerable interest. One advantage laser ablation has over the traditional etching technology is that also the third dimension of surface structures can be shown in a defined manner. The technology is based on a continuous digital process chain. There are no chippings, no cooling water and no dielectric is required – only a dust extraction is attached to the head of the laser. This process can, for instance be used for producing leather structures but also for technical structures, such as pyramids or hemispheres that can be easily changed or adapted in a virtual manner. Laser technology also involves, in most cases automation, ensuring that multiple machining or repeat orders produce the same excellent results. Adaptation to differences in materials is also easier for lasering than for etching.

The usual process steps commence with the scanning of an actual 3D surface pattern outside of the machine, using a light beam. In this way the topography of the surface is mapped, depicted in 256 grey tones and imported into the CAD/CAM line. A selection of structures is shown on sample panels. Structures can also be constructed virtually. The maximum capability for the different grey levels is 256 layers. The material is machined in various passes from different directions. Each pass removes a layer of approx. 5 to 10 µm. It is quite usual for a process to involve 50 passes. We are in close contact with the Fraunhofer Institute for Production Technology (IPT), in Aachen, Germany. The Frauenhofer Institure runs a research project studying this laser technology (high-precision structures for freely formed surfaces). Our company is involved in this research project. It is our aim to be and remain the worldwide leading industrial user of this technology.
Laser technology opens up possibilities of which designers have only dreamt of in the past. We have some development orders that show an extraordinary effect on the surface.  Apart from some enthusiastic customers there are also many who are somewhat skeptical and doubt the advantages and possibilities. During a phase such as the present, we welcome customers who are prepared to go one step further together with us.

For further Information:
Elke P. Magnin
Press Relations & Publishing Manager
Mikron Agie Charmilles AG
Ipsachstrasse 16
CH-2560 Nidau, Switzerland

Phone. +41 (0)32 366 12 10
Fax: +41 (0)32 366 12 19
elke.magnin@ch.gfac.com
www.gfac.com

Measurable results

GF AgieCharmilles, Hexagon Metrology extend collaboration; complementary technologies to be featured at EXPOlaser 2009.

GF AgieCharmilles and Hexagon Metrology, two globally-renowned technology leaders, are stepping up their partnership to bring leading-edge laser technology and the latest metrology instruments to EXPOlaser 2009, Nov. 19-21, at Piacenzaexpo, Piacenza, in Italy. Thanks to this partnership, visitors to EXPOlaser 2009 will get a close-up look at how  GF AgieCharmilles’ laser ablation technology and products are complemented by Hexagon Metrology’s laser scanners which digitally capture 3D-shapes and textures precisely and effortlessly, and play a key role in quality assurance.

From concept to finished products
GF AgieCharmilles’ Laser products offer manufacturers new possibilities for fine texturing and, thanks to Hexagon Metrology’s expertise in all areas of metrology, cover the whole design process chain from concept to finished product and quality assurance, as well as the possibility of reverse engineering. The cooperation between GF AgieCharmilles and Hexagon Metrology began earlier this year with the installation of Hexagon Metrology 3D measuring machines in GF AgieCharmilles’ application centers. Customers are the ultimate beneficiary of GF AgieCharmilles and Hexagon Metrology’s shared passion for high precision.

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To the service of customers
Measurable results are at the heart of GF AgieCharmilles’ commitment to customers, and Hexagon Metrology provides the instruments and knowledge base to let customers see for themselves the value delivered by GF AgieCharmilles Laser machines.

http://www.gfac.com/laser-website/

New line of micro EDM machining centers by Sarix

Sarix SA, Switzerland presented, for the first time at the EMO 2009 the MACHLine. This new line of machines for micro erosion is based on the new micro-EDM CORE of SARIX. Micro-EDM CORE is a new concept of multiaxis EDM machining. The versatility of the module allows flexible EDM configurations and the combination of EDM with other machining processes, on the same machine.

Ideal working conditions
The MACHLine center shown at the SARIX booth was presented in a configuration for the machining of cooling holes in aerospace and stationary gas turbine. The machine has a large working space to apply micromachining to large parts. It contains an EDM head for the machining of cooling holes and one supplementary laser ablation unit for the ablation of the ceramic thermal barrier of the turbine blades.

Attractive design and more
The unconventional and innovative design of the MACHline machining centers attracted many visitors to the SARIX booth, where more products were presented for the first time at EMO. For example a new Micro Deep Hole Device for mould makers can drill high precision holes in the 0.1mm range,  up to 15 mm in tungsten carbide.

Technical characteristics of the MACHline

• EDM Axis X: 100 mm, Y: 100 mm and Z: 100 mm. Glass scale resolution: 0.1 micron
• Accuracy: +/- 2 microns
• Positioning axis: U: 650 mm, V: 500 mm, W 450 mm. Glass scale resolution: 0.1 micron
• Tilting positioning axis: A: +/- 90 degrees, B: 360 degrees
• Power supply: 400 VAC, 3 Phase, 6 KVA

Additional advantages

• Integrated basic pneumatic cabinet
• Machine temperature conditioning
• Safety operation area
• Ergonomic control panel
• Standard options available

Want to know more about the Sarix technology?
Read the Eurotec about 3D micro EDM Milling here.

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Sarix SA
CH 6616 Losone
Phone +41 91 785 81 71
Fax +41 91 785 81 77
www.sarix.com

Uniquely positioned to help companies achieve more

More technology, more precision, more automation, more productivity and more satisfaction are at the heart of GF AgieCharmilles’ commitment to helping customers achieve more success.

A place not to miss at EMO
The exhibition space at EMO Milan 2009 is the place to “Experience more” of the solutions the company has developed specifically to enable customer’s success today, tomorrow and beyond. Visitors will have the opportunity to discover the complete, actual range of technologies and services offered by GF AC.

A wide solution range
Wire-cut EDM
The new CUT 1000 OilTech, optimal for precision and materials better suited to oil dielectric than water-based dielectric, has built-in thermo stabilization and is sure to respond to highest expectations. The company is now introducing the new P version to increase price/performance advantage.

Die sinking EDM
In response to the increased demand for small and micro applications in die sinking Agie Charmilles has created a new product: the FORM 1000, a machine which will set new standards in industrialized machining of smallest parts.

Milling technology
Customer support has made the MIKRON XSM/HSM 400 and 400U a real success, and the company now present the new MIKRON XSM/HSM 400 LP and 400U LP offering the benefits of the existing products and many improved features. Five-axis machining of large and heavy work pieces is the domain of the MIKRON HPM 600U and 800U. The MIKRON HPM 600 HD makes sure users benefit from the strong machining and newest tools for large mold productions. Its tool magazines and automation solutions make it the modern answer for maximizing output without compromising precision or surface quality.

The modern HSM centers benefit from highly reactive motorspindles. Rotation speed between 10 000 and 60 000 rpm are usual!

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Laser Technology
GF AgieCharmilles has entered the fast-growing laser technology field with its many interesting advantages for machining. This technology will, over time, become strong pillar within GF AgieCharmilles.

EMO Milan, Italy, in hall 7, booth no. F13/E20

Want to know more? www.gfac.com/EMO
Every contact details? That’s here.

www.gfac.com

3d micro EDM milling technology

As small-scale 3D machining is being developed to keep pace with the product miniaturization trend, SARIX offers the high performance Micro EDM machine line, the SX-100/200 series which have been especially designed for medium volume production of high-precision micro instruments, components and also for microinjection molding of micro-fluidics cavities.

Based on know-how
Now Sarix, through its strong and accumulated experience since 1994 as market leader in the Micro EDM Machining field, brings the EDM to the increasingly stringent requirements of 3D Micro Milling operations. Its innovative and reliable machine concept shows the capability of small cost effective machines performing precision and high-precision tasks with great accuracy and 3D machining for the manufacturing of medical devices. The medical industry is one of the application fields that have been able to take the benefit integrating this attractive technology on the production line of advanced components.

Ultra precision and high surface finishing
Both machines combined with the most advanced Micro EDM technology incorporated on a Micro Fine Pulse Shape (MFPS) generator allows new possibilities for smaller, deeper and more precise perfect round holes. This enables to achieve unique combination of drilling holes diameters from 1 mm down to 10 micron with high surface finishing down to Ra 0,05 µm (50 Nano).
The SX-100/200 series supports a wide range of accessories to suit the customer’s applications and their high performance requirements in term of Micro-drilling, Micro-sinking and Micro-Milling. Associate with an automatic electrode re-feeding and wear-compensation spindle with a built-in micro-scale wire-EDM device for electrode Micro-Grinding, the SARIX 3D Micro Milling machine opens up new opportunities for machining intricately shaped forms, thin walls, and extreme microstructures.

3D micro EDM milling
It also provides various option levels to perform very fine 3D Micro EDM Milling up to 4 simultaneous axes enabling manufacturing of complex forms or shape holes for catheters, needles and device components.
The latest feature launched by SARIX, the SX-Micro-EDM-Milling CAM software, have confirmed Sarix’s 3D Micro EDM Milling capability to thin depth within a very precise depth control below 1 micron. Each end-user and engineer active on micro-machining can understand clearly which issues can be solved when the Z-control can be achieved on such level. It is the answer to the usual weak point of this field. [...]

Success story
With the help of Sarix achiness, Diamond S.A. (Losone, Switzerland) met NASA’s space applications component requirements. Flashback on this success story.
Diamond S.A., a leading global specialist in the manufacture of fiber-optic components, did not have to look far afield to find a supplier of the sort of technology it needed to keep up with the trend toward ever greater device miniaturization and the shrinkage of part features. The Losone, Switzerland-based company turned to Sarix, headquartered in the same city, when it had to meet the challenge of producing multi-fiber optical connectors for a collaborative project with NASA, Photonics Group, Goddard Space and Flight Center.

www.diamond.ch

Sarix SA
C.P. 621
Via Ai Molini 22
CH-6616 Losone
Tél. + 41 91 785 81 71
Fax + 41 91 785 81 77
www.sarix.com
sales@sarix.com