GF Machining Solutions’ new AgieCharmilles FORM X 400 and FORM X 600 EDM die-sink machines help precision mould makers 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 AgieCharmilles FORM X 400 and AgieCharmilles FORM X 600 machines, GF Machining Solutions' Research and Development Team focused its attention on temperature fluctuation (occurring within the machining environment and/or within the machine itself), and its impact on delivering and maintaining the highest levels of accuracy.
The results of their research has led to the design of a sensitive and sophisticated thermo-control system that has been integrated into the new FORM X series and that guarantees unrivalled precision irrespective of prevailing machine shop conditions.
The unique 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 of the machines are isolated from both loading and machining areas to ensure that 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 AgieCharmilles FORM X series.
Moreover, the AgieCharmilles FORM X machines’ structure has been specially designed with a frame of polymeric material that ensures constant positioning accuracy:
The machine’s 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 based on highly-accurate calculations in order to reduce their 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 AgieCharmilles FORM X 400 and AgieCharmilles FORM X 600 machines deliver improved positioning accuracy.
In addition to offering optimal thermo-stabilisation, the machines themselves are assembled with highest accuracy and, under strict manufacturing conditions, are aligned with a laser interferometer during the final steps of production to ensure perfect 3D positioning.
Like all GF Machining Solutions die-sinking EDM machines, the range features the Intelligent Speed Power Generator (ISPG), the world’s most powerful generator for die-sinking EDM machines.
The advantage of this generator is that it has been constantly updated to keep pace with the need to machine new and demanding applications.
With the machine's new discharge circuit for spark erosion power modulation and the flexibility to maximise material removal, customers can achieve an unprecedented level of quality and efficiency. This means, for example, that a customer's micro-machining processes are optimised so that fewer electrodes are consumed and a new level in machining sharp internal corners can be achieved.
AgieCharmilles’ FORM X 400 and FORM X 600 machines also feature the latest-generation and highly-ergonomic AC FORM human-machine interface (HMI) for an advanced level of speed, reliability and safety.
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. (Should it be required - help is only one click away).
With integrated quality-enhancing and cost-saving intelligence, onboard software modules such as TECFORM ensures that the EDM process is continuously optimised with each pulse calibrated to reduce electrode wear and ensure that the finest surface finishes can be realised. The embedded TECFORM module allows the FORM X 400 and FORM X 600 machines to quickly and safely achieve the best performance and produce the desired results.