Read 24 EXP 6.5.04 ING mod text version

PARTNER TO THE BEST

NO. 24

50 years of ED machining: Agie celebrates an anniversary Agietron Hyperspark: Unique in performance and application

ProTechnique - Canada Wire-Tech - USA Tesla - Czech Republic MMPP Salut - Russia Pripor - Russia Elemash - Russia Weidmüller - Germany

T H E

A G I E

E D M

M A G A Z I N E

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AGIE experience No 24 May 2004

``50

Dear Reader, Agie can look back with pride over half a century of research, development, production and sales of EDM machines. During this time, Agie launched products in ever shorter innovation steps that became models for a whole branch. Agie constantly shifted the bounds of the possibilities of EDM with new developments, opening up new dimensions with respect to speed, precision, operating convenience and process reliability. Our customers have also set best grades in production, as you can read about in this issue of experience. I wish you stimulating reading. Kind regards, your Nr. 24 May 2004 Appears in English, French, German and Italian. Edited and text by: M. Katz Graphics: R. Grizzi Printed by: Tipografia Poncioni SA Losone - Switzerland © AGIE An Agie Charmilles Group Company. No responsibility is accepted for technical data or the content of articles. AGIE SA CH-6616 LOSONE TEL. +41 91 806 91 11 FAX +41 91 806 92 60 www.agie.com [email protected] Cover picture: There is hardly any field in our life that is not affected directly or indirectly by electrical discharge machining: The mould for the production of this iron was manufactured on an Agie ED diesinking machine belonging to

Michael Katz Technical Editor

years of ED machining

1954 First laboratory

in Muralto/Ticino.

1957 start Production

in Losone/Ticino.

1973Baureihe DEM. Agiecut

First wire EDM machine fot taper cut with coaxial flushing.

1976 Baureihe EMS. Agietron

First sinker EDM with planetary movement.

1996/97 und Agietron Innovation. Agiecut Evolution

First sinker and wire EDM system with Agievision.

2002Vertex. Agiecut

The wire EDM system with the highest accuracy.

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AGIE experience No 24 May 2004

AGIETRON HYPERSPARK: Unique in performance and application

Agietron Hyperspark is an ED die-sinking system which meets tomorrow's machining requirements with trailblazing functions and technologies and is already without any alternative today. This includes detached features which make this series unique: Generator for high removal rates A generator with a patent pending which, through the intelligent interaction of six functions, achieves removal rates lying far above the average of conventional products in all fields of application ­ from the tightest lamellas through pointed tapering cavities to pre-milled moulds. Control system for flexible planning A control system that allows express orders to be slipped in without having to newly program the interrupted job, as the actual situation of the current job in progress is recorded, including the number of roughing and finishing sequences, and machining is then resumed exactly there where it was interrupted. Data input for top results A control system that makes it possible, by means of purposeful, object-oriented data input, to achieve results straight off that meet the required quality and economic viability criteria. Autonomy for long running times as standard An autonomy with which automated machining sequences can become realisable already as standard. Agie for top EDM results For 50 years, Agie has been the trend-setter for electrical discharge machining. The most recent example is the Agietron Hyperspark ED die-sinking system that sets new standards in ED die sinking with a generator with a patent pending.

1963 Agiepuls.

First static impuls powersupply with transistors.

1969DEM 15. Agiecut

World first wire EDM machine with NC-control.

1984200. Agiecut

First wire EDM with pivot-head.

1986 100C. Agietron

First sinker EDM with expert programme Agiesoft Expertron and Equimode.

2003

Agiecut Progress. The wire EDM system with the highest cutting speed.

2004

Agietron Hyperspark. The sinker EDM system with the highest removal rate.

celebrates an anniversary

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AGIE experience No 24 May 2004

ProTechnique EDM Inc.

Country Production Canada Micro-production Communication, aerospace EDM wire cutting with finest wire Hard metal punches and dies Precision blanking punches and die sections 4-axes ED machining

Target market Employees Founded EDM systems

North America 4 2001 1 1 1 1 Agiecut Progress 2 Agiecut Challenge 2 Agiecut Classic 2S Actspark SD 1

Programming

- Peps from Camtek - IGES and DXF for data retrieval

Clamping systems - Hirschmann Measuring testing - Measuring system from Zeiss - Measuring system from Mitutoyo - Profile projector

ProTechnique EDM Inc. 781 Main St., Unit 6 Milton, ON L9T 5A9 Canada Tel. 905-693-0615 Fax 905-693-9078 [email protected] www.protechnique-edm.com Contact Grant Fowler, Company proprietor

ProTechnique EDM Inc. has specialised in EDM wire cutting and is based in Milton near Toronto. The company supplies the high-tech sector as well as precision toolmaking. Renowned for outstanding quality and precision, ProTechnique also carries out express orders within far below the usual delivery times.

0.2058

0.0018

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AGIE experience No 24 May 2004

Progressive ED wire cutting brings 40% saving in time

Accept the challenges of the most complicated projects ProTechnique EDM Inc. was founded as a job EDM company in 2001, has 4 employees on its payroll and is based in Milton near Toronto. The founder and proprietor, Grant Fowler, can look back over 20 years of EDM experience and is renowned for carrying out the most difficult jobs in an innovative and punctual manner. ProTechnique EDM Inc. is specialised in the following EDM wire-cutting applications: - Micro-parts - Components for communication, aerospace - Finest wire workpieces - Punches and dies made of hard metal - Punch and die sections for precision blanking tools - Four-axis ED machining. Offering application and time solutions of the highest quality is the company's philosophy, with which ProTechnique EDM Inc. has created a large circle of customers for itself within the shortest time. An "external tuner", which is employed in communication, shows how efficiently Grant Fowler uses Agie brand ED wire cutting.

The drawing for the "external tuner for communication" with the smallest inner radii and webs.

Following the drawing, using Peps, Grant Fowler prepares the cutting geometries which are then completed on Agiecut Progress with the cutting technologies.

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AGIE experience No 24 May 2004

ProTechnique EDM Inc.

Owner of the first Agiecut Progress in North America In the same year as the market launch of Agiecut Progress 2, ProTechnique EDM Inc. decided to buy this EDM wire-cutting system. One of the first jobs to be implemented with it was the production of a small series of 2 times 5 "external tuners", such as are used for transmission technologies in communication. It was only possible to manufacture the small series using EDM wire cutting, as one of the requirements was to work without chip cutting in order to avoid material changes and surface damage. Further requirements were: - Material: Brass - Blank: approx. 4 x 4 x 5 cm - Surface quality: Ra 0.8 µm - Tolerance: ± 5 µm - Quantity: 2 x 5 units Grant Fowler was now able to bring his over 20 years of EDM experience to bear by structuring the machining in accordance with quality and time criteria: 1. Clamping of the brass blocks on 1 pallet with 5 units each 2. Making the starting holes 3. Plotting the positions of the 5 brass blocks with automatic measuring cycles 4. EDM wire cutting of the outside contours 5. Repeating working steps 1 to 4 for the second pallet 6. Rotating the pallets by 90° 7. Overnight EDM wire cutting of the slits with one main and one trim cut each 8. Turning the 2 pallets back 90° 9. EDM wire cutting of the inside contours with one main and one trim cut each. ProTechnique EDM Inc. was able to carry out the production of this small series in just one week, thanks to its know-how and new EDM wire-cutting technologies.

Economic viability improved through savings in time and material According to Grant Fowler, with the small series production of the 10 "external tuners", the performance features of Agiecut Progress were fully confirmed in practice. For ProTechnique EDM Inc. these were: - Set-up times have been cut by 20% thanks to Agiesetup 3D. - The cutting rates of Agiecut Progress are 40% higher on average thanks to the new eCut technologies. - The new eCut technologies have made a second trim cut unnecessary. - Wire consumption has fallen by 50%. - Thanks to eCut technologies, cheaper brass wires can be used for many machining jobs. - Maintenance costs have fallen by 10% with Agiecut Progress. - The high threading certainty is captivating. All in all, in this small series order, the machining time was reduced by 40%, representing a significant savings potential for ProTechnique EDM Inc.

View of the air-conditioned EDM department of ProTechnique EDM Inc. The three EDM wire-cutting systems, Agiecut Progress 2, Challenge 2 and Classic 2S, are employed in accordance with precision and economic viability criteria.

The geometry program for the "external tuner" is loaded onto Agiecut Progress 2.

Grant Fowler aligns the workpiece for ED machining.

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AGIE experience No 24 May 2004

As a small series of two times 5 units, in the case of this job, ProTechnique EDM Inc. was dependent on the great autonomy of EDM wire-cutting systems in order to be able to ED machine in unsupervised operation by night too.

The workpiece data

Finished part's name Quantity Material Startling holes Wire type Number of cuts Contour accuracy Surface roughness External tuner for communication 2x5 Brass 1.5 mm diameter Brass 0.2 mm diameter 1 main and 1 trim cut ± 5 µm Ra = 0.8 µm

"

Shorter set-up times, higher cutting rates, lower maintenance costs and wire consumption, as well as reliable wire threading have quickly convinced us of the Agiecut Progress 2. We bought this

We would like to thank Grant Fowler, the proprietor of ProTechnique EDM Inc. as well as Sean Smith, the manager of the EDM Group of Elliott Matsuura Canada Inc., for their kind support and helpful co-operation on this report.

Responsible

EDM wire-cutting system in the same year as its market launch and were thus the first in North America to have bought an Agiecut Progress.

Grant Fowler,

Sales engineer: Michael R. Powers, Agie Ltd.

"

Proprietor of ProTechnique EDM Inc.

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AGIE experience No 24 May 2004

Wire-Tech, Inc.

Country Production U.S.A. Plastics molding Aerospace Precision stamping dies, gages and tooling Components for measuring devices

Target Market Employees Founded Machines

International 12 1983 1 Agiecut Excellence 2F 1 Agiecut Progress 2 1 Agiecut 250 HSS 1 Agiecut 200D+SF 3 Agiecut 100D 1 Agiecut DEM 315 1 Agietron Integral 3 1 Agie Mondo Star 50 1 Agie Mondo Star 20 1 Mikron HSM 700 High Speed Machining Center - Mecanic 02 - Peps - Unigraphics NX System 3R Starett DCC CMM HGDC 2424-18 with Apogee level 4 scanning software Wire-Tech, Inc. 1030 N Stadem Drive Tempe, AZ 85281 U.S.A. Tel. +1-480-966-1591 Fax +1-480-829-1462 [email protected] www.twire-tech.com Contact Person Rick Erickson, President

Programming

Clamping System Measuring, Checking

The Wire-Tech, Inc., located in Arizona, has over 10.000 sq.ft. of plant size. The 1983 established company services a wide range of industries including aerospace, plastics molding, precision stamping dies, gages and tooling.

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AGIE experience No 24 May 2004

Biggest claim to fame: Quality with EDM

Established in 1983, Wire-Tech, Inc. opened its doors with one Agie model 315 Wire EDM, at that time the most accurate and dependable EDM on the market. This machine is still in operation today. Rick Erickson, President of Wire-Tech has had continual success with Agie equipment and confidently placed a total of 11 wires and 3 conventional EDMs into service at their Tempe, AZ facility. Wire-Tech services a wide range of industries including aerospace, plastics molding, precision stamping dies, gages and tooling. WireTech's expertise helps them meet the challenges of each area with its own requirements: maximum recast layer, form and surface, and ultra precise forms, respectively. Agie has helped us consistently meet those challenges. With our Excellence, we are able to wire tolerances as close as .001 mm and finishes to a Ra .3 µm. All of Agie's Wire EDMs can maintain a .0001 maximum recast layer on most aerospace exotics, enabling us to use any of our machines. With Agie we have it all: accuracy, reliability, process control and surface integrity. Twenty years after the 315 started running, Wire-Tech stands proud by our three newest Agie machines. We chose the Excellence because of its close tolerance and surface finish abilities. These are essential components in the gage industry that makes it very difficult for other shops to

AGIE provides us with process control abilities conducive to repeating job performance identically years later. From design to finished components, we are a full-service E.D.M. source.

"

Rick Erickson,

"

President of Wire-Tech, Inc.

accomplish. We had been running the Mondo Star 50 for its rib burning and close tolerances in mold work and aerospace manufacturing, so when we looked for another machine like it, the small, equally easy-to-run Mondo Star 20 was the perfect choice. Most recently, as we are always striving to improve productivity, we looked at the Progress, cautious that speed should not hinder accuracy. We were concerned about the 47 in2/hr speed, but it not only cut as fast as advertised, it was also capable of holding close tolerance. In summary, the Excellence the Mondo Star 20 and the Progress have been seamless additions to our assembly of Agie machines. Wire-Tech utilizes three software packages in our engineering department to meet the needs of all customers: Mecanic CAM 2000, Peps CAM and Unigraphics CAD/CAM. Mecanic and Peps work flawlessly with our Agie Wire EDMs. While Uni-

graphics is used for design, importing and working with solid models. Unigraphics is also used to produce G-Code for complex hard milling and graphite electrode manufacturing in the new Mikron High Speed Machining Center. After production, all of our parts are subjected to a 100% quality inspection using our Starret DCC CMM. All jobs are certified to their specifications prior to shipping.

Wire-Tech has had continual success with Agie equipment and confidently placed a total of 11 wires and 3 conventional EDMs into service at their Tempe, AZ facility.

We would like to thank the WireTech, Inc., in particular its Rick Erickson, President, for their kind support and helpful collaboration on this report.

Responsible Sales Manager: Scott Kowalski, Agie Ltd.

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AGIE experience No 24 May 2004

TESLA Jihlava, a.s.

Country Production Czech Republic - Connectors - Automotive components Europe 950 all told, 150 of them in tool-making 1958 1 1 1 1 1 1 1 2 Agiecut Excellence 2 Agiecut 270 HSS + SF Agiecut 100 Agiecut DEM 15 Agietron Exact 3 Agietron Compact 2 Agietron EMS 15 Agietron EMS 2.20

Target market Employees Founded EDM systems

Programming

- ProEngineer - AutoCAD

Clamping systems - System 3R Measuring, testing - Microscope from Zeiss - Kordimet co-ordinates measuring device from Johansson - 3D measuring machine IMS Impact with Trimos column

Tesla Jihlava, a.s. Havlíckova 30

Jihlava, located between Prague and Brno, is the home of the Tesla company founded in 1958. The enterprise, that is certified in accordance with ISO 9001, has 950 employees on its payroll, 150 of them working in tool-making. The main fields of business are the production of connectors, membrane switches and components for the automotive industry.

58626 Jihlava Czech Republic Tel. +420 56 71 13 429 Fax +420 56 73 07 157 [email protected] www.teslaji.cz Contact Ing. Jan Matula, Manager Machines +Tools

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AGIE experience No 24 May 2004

Excellent and acurate electric discharge machining

One of the largest in the Czech Republic If you drive from Prague on the motorway towards Brno, after about an hour and a half you reach Jihlava, where one of the largest Czech manufacturers of electromechanical components is based, Tesla Jihlava a.s. The company has specialised since 1958 in the complete production of connectors and switches. For this, Tesla Jihlava a.s. has an extremely efficient tool-making department at its disposal that ensures the production on schedule of the punching and injection moulding tools. The range of machines includes surface, profile and co-ordinate grinding machines and drills, as well as vertical machining centres. Tesla Jihlava a.s. attaches particular importance to ED die-sinking and wire-cutting systems, as they have a key role with respect to precision and autonomy in the production process for tools, as the example of a lock casing for a car shows.

Tesla Jihlava a.s. makes use of networked programming, measuring and control systems from receipt of the customer's order as a construction drawing, through the generation of the CAD data with solid models to the finished lock casing made of plastic.

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AGIE experience No 24 May 2004

Tesla Jihlava, a.s.

Economic viability determines the use of machining techniques Tesla Jihlava a.s. prepared the CAD program on the basis of the construction drawings for the lock casing. The various tool elements were differentiated in colour in the solid model. Then the machining steps and techniques were laid down in accordance with precision and economic viability criteria. Because the fast machining procedure does not always satisfy quality requirements, and often the supposedly slow machining technique is the more economic one. Thus the injection moulding tool and the mould insert respectively for the lock casing were manufactured in the following steps: - Milling - Drilling - Hardening - Grinding - ED wire cutting - ED die sinking - Adjustment, assembling Tesla Jihlava a.s. uses electric discharge machining as the quality-giving machining process in conclusion in order to achieve the finest and burrfree surfaces on the lock casing when injection moulding. Mould accuracy and precision with ED machining After the mould insert was hardened, all the cylindrical contours were ED wire cut with a surface quality of VDI 25 with the Agiecut Excellence. Cavities and moulds were also ED die sunk with a surface of VDI 25 and a dimensional accuracy of 0.1 mm was achieved for edge and mould separation. It was possible for the complete ED die sinking process to run automatically as Tesla Jihlava a.s. has an ED die sinking system at its disposal with Agietron Exact, allowing unsupervised operation:

- Electrode changer for 12 electrodes - Dielectric unit for over 150 consecutive hours of operation - ACC (Adaptive Current Control) for automatic adaptation to the active EDM surface - ACO (Adaptive Current Optimisation) for maximum removal and minimum wear with maximum safety - HVP (High Velocity Pulsation) for optimum ED machining of small and deep cavities. - Drop tank with automatic adjustment of the bath level to the workpiece. This enables Tesla Jihlava a.s. to shorten machining times as offpeak times and weekends can be used flexibly.

The mould insert for the lock casing at the various machining phases of EDM: - Final check of the copper electrodes before loading the electrode changer of the Agietron Exact 3. - ED die sinking on the mould insert. - Process check on the Agievision monitor of the Agietron Exact 3. - Data input on the Agiecut Excellence 2 ED wire-cutting system for the production of copper electrodes.

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AGIE experience No 24 May 2004

A mould insert of the injection moulding tool for the production of lock casings with the workshop drawing on which the planned ED machining jobs are marked in colour. Precision and quality, both on the tool and on the finished part, are continuously documented at Tesla Jihlava a.s. by means of measuring and testing systems.

The tool data

Name Finished part name Tool material Tool weight Finished part material Tool life Electrode material Electrode production Surface roughness Injection moulding tool Lock casing for cars Steel 1.2379, mould plate 1.2312, mould insert 1.2343 370 kg PPT plastic GF 30 + ASA 300.000 Copper ED wire cutting and grinding Ra = 1,4 µm, VDI 25

"

Thanks to their system openness, we were able to integrate the Agietron Exact and Agiecut Excellence EDM systems into our production sequence without any problems. In addition, both machines convinced by their great autonomy and high degree of automation so that we are able to deal with many machining jobs in unsupervised operation.

Ing. Jan Matula, Manager Machines & Tools of Tesla Jihlava a.s.

We would like to thank Tesla Jihlava a.s., in particular their Manager Machines + Tools Ing. Jan Matula, for their kind support and helpful co-operation with this report.

Responsible

"

Sales engineer: Reto Parolini, Agiesales Ltd.

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AGIE experience No 24 May 2004

MMPP Salut

Country Production

Russia - Engines for civil aviation SU 27, SU 30, TU 334, Antonov 70 - Gas turbines for stationary plants and test plants up to 20 MWatt - Components for aviatics International 1 plant in Moscow, 9 plants in further CIS countries Total over 17.000 1958 4 Agiecut Evolution 2 3 Agiecut Evolution 3 1 Agiecut Classic 2S 1 Agiecut Classic 2 1 Agiecut 350 1 Agiecut 370 1 Agiecut 300D+H 2 Agiecut 100D+F 2 Agiecut 200 1 Agietron Innovation 2 1 Agietron Integral 4 2 Agietron Integral 5 1 Agietron Advance 4 4 Agietron Compact 1 Micro 1 Agietron Mondo Star 50 2 Agietron 200C 1 Agietron 2U 1 Agietron EMS 4.40 Unigrafik Cimatron PCAM for wire EDM AutoCAD 14 and others

Target market Locations Employees Founded EDM systems

The Moscow Machine Factory Salut was founded in 1912 and has established itself in the course of its history as a world-wide renowned manufacturer of aircraft engines and turbines. Already over 40 years ago, the at that time still new machining process ED machining was being used, and with a total of 30 EDM systems in use, ED machining has lost nothing of its importance as a key technology at Salut.

Programming

Clamping systems - System 3R - Mecatool Measuring, testing - Option UMK-850 - LK-G90C - Tesa 3D Certification ISO 9001

Federal State Unitary Enterprise Moscow Machine Factory FGUP Salut Prospekt Budjonnogo, 16 105118 Moscow Russia Tel. 007-095-369-8001 and 007-095-369-8724 007-095-369-8029 and 007-095-369-8611 007 096 365 55 55

Fax

[email protected] www.salut.ru Contact - Dr. Jury S. Eliseev, Director General - Valery A. Poklad Head engineer

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AGIE experience No 24 May 2004

ED machining as an efficient means of production

The Russian No. 1 for aircraft engines Federal State Unitary Enterprise Moscow Machine Factory MMPP Salut is the exact company name of the well-known Russian manufacturer of aircraft engines and turbines in the east of Moscow and with a further 9 works in the CIS countries. As the company's name indicates, the undertaking looks back over a long tradition in engine construction and today has over 17,000 employees on its payroll. Salut has 30 ED machines at its disposal for the manufacture of aircraft engines and turbines which are used in the series production of complex moulds, micro drill holes and for machining of titanium alloys, as is described in the following example from practice of a fan wheel. Electric discharge machining is the more economic procedure Drilling, turning and milling are manufacturing processes which are, of course, used at Salut. However, if it is a matter of the final precision, the realisation of complex moulds and, above all, of the repeatability of results, electric discharge machining is the indispensable machining technology which stands up to all profitability appraisals. The fan wheel was manufactured in the following steps: - Turning from the solid blank - Drilling the hub opening - Milling the profiles - ED wire cutting of the graphite electrodes - ED die sinking of the fan blades - Micro ED die sinking of the cooling drill holes - Measuring, testing The given mould tolerances were met with ± 0.05 mm and the surface quality met the quality target with Ra 0.8 to 1.6 µm. Thanks to six-fold clamping and the automatic replacement of electrodes, the machining times when ED die sinking were clearly reduced.

Turbine elements are provided with complex mould details or with cooling louvres or drill holes. Again and again, Agie ED die-sinking units play the main role in the production sequence at Salut.

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AGIE experience No 24 May 2004

MMPP Salut

The control gives the vision for the whole machining For the manufacture of the four electrodes made of fine graphite required, Salut transferred the CAD data to the Evolution's control and linked the cutting geometries with the machining technologies. For this, the operator only had to input a few data: 100 mm (workpiece height), fine graphite (workpiece material), 0.3 mm Ø brass (wire type), Ra 0.8 µm (surface roughness) and Tkm ± 0.05 mm (contour tolerance). In the course of this, the data input is continuously checked by Agievision, giving the operator certainty for the whole machining job. The Agiejet threading system, that threaded automatically 31 times for this machining job in order to ED machine the 31 contours for the fan blades, also gave certainty. The data input for ED die sinking was just as problem-free, because, when die sinking, the Agievision control only differs from the operator surface for wire cutting by a few process control requirements. Here too, a few details on the workpiece, electrode and machining target sufficed in order to start ED die sinking with Agietron Innovation. It was possible for the six-fold clamped workpieces to be worked through for the most part autonomously thanks to the automatic changing of the electrodes. The Agievision Toolmanager function, which automatically continues to use finishing

electrodes for pre-finishing, and pre-finishing electrodes for roughing, assigning them and calling them up according to the state of machining, was also felt by Salut to be extremely efficient. The whole ED die sinking job was completed after 48 hours.

Cooling drill holes of 0.5 mm diameter are made in the fan wheels on an Agietron Compact 1 Micro. The cavities are made with multiply clamped electrode rods which are fixed by devices of their own development.

With a graphite electrode the fan blades are diesunk into the prepared fan wheel.

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AGIE experience No 24 May 2004

" "

We know the best products on the world market of ED machining, manufacturers from Geneva, from Germany or from the Far East, but no product has a control available that is comparable with Agievision. The operator convenience, the simplicity in the case of multiple moulds, as well as the purposeful, object-oriented data input give certainty for the whole machining job and convinces us again and again.

Nikolai N. Nosov, Manager of the EDM department at Salut

The fan wheel after the production steps turning, drilling, milling.

The electrode made of fine graphite for roughing, finishing and fine finishing.

The fan wheel after ED die sinking and ready for fitting with the cooling drill holes made by micro ED die sinking.

The workplace data

Name Workplace material Dimensions Fan wheel for aircraft Titanium alloy 81 mm diameter, from 4.0 mm to 7.3 mm high, flat tapering fan blades Mould accuracy Surface roughness Electrode material Electrode production ± 0,05 mm Ra = 0,8 ­ 1,6 µm Fine graphite, 100 mm high ED wire cutting with brass wire 0.3 mm Ø, 1 main cut, 2 trim cuts, Ra = 0.8 µm

We would like to thank the Federal State Unitary Enterprise Moscow Machine Factory MMPP Salut, in particular their deputy Chief Engineer Vladimir N. Spatchenko, for their kind support and helpful co-operation with this report.

Responsible Sales engineer for Russia: Hans Wyss

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AGIE experience No 24 May 2004

Tens hours by train to the south of Moscow lies Kursk, the home of the Pribor company founded in 1960. Aircraft instruments, household appliances, door hardware and pumps belong to the production programme of the stock-market quoted company that, with 3500 employees on its payroll, is one of the largest employees in the region.

Kursk Pribor

Country Production Russia Instruments for civil and military aviation Household appliances Door hardware Pumps

Target market Employees Founded EDM systems

CIS countries 3.500 1960 1 Agiecut Classic 2 1 Agie Mondo Star 50 1 Agietron 100C - Unicam - System 3R

Programming Clamping system

Measuring testing - Unicam - Solidworks - Mastercam

Pripor Joint-Stock Company 47, Zapolnaya Street 305040 Kursk Russia Tel. 007 07122 2-01-31 Fax 007 07122 2-29-12 Contact - Alexander S. Sparonov, General Director - Alexander A. Zinkevich, Technical Manager - German T. Bajandin, Stv. Deputy Technical Manager

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AGIE experience No 24 May 2004

Electric discharge machining ­ from complementary to the key technology

ED wire cutting on punching tools Pribor developed and designed a punching tool for the production of 0.5 mm thick stator-rotor plates that is designed for a tool life of 300,000 parts and with a clearance of ± 10 µm between the punch and die in order to achieve burr-free parts when punching. The data relevant for the ED wire cutting according to the construction drawing were input on the Agiecut Classic 2 and linked with the machining technology which the system generated independently from these target settings:

The workpiece was clamped in place, the position determined by measuring cycles and the reference values allotted to the geometry program. The EDM sequence then took place unsupervised, the operator was only required for the separation cuts and for removing the drop-out part. The order was carried out to complete satisfaction for Pribor and has considerably expanded the tool-making department's production spectrum, thanks to Agiecut Classic.

Die Material Steel, hardened to 62 RC Cutting height 10 mm Wire type Bercocut brass wire 0,25 mm Ø Roughness Ra = 0,3 µm Contour tolerance ± 10 µm Number of cuts 1 main cut, 1 trim cut

The tool for punching 0.5 mm thick stator rotor plates with a punch and die made of hardened steel.

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AGIE experience No 24 May 2004

Kursk Pribor

ED die sinking for injection moulds A further order for Pribor was the complete production of a steam iron for the Russian market. After receiving the construction drawings, the mould-making department decided on the production procedure for manufacturing the injection mould, with which the body of the iron was to be produced, in accordance with the production technique aspects. It then turned out that 15 different moulds had to be manufactured, as the body consisted, firstly, of various coloured plastics, secondly, of various materials and, thirdly, of parts with different surface qualities. 500,000 units were stipulated as the working life of the injection moulding tools. The CAD data for the mould inserts of the injection mould were prepared on the basis of the construction drawings, and then served for the milling programs for producing the graphite electrodes. Already when planning the electrodes, particular attention was paid to ensuring that as many geometries as possible were linked to one electrode in order to keep the number of electrodes small. The EDM program on the Agie Mondo Star 50 was input in three steps: On the 1st display page, all the data for setting up, on the 2nd page, the data for preparing the job, and, on the 3rd page, the process optimisation was carried out.

The clear structuring of the input pages, the marking and clicking technique with mouse operation, as well as clearly understood symbols and icons reduced the otherwise normal "programming" to a few target-oriented data inputs. But the high removal rates under all ED machining and flushing conditions also convinced. For Pribor, the Agie Mondo Star 50 with its reliability and high operating and ED machining convenience has in the meantime become the most important link in the production chain in mould making.

Milled graphite electrode for ED die sinking the mould insert bottom part of the iron's body.

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AGIE experience No 24 May 2004

"

The two EDM machines Agiecut Classic and Agie Mondo Star complement each other outstandingly for our application spectrum, and in our tool and mould making they have changed from being initially a complementary technology into the key technology.

Alexander A. Zinkevich, Technical Manager of Pribor

The tool data

Tool name Number of mould inserts Finished part name Workplace material Tool life Body material Electrode production Electrodes Surface roughness Injection moulding tool 15 Body for iron Tool steel 500.000 parts ABS-plastic Milling with Biomax from Fehlmann 1 roughing and 1 finishing electrode made of graphite Ra = 0.25 µm, polishing to Ra = 0.16 µm

We would like to thank Pribor, and in particular their Technical Manager Alexander A. Zinkevich, for their kind support and helpful co-operation with this report.

Responsible Sales engineer

"

for Russia: Hans Wyss

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AGIE experience No 24 May 2004

Elemash

Country Production Russia Fuel elements Magnets Metallic calcium Transformers Heating elements for reactors Heating spirals for household appliances

Target market Employees Founded EDM systems

International 12,000, over 350 of them in tool-making 1916 1 1 2 1 1 1 1 1 Agiecut Evolution 2 Agiecut 350 HSS Agiecut 350 Agiecut Sprint Agiecut 200D Agietron Innovation 2 Agietron Compact 2 Agietron 3U

Programming Clamping system

Unicam System 3R

Measuring testing - Gage 2000 - UM 500 from Opton

Elemash Public Joint-Stock Company Mashinostroitelny Zavod 12, Karl Marx Street 144001 Elektrostal - Russia Tel. 007 095 702-9078 007 095 702-9870 007 095 702-9902 007 095 702-9108

Fax

Contact - Igor V. Petrov, Technical Director - Vladimir M. Bytchkov, Tool-Making Manager - Michail Kordjukov, Deputy Tool-Making Manager

The stock-market quoted Elemash company has its head office in Elektrostal, 60 km to the east of Moscow. The company was founded in 1916 and can look back over a long history of technical developments. Today, Elemash with 12,000 employees on its payroll, produces transformers, heating elements, magnets as well as components for the nuclear power industry.

23

AGIE experience No 24 May 2004

Productivity increased by 80% with ED wire cutting

Utilising the possibilities of ED wire cutting in full The tool-making department of Elemash received the order to manufacture press moulds in accordance with the construction drawing for an edge life of 5 million for the production of magnetic starters for Volvo-Automobile. Taking the example of dies for the pressing tool, we show how efficiently ED wire cutting can be used, and how Elemash has replaced time-consuming co-ordinate grinding by it. The machining steps in detail: - Preparation of the cutting geometries - Generation of the cutting technologies in accordance with target-oriented data input - Clamping and setting up the workpiece - ED wire cutting of the 16 pressing dies (always 2 in succession in order to remove material stresses) - 16 separation cuts for the drop-out parts - Chemical hardening of the surface - Pressing in the 16 dies - Rotating the complete workpiece by 90° - ED wire-cutting the 300 mm high profile - Measuring and testing finished dies. Repeatable machining results By utilising all the possibilities that ED wire cutting offers, Elemash succeeded in reducing the traditional production procedures, such as milling, co-ordinate grinding and turning to two machining steps with ED wire cutting. In addition there is the high repeatability of the results achieved, as well as the short set-up times, as it is only necessary to clamp twice. As the complete workpiece was rotated clamped by 90°, the workpiece width became the cutting height, so that the openings had to be taken into account in the profile to be cut. A typical application for the Variocut module that records the cutting section while running in real time, and then automatically optimises the performance. For Elemash a further feature in keeping with the high performance standard of Agie ED machines.

The tool data

Name Workplace material Tool edge life Pressing material Dimensions L x W x H EDM wire Number of cuts Surface roughness Die for the pressing tool for manufacturing of car starter magnets high alloy, stainless steel 5 million Ferrite powder amalgam 780 x 300 x 80 mm CCA 0,25 mm 1 main cut, 1 trim cut Ra = 0,32 µm

The pressing die, ready for fitting into the pressing tool.

We would like to thank Elemash, in particular their Tool-Making Manager Vladimir M. Bytchkov and his deputy Mikhail Kordyukov, for their kind support and helpful co-operation with this report.

Responsible

"

Since 1986 our first Agiecut has been running reliably like a

"

Sales engineer for Russia: Hans Wyss

Swiss watch movement. In the meantime, 7 ED wire-cutting and 3 ED die-sinking machines from Agie are in use in our works with which we have been able to increase productivity by 80% in the past 5 years.

Vladimir M. Bytchkov, Tool-Making Manager at Elemash

24

AGIE experience No 24 May 2004

Weidmüller Interface GmbH & Co. KG

Country Production Germany - Field wiring products - Switch cabinet products - Printed circuit board components International ca. 2.300 of the Weidmüller group 1948 1 Agietron Innovation 2 with Agie WEC loading system 1 Agietron Hyperspark 2 with Agie WEC loading system - Agievision PC - Catia CAE-system

Target market Employees Founded EDM systems

Programming

Clamping systems ITS and UPC from Erowa Measuring, testing Pre-setting area with a Mitutoyo measuring machine Weidmüller Interface GmbH & Co. KG Klingenbergstrasse 16 32758 Detmold Germany Tel. +49 (0)5231-14-0 Fax +49 (0)5231-14-2083 [email protected] www.weidmueller.com Contact - Lothar Pöhlker, Manager Operating Material Construction - Uwe Fiene, Production Manager Operating Material Construction - Ralf Runte, Milling and ED Die-Sinking Technology Tool-Making

Weidmüller is the leading manufacturer of components for electrical connection technology. The Weidmüller product portfolio includes terminal blocks, pin-and-socket and circuit board connectors, protected assemblies as well as relay couplers through to power supply and surge protection modules in all

connection types. Material for electrical installation and electrical equipment marking, input/output basic components and tools round off the programme. As an OEM supplier, the company sets standards world-wide in electric connection and link technology.

25

AGIE experience No 24 May 2004

"Time to Market" with acurate and fast ED die sinking

The core competence is electrical connecting systems World-wide, Weidmüller stands for top performance, highest quality and customer orientation. The company is strategically oriented towards five market segments: - machine building - installation - process - railway/ship building - appliance manufacturer plus OEM (Original Equipment Manufacturer) and three portfolio groups: - switch cabinet products - circuit board components - field wiring products. Weidmüller's success is based on gearing itself consistently towards their customers' needs. Regular product improvements and new developments take account of this strategy. Thus, the tool-making at the Detmold location is geared exclusively to the manufacture of new products. The example of an injection moulding tool for a terminal block shows how an Agietron Hyperspark helps to shorten lead times with the latest technologies in order to be on the market in time ­ Time to Market.

A typical Weidmüller product is a terminal block for medium-voltage switch installations.

Detail photos of both the graphite electrode and the mould insert show the complexity of the terminal block that has

The mould insert and graphite electrode for the terminal block are displayed as a CAD model.

tolerances of just ± 0.01 mm in the contour range.

26

AGIE experience No 24 May 2004

Weidmüller Interface GmbH & Co. KG

Efficient tool management Time to Market also means for Tool-Making at Weidmüller close co-operation with Development and Production with the objective of standardising article and tool geometries, as well as fixing strategies for tool variants and production procedures. So the product terminal block also passed through these interlocking phases in Tool-Making: - Production concept - Tool concept and feasibility study - Construction and mechanical manufacturing - Tool assembly and testing - First equipment for stock - Injection moulding production - Market launch. Every phase has its special data requirement: CAD geometries, mould-flow models, CAM and CNC programs, measuring positions, job and time-recording, management and product description. In this connection, Weidmüller consistently backs paper-free data continuity and standardised sequences. Thus it is still possible to optimise or make changes in every phase without great expense. With ever shorter product cycles today, which are determined by the market, a further advantage for Weidmüller for successfully realising die Time-to-Market philosophy. ED die sinking has the highest standing once again Some years ago, the opinion was quickly formed that highspeed milling, especially applied to hard milling, would displace ED die sinking. The HSM process has Indisputably its advantages with respect to speed and removal. However, the reality is more differentiated. There are geometrical limits to the process, it requires great programming effort, tools are expensive and the presence of an operator is almost always absolutely necessary. The slow-

Graphite electrodes are produced by high-speed milling on a Mikron HSM 300.

Thanks to the striking Agie design, the Agietron Hyperspark 2 ED die-sinking system with the Agie WEC loading system are perceived as one unit.

The dual injection moulding tool is employed with hot nozzle direct injection.

A mould core of the injection moulding tool for terminal blocks.

27

AGIE experience No 24 May 2004

The tool data

The loading systems for the Agietron Innovation and Impact ED die-sinking systems each offer space for 144 electrodes and 6 tool pallets.

Name Finished part name Tool material Tool working life Electrode material Electrode production Tolerances Surface roughness

Dual injection moulding tool with hot nozzle direct injection Terminal block ZRV 2.5 Tool steel 1.2767 approx. 6 million parts Graphite High-speed milling ± 0.01 mm in the contour range VDI 24, Ra = 1,2 µm

ness of ED die sinking is, however, compensated for by the process's high degree of autonomy and automation, as machining jobs can be carried out unmanned overnight or at weekends. So what is more obvious than to combine both processes intelligently, as is practised successfully at Weidmüller: Hard milling for large surfaces and simple geometries, ED die sinking for complex shapes and filigree details. If, in addition, as is the case at Weidmüller, graphite is used as an electrode material, and as many geometries as possible are linked to one electrode, a first step is taken towards the economic use of ED die sinking. Weidmüller has achieved a further improvement in productivity with the use of graphite electrodes making it possible to reduce the total number of formerly 100 copper electrodes to 25 HSM-milled graphite electrodes.

Compared with our other ED die-sinking equipment, the introduction of the new Agietron Hyperspark brought a time reduction of 30 to 40%. Time to Tool in service for Time to Market.

Lothar Pöhlker, Operating Material Construction Manager of Weidmüller Interface GmbH & Co. KG

" "

We would like to thank Weidmüller Interface GmbH & Co. KG for their kind support and helpful co-operation on this report.

Responsible Sales Engineer: Udo Pohl, Agie GmbH

027.588

50 years of

EDM

For 50 years, Agie has been the trendsetter in electric discharge machining. In this time, Agie launched products which became the model for a whole branch. With Agie, the exotic machining process was transformed into the key technology in tool and mould making. Agie ­ with today's technology for tomorrow's applications.

2004 Agietron Hyperspark. The EDM die-sinking system with the highest removal rate.

PA RT N E R TO THE BEST

AGIE SA CH-6616 LOSONE TELEPHONE +41 91 806 91 11 TELEFAX +41 91 806 92 60 WWW.AGIE.COM [email protected]

AGIE CHARMILLES Group GEORG FISCHER GF Manufacturing Technology

1954 The first Agie EDM machine

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