Experience: Issue 23 (PDF | 2.8 MB)
Transcription
Experience: Issue 23 (PDF | 2.8 MB)
PARTNER TO THE BEST EMO 2003: Top event in the tool branch NO. 23 Top speed with Agiecut Progress Top removal rates with Hyperspark Mecasoft Dal Sasso Forez BTMT PNPPK T H E A G I E E D M M A G A Z I N E 027.158 The speed is not everthing... mm The Agiecut Progress EDM wire cutting system has been designed with new performance features for maximum productivity: 100 ■ Cutting rates of 350 up to 500 mm2/min are reached with standard wires in most cutting heights. ● Automated with a robot, Agiecut Progress becomes a highly efficient manufacturing cell for series production, prototypes, as well as in tool and mould making. ▲ The cutting technology eCut allows precision cuts requiring up to half the time and expense. Agiecut Progress: advanced technology for progressive productivity in wire EDM. ▲ The Agievision control allows the adjustment and optimising of process cycles, thus drastically cutting non-productive times. 50 AGIE SA CH-6616 LOSONE TELEPHONE +41 (0)91 806 91 11 TELEFAX +41 (0)91 806 92 60 WWW.AGIE.COM [email protected] 20 350 400 450 AGIE CHARMILLES Group GEORG FISCHER GF Manufacturing Technology 2 500 mm /min 2 AGIE experience No 23 October 2003 ‘‘ No. 23 of October 2003 Appears in German English, French and Italian. Editor: M. Katz Graphics: R. Grizzi Printed: Tipografia Poncioni SA Losone - Switzerland © AGIE A company in the AGIE CHARMILLES Group. No responsibility is taken for the technical data or 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: The small series production of designer jewellery which the Belgian company Mecasoft creates using ED wire cutting proves that electrical discharge machining can also have aesthetic aspects. EMO 2003: Top event in the tool branch Top speed with Agiecut Progress Dear Readers, The EMO taking place every two years is the worldwide largest machine tool exhibition. An event, which all major manufacturers take as the opportunity, to propagate their latest products. However the two yearly event, is also giving a good indication on: Which company has set new trends? Which products have made a technological leap? Which ideas have gained acceptance after two years on the market? If this way of looking at things is taken as a yardstick for innovation and progress, Agie does not have to fear any comparison. Since the last EMO two years ago in Hanover, Agie has launched two new products each in ED die sinking and ED wire cutting, introduced various systems for automating ED machining and implemented numerous new, in part patented, software modules in the EDM system controls. With time-cutting and performance enhancing technology, Agie products are designed for customers’ everyday machining tasks: ▲ Top cutting speed ▲ Top precision ▲ Top removal rate ▲ Top flexibility ▲ Top universality Under every application aspect Agie can offer a tailor-made product which then convinces with top performances. Innovation that can be measured against the machining result. Such as Hyperspark and eCut, the two new products, which we present to you here below. Michael Katz Technical Editor Numerous influencing variables determine a machine tool's productivity. Thus an ED wire-cutting machine is not yet productive because of the fact that high cutting rates are achieved, but only the sum total of all the functions, that have been matched to each other, such as setting-up, programming, optimised EDM non-productive times and cutting technologies bring maximum productivity. With its integrated solution approach, Agiecut Progress offers genuine competitive advantages, from job planning through setting-up to the finished workpiece. For this, Agie’s Research and Development Department first evaluated over 1200 concrete requests by customers. They formed the basis for the new development of Agiecut Progress. All the influencing variables with respect to productivity were examined again and again in theory and practice and taken into account in accordance with their significance. The requirements from the customers’ point of view were: With an identical cutting rate, a workpiece cut left with and right without Dynamic Corner Control. The advantages of the new generator technology eCut. Vsm 2,5 200% Ø 0.15 mm Vsm 1,5 Cutting speed 40% Less filter consumption 40% Ø 0.25 mm Less resin consumption 60% Less wire consumption 3 AGIE experience No 23 October 2003 ▲ High precision and surface quality with one single cut ▲ Machining times which are also interesting for the production of parts ▲ Absolutely minimum operating costs ▲ Highest possible removal rate with variable workpiece heights ▲ ED machining at full speed, but at the same time with high precision corners and radii. The result: ED wire cutting systems which deal with machining jobs with just one single precision cut, thus dispensing with trim cuts. The new EDM technology, eCut, saves time, wire, filters and deionising resin to a previously unknown extent. Cuttings rates of 350 to 500 mm2/min are achieved using standard wires for most cutting heights. New possibilities with Agievision control halve the nonproductive times. Thanks to Dynamic Corner Control, corners and radii are ED machined unbraked, but with the highest precision. With Wire Bending Control, precise workpieces are achieved in real time by detection and correction of the wire sag. Agiecut Progress ED wire cutting systems open up the widest application possibilities thanks to their incision technology, high cutting rates, reduced non-productive times and faster optimising of the task-dependent parameters by the operator, both in tool and mould making, and in prototype and mechanical production. ’’ Top removal rates with Hyperspark It is possible to imagine the EDM process as a balance between ED machined material in the gap and evacuated material. If this balance is not present, then either you flush the machining zone unnecessarily, entailing a loss of time and additional process instability (a minimal contamination of the gap is necessary, because if the gap is too clean, the Servo must move too close to the workpiece in order to trigger discharges, but then correct backwards immediately in order not to damage the surface) or you ED machine the same particles several times which cannot be removed sufficiently quickly from the gap. The new machining strategy (asymptote detection, increase in current and impulse interruption) is the subject matter of a patent application and will be employed in all new Agie ED diesinking systems with immediate effect under the name Hyperspark. The results correspond with the theoretical ideas, especially there where good flushing is guaranteed, such as, for example, in the case of pre-machined workpieces. For these machining jobs we have doubled the removal rate. In the following applications, the gains lie between 25 and 40%. In general, the innovative generator Hyperspark offers an increase in productivity of approx. 30%, however, up to 100% in the case of pre-milled moulds, something that is encountered increasingly nowadays through the synergies with high-speed milling. This refers to all roughing to finishing operations using copper and graphite electrodes. The advantages are particularly great with good flushing conditions, and above all with premilled workpieces. These convincing results confirm: Yes, it is certainly possible to increase the speed and the productivity of the ED die-sinking process. And: The potential for improving this technology is still considerable. You can find the full article by El. Ing. Dipl. ETHZ Marco Boccadoro under www.agie.com. A tapered, 40 mm deep slit is to be ED machined using a lamellar electrode. In this well-known example, the challenge lies in reaching an optimal homogeneity of surface roughness. With a lamellar electrode (20 x 1 x 40 mm, 1 degree taper, undersize 0.5 mm, graphite EDM3, only movement flushing) without Hyperspark a depth of 40 mm was achieved with a surface quality of VDI 24 in 230 minutes. With Hyperspark, the time required was just 170 minutes, equivalent to an increase in speed of 36%. The electrode wear was 0.3 mm and the surface quality impeccable. The EDM process must be a balance of the removal to the lifting movement and flushing. 4 AGIE experience No 23 October 2003 Mecasoft SA Country Belgium Production - Contract EDM - Prototypes - Small series Target market Europe Employees 17 Founded 1986 EDM systems 1 1 1 1 2 1 1 1 1 1 Programming - Mecanic Agiecut Challenge 3 Agiecut Classic 3 Agiecut 320 Agiecut 120 Agiecut 200D Agiecut DEM 315 Agiecut DEM 425 Agietron 200C Agietron 1U Agietron EMT 1.20 Clamping systems - Mecatool Measuring, testing - Profile projector Mecasoft S.A. Zoning Molignée Anhee B-5537 Tel +32 (0) 82 61 16 12 Fax +32 (0) 82 61 36 35 [email protected] www.users.skynet.be/mecasoft Kontakt Mecasoft SA, based in Anhee in Southern Belgium, is a contract EDM company with 17 employees and 11 EDM machines. The customers come from the automotive, surgical and medical, nuclear, aerospace, jewellery and design sectors, as well as the manufacturers of precision components for tools, machines and mechanics. The application spectrum ranges from prototypes through small series to single part production of the highest precision. R. Brandt, Commercial Manager 5 AGIE experience No 23 October 2003 hours of ED wire cutting in unmanned operation Established among modern technology companies Mecasoft SA was founded in 1986 and today has 17 employees on its payroll. The company based in the southern part of Belgium has twenty years of EDM know-how at its disposal that is supported by a long list of references from satisfied customers from the whole of Europe. Mecasoft SA’s customers come from various branches with the most varied orders: - Automotive: plastic injection moulding tools, threaded and calibrated extrusion for complex profiles, prototypes and accessories. - Automotive: plastic injection moulding tools, threaded and calibrated extrusion for complex profiles, prototypes and accessories. - Nuclear: precision parts and prototypes. - Jewellery and design: rings, pendants, earrings, prototype parts, style studies, bracelets, works of art and cups. - Precision mechanics and tools: components for machine building, calibration, punching, pressing, extruding and injection moulding tools. - Surgery and medicine: small series production of surgical instruments, machine components and special instruments. The example of an extrusion die conveys an idea of the capability of Mecasoft SA, beginning with the receipt of the order through the generation of a program, job preparation and ED machining to the finished product. ED wire-cutting programs are generated from the data which Mecasoft SA receives from its customers as CAD, CAM or DXF files, and optimised to suit the material and workpiece with the various software modules of Agievision control. 5 6 AGIE experience No 23 October 2003 Mecasoft SA Shaping the EDM sequence to suit their own requirements Mecasoft SA received the geometry data for the extrusion die from the customer as a DXF file. The workpiece was measured directly on the Agiecut Classic 3, with the EDM wire and an integrated touch probe carrying out the measuring cycles. The control system took account of any possible offset in the level and height, and allocated the new reference values to the geometry program. The machining technologies, as well as the working sequence and procedure were then generated automatically with a few requirements, such as surface roughness, contour tolerance, workpiece material and height, as well as the EDM wire type. Teccut, a further Agievision module, made technology suggestions for this which the system called up from a complete, intelligent database. As orders for extrusion dies of this kind are received again and again, Mecasoft SA has stored this machining as a model using the Agievision module Workmodel so that it can be called up as required. High machine autonomy guarantees long machining times The job preparation with clamping, plotting and data input is complete. The ED machining can start. The advantages of an Agiecut ED wire-cutting system now became apparent to Mecasoft SA: - Thanks to 25-Kg wire spools, long machining times can be achieved. - Thanks to the automatic adjustment of power for entry cuts or in the case of wire breaks, there are no interruptions because Agiecut Classic 3 also threads automatically. - Thanks to the generously dimensioned wearing and non-repairable parts, long service intervals are possible. Flexibility for the most varied machining jobs The Agiecut Classic 3 ED wirecutting system offers further plus points for Mecasoft SA as a contract EDM company: - Thanks to the combined wireguide system for all diameters, no wire guides have to be exchanged, and thanks to the simplicity of the system the threading of wires of any diameter is extremely reliable. - After a change of job, no new programming has to be carried out because, thanks to Pieceinsert. In Mecasoft SA’s day-to-day business, where it is necessary to calculate very exactly, these are time and cost advantages which quickly pay off. Diagrammatic representation of the supply unit of an extrusion tool. Measuring a workpiece on the Agiecut Classic 3. View of the EDM department at Mecasoft SA with the two ED wire-cutting systems, Agiecut Classic 3 and Agiecut Challenge 3. A finished ED machined extrusion die with metering flap. 7 AGIE experience No 23 October 2003 The drop-out part of the extrusion die makes clear the long cut contour of this machining and the complexity of the mould. The tool data “ Tool name Extrusion tool Finished part name Extrusion die Die material Stainless steel, hardened after machining Workplace height 300 mm Cut height 114 mm EDM wire CCD 0.25 mm diameter Number of cuts 1 main cut, 1 trim cut Surface roughness Ra = 1,4 µm EDM time 100 hours in unsupervised operation As a contract EDM company, we are dependent on reliable ED machines with high autonomy. Only thus can we react quickly and flexibly to EDM orders with the most varied requirements. With Agiecut Classic 3 and Agiecut Challenge 3 we have the ideal ED wire-cutting systems for this so as to be able to offer small series with long services lives or competitive contract EDM and proto- ” types. We would like to thank Mecasoft SA, in particular their managing directors R. Brandt and Fr. Henry de Frahan, for their kind support and friendly collaboration with this report. Responsible R. Brandt, sales engineer: Commercial Manager of Reto Parolini, MECASOFT SA Agiesales SA 8 AGIE experience No 23 October 2003 Dal Sasso S.r.l. Country Italy Production - Manufacture of injection moulding tools to order and for own requirements - Production of plastic and thermoplastic parts - Co-Design Target market International Employees 65 Founded 1981 EDM systems 1 Agietron Impact 3 Programming 4 Stations 3D-CAD Think3 15 Stations 2D-CAD LT Auto-CAD Clamping systems Erowa Measuring, testing CMM from Brown & Sharpe networked directly online Certification in accordance with ISO 9001 Dal Sasso S.r.l. Via dei Rutuli 101 I-04011 Aprilia Provinz Latina Tel +39 (0)6 92 50 00 08 +39 (0)6 92 56 255 Fax +39 (0)6 92 55 175 [email protected] [email protected] www.dalsasso.it Contacts - Marco dal Sasso, Director Tool and Mould Making - Luciano dal Sasso, General Director - Giorgio dal Sasso, Production Manager The Dal Sasso S.r.l. company based to the south of Rome is a producer of plastic and thermoplastic parts which are used in the most varied branches. Dal Sasso S.r.l. offers a full service: From projecting through designing and tool making to the finished product, with a throughput time of just 3 weeks. 9 AGIE experience No 23 October 2003 ED die sinking is a key technology in the production network With consistent investments to success The Dal Sasso S.r.l. company, based to the south of Rome in the province of Latina, can look back over 20 years of company history. Founded as a family company in 1981, Dal Sasso S.r.l. today offers a full service in the production of plastic and thermoplastic parts, in a factory area of 3200 m2 with 65 employees, 18 automatic injection moulding machines from 25 to 750 t mould clamping force, 18 machine tools and 19 CAD workstations. This includes: - Projecting - Co-Design - Design from a specimen part, drawing or other CAD data via IGES, VDA, DXF, DWG or STL. - Tool and mould making for own requirements or as a customer order. - Pilot production on 3 automatic injection moulding machines specially available for sampling. - Injection moulding of parts up to 4.5 kg weight. Dal Sasso S.r.l. regards the ever greater demand to cut delivery times (time to market) as a challenge to provide its customers with this time advantage by reducing the floor-to-floor times within the company. This was possible, on the one hand, through the complete networking of all machines and computer stations and, on the other hand, through consistent investment in modern operating equipment, such as, for example, the Agietron Impact 3, which today has a key function in tool and mould making at Dal Sasso S.r.l. As the example of a casing for a medical device shows, the flow of data at Dal Sasso S.r.l. is continuous at all stages of planning and production: From the receipt of the customer’s specimen part through the CAD design, the mould-flow simulation, the electrode and mould production to the injection moulding tool ready for use – everything is networked online and can be called up at any time. 10 AGIE experience No 23 October 2003 Dal Sasso S.r.l. Continuous data flow in all production phases As the example of a casing for a medical device shows, Dal Sasso S.r.l. is often also involved already in the project phase. Thus, on the one hand, Dal Sasso S.r.l. together with the customer was able to optimise the casing to suit the tool and, on the other hand, it was possible to carry out improvements to the design with respect to the functionality. Even in the tool-making phase it was still possible to carry out detail modifications. Everything is networked online at Dal Sasso S.r.l. so that changed CAD programs can be transmitted in seconds to the appropriate machine tools. This internal software is an own development by Dal Sasso S.r.l. with which a report is also prepared for each product. In this way it is possible to trace back every step in production. In hectic times this is a reliable documentation to present to the customer, and internally a check of productivity and machine utilisation. Floor-to-floor times of just 3 weeks, as in the case of the two-part casing for a medical device, are thus quite realistic at Dal Sasso S.r.l. Economic employment of ED die sinking The economic ED die sinking of high precision and complex mould inserts requires a great spectrum of machining technologies and generator outputs, both for a high removal rate and for the finest surfaces. Features which are convincingly applied at Dal Sasso S.r.l.: - The mould inserts for the upper part were ED machined in 24 hours. The machining took place autonomously by changing the four HSC milled electrodes made of medium-fine graphite which had an undersize of 0.5 mm in each case. The cavities were shaped spherically with Equimode and had a surface roughness inside of VDI 22 and outside of VDI 28. - Sixteen hours were required for the mould inserts of the lower part. The changing of the 5 electrodes also took place autonomously and the shaping was carried our circularly. The same surface roughness figures were achieved as in the case of the upper part. - The 45 mm high ribs of the casing were realised using a ribbed electrode, and by pressure flushing from above. Mould half for the rib structure of the casing. A workpiece is set up on the ED diesinking system Agietron Impact 3. The lower part of the casing is plotted on the measuring machine after the specimen-taking. The data determined are sent online to tool making that can then carry out a variance comparison with them. 11 AGIE experience No 23 October 2003 High autonomy makes short throughput times possible With the automatic changing of electrodes as standard, the selfadapting change in generator output to the state of machining, as well as the high removal rate with low wear, the Agietron Impact 3 contributes considerably towards reducing the floor-tofloor times, and is thus an important part of the production network for tool and mould making at Dal Sasso S.r.l. Various mould inserts for the medical device casing. Both machining processes, hard milling and ED die sinking, are employed in accordance with economic viability and precision factors. The complexity of the casing results from the interior structure of the device that was designed to accommodate electronic and mechanical components. The tool data Name Injection moulding tool with 3 slides Name of finished part Casing for medical device Tool material Steel 1.2083, Stavax, hardened to 54 HRC Finished part material Polycarbonate Surface roughness Inside VDI 22, outside VDI 28 Material electrodes EDM 200, graphite medium fine from HKZ Tokai Number of electrodes 4 for upper part, 5 for lower part EDM time 24 hours for upper part, 16 hours for lower part “ At Dal Sasso S.r.l. the standard in tool and mould making is already far above the average. Our demands on a new ED die sinking system were all the higher. The high removal rate with low wear and the great autonomy with unsupervised operation were the main arguments why we decided on an Agietron Impact 3. Marco del Sasso, Director Tool and Mould Making Dal Sasso S.r.l. ” We would like to thank Dal Sasso S.r.l., in particular Marco dal Sasso, Director Tool and Mould Making, for their kind support and helpful collaboration with this report. Responsible Sales Engineer: Giuseppe Bottazzi, Agie Spa, Italy 12 AGIE experience No 23 October 2003 Forez Country Czech Republic Production range - Market 60% Czech Republic, 40% Europe Employees 130 Founded 1996 ED machining 1 Agietron Innovation 2 1 Agietron Impact 2 1 Agietron Impact 3 1 Agietron 2U 1 Agie Mondo Star 20 2 Agiecut Challenge 2 1 Agiecut Challenge 3 1 Agiecut Classic 2 Clamping - Erowa for ED die sinking - Own developments for ED wire cutting Software - 3D-CAD/CAM from Unigraphics - Complete networking of CAD/CAM/CAQ Certification - In accordance with ISO 9001 - In accordance with ISO 14001 Measuring - CNC measuring device DEA from Brown & Sharp Production of blanking, bending and deep-drawing tools Production of injection moulding tools up to 3500 kg Production of test tools and moulds Contract production of precision spare parts Production of metal pressed parts Production of injection moulded parts Forez s.r.o. Ostrov 2 CZ-56122 Tel +420 465 352 111 Fax +420 465 352 222 [email protected] The Czech company has 130 employees on its payroll and is based to the west of Lanskroun in east Bohemia. Forez s.r.o. is divided into two business sectors: Production and tool making. Stamped, pressed, bent and deep-drawn parts are produced on their own machines, as well as injection moulded parts on their own automatic injection moulding machines with a clamping force of 200 t. In tool making, for the most part progressive dies, compression moulding and deep-drawing tools are manufactured. In addition for both sectors comes designing on various CAD/CAM stations. Forez s.r.o. thus belongs to the mediumsized companies in this branch in the Czech Republic. www.forez.cz Contact Ing. Jindrich Marek, Director 13 AGIE experience No 23 October 2003 Impact: ED die sinking that makes an impression Complete supplier of metal and plastic parts The Forez s.r.o. company, founded in 1996 with 130 employees on its payroll, is one of the medium-sized companies in the tool and mould making branch in the Czech Republic. With state-of-the-art CAD/CAM systems, ED die sinking and wire cutting systems, milling and HSC machines, as well as automatic pressing and injection moulding machines, Forez s.r.o. has set itself the target of establishing itself as a system supplier in the market. Already today, renowned companies, such as Bosch, Witte, Schneider Electric, Visteon or Valeo, are among the companies which all take ad- vantage of the complete service offered by Forez s.r.o. Annual growths in turnover of 20 - 40% are a further proof of the company’s high quality and production standard. The whole performance spectrum of Forez s.r.o. can be shown by a car door insert made of glass fibre reinforced polyamide that was commissioned by an automobile manufacturer. The extremely complex form with several undercuts required more than fifty shaped electrodes. For this the two Agietron Impact were also used which offered the greatest machining autonomy with their changers with spaces for 12 to 56 electrodes. Three-dimensional representation of the double injection moulding tool with a mould insert for a car-door insert. View of the development and design department of Forez s.r.o. The development and design of injection moulding tools are based on mould flow technology by means of which the flowability in the mould is checked. Representation of a mould half for the car door insert as a volume model. A virtual world of tool and mould making In order not to experience any unpleasant surprises during the final sample-taking, nowadays the flow property in the tool or the functionality of the slides can be simulated by means of various software programs. The “dismantling” of the tool according to the machining steps or the generation of electrode moulds from the CAD data has nowadays become everyday routine on the PC. Virtual measures which make tool making more certain and accelerate the production sequence at Forez s.r.o. too. 14 AGIE experience No 23 October 2003 Forez Over 500 hours of reliable EDM sequence The production sequence for the door insert was carried out by Forez s.r.o. as follows: - The injection moulding tool was designed as a double tool in order to economically achieve the required service life of 2 million single parts. - After receipt of the CAD data for the door insert from the cus- The 2-fold injection moulding tool for the production of automobile door inserts. The view of the lower und upper die half as well as the final product can be easily made with the help of a 3D computer animation program. The EDM parameters are examined on the EDM system Agietron Impact 3. tomer, the injection moulding tool with the various mould inserts was designed using the 3D-CAD program from Unigraphics. - The production procedure was determined on the basis of the tool data. - The electrode shapes were generated from the CAD data of the mould inserts. - With these data, the programs for the high-speed machining and ED wire cutting for the electrode production were prepared. - The CAM data were transferred by Agie Scriptfile to the appropriate ED wire-cutting or high-speed milling machine. These data contain all the specific requirements for production, such as roughness, precision and production sequences. - Before loading the Agietron Impact changer, the electrodes were measured and preset on the measuring machine. - Then the CAD electrode data were supplemented with details of the material type, undersize and degree of difficulty. - The input of data to the Agietron Impact was carried out by describing the workpiece in accordance with the material, as well as the placing, quality and priority targets of the machining. Various mould inserts made of tool steel 1.2343 for the double injection moulding tool. In order to be able to eject the car door insert made of glass-fibre reinforced polyamide with 7 spring-loaded catches and further undercuts, the tool has 2 times 12 slides at its disposal. 15 AGIE experience No 23 October 2003 “ With the open system Agievision control, the user surface of which is nearly identical for both ED die sinking and wire cutting systems, we have the advantage that we can standardise our internal sequences. Starting from the transmission of CAD data through measuring in the machine to target-oriented data input on the Agietron or Agiecut. Especially the Impact ED die-sinking models make an exceptional impression. Jindrich Marek Director of ” - On the basis of the machining task, the electrodes were put together to form a family which could then be shifted to any coordination point without any further data input. - After the input of the degree of difficulties, the Agietron Impact will then generate the technology from this and prepare the machining sequence in accordance with the number of electrodes available. - The workpieces were plotted by Agiesetup 2D directly on the Agietron Impact. - As it was a double injection moulding tool, all the mould inserts also had to be ED machined twice so that, for example, it was possible to use the finishing electrode from the first mould as the roughing electrode for the second mould. These sequences were input, managed and called up via the Agievision module Toolmanager. - Individual mould inserts were pre-milled so that they only had to be ED machined 0.5 mm with planetary spotting. - The ED die sinking works were completed after 545 hours and the use of over 50 electrodes. - On all the forming parts, the required surface roughness of VDI 24 was achieved. For Forez s.r.o. ED die sinking that made an impression with its autonomy and scope of performance. Forez s.r.o. Every detail of the mould inserts is plotted on the DEA measuring machine from Brown & Sharp. The data obtained are sent online to design, compared with the given geometry data there and, if necessary, passed on to mould making for correction. The finished door insert made of glass-fibre reinforced polyamide as it is then used by the million in cars. The tool insert data Tool name double injection moulding tool Finished part name car door insert Mould inserts material tool steel 1.2343 Finished part material glass fibre reinforced polyamide Tool weight approx. 900 kg Electrode material Graphite Electrode production high-speed milling EDM time 545 hours Surface roughness outside VDI 24 We would like to thank Forez s.r.o., in particular Director Ing. Jindrich Marek, for their kind support and helpful collaboration with this report. Responsible Sales Engineer: Reto Parolini, Agiesales Ltd. 16 AGIE experience No 23 October 2003 BT MagnetTechnologie GmbH BTMT Country Germany Production - Ferrite magnets - Sintered compacts - Sintered bearings Target market International Employees approx. 500 Founded Established in1989 by the companies Bosch and TDK EDM systems 1 1 1 1 Programming - PCam - Mecanic Clamping systems - 3R - own system solutions Measuring, checking Agietron Exact 3 Agietron Intergral 3 Agiecut Evolution 2SF Agiecut 220 - Measuring system Vista from Zeiss - Contour measuring device from Hommel - Measuring system Venturion from Zoller BT Magnet-Technologie GmbH Werkzeugbau Forellstrasse 100 Herne D-44629 Tel +49 (0)2323 201 361 Fax +49 (0)2323 201 402 The name BT Magnet-Technologie GmbH stands for a company that is present with its technologies in the markets for ferrite magnets and sintered metal parts world wide. The works in Herne (North RhineWestphalia, Germany), with over 500 employees on the payroll, produce around 18.0 million ferrite magnets as well as 8.0 million sintered compacts and approx. 6.0 million sintered bearings monthly that are supplied primarily to the automotive, automotive supplies and electric tools industries. [email protected] www.btmt.de Contact Frank Pietzuch, Manager Toolmaking 17 AGIE experience No 23 October 2003 Roughness values and EDM time halved Open up new markets with new technologies BT Magnet-Technologie GmbH is a joint venture by Robert Bosch GmbH and the TDK Corporation, Japan. BTMT utilises the synergies resulting from these two companies’ many years of experience with the production of ferrite magnets and sintered metal parts. BTMT’s customers include companies such as Robert Bosch, Siemens, DaimlerChrysler, Volkswagen, Valeo, Luk, Visteon and Denso. Already from the component development stage through to the launch of a series, each project is continuously attended by experts from various specialised departments. Modern sinter technology offers the following advantages: - Production almost without any loss of material - High repeating accuracy with large quantities - Outstanding surface quality - Material compositions which cannot be presented with molten steels. The correct choice of materials, as well as the mastery of the production of high precision and geometrically demanding components are decisive for the success of the workpiece. As the production example of a clutch hub shows, electrical discharge machining plays a key role in this: Repeatable results, super fine surfaces, as well as high machining autonomy. At all stages of the production and development of the clutch hub, BTMT makes use of the most modern technology – from computer-aided design through automated production and quality monitoring to the planning of delivery (workshop drawing, mould insert and moulding plug of the sintered pressing tool, check of the tool insert on the Zeiss Vista measuring machine). 18 AGIE experience No 23 October 2003 BTMT The outside contour of the sinter moulding plug is ED die sunk in the reverse process on an Agietron Exact. On account of the high precision requirements and the complexity of the forms, all the electrodes, both those made of graphite and those made of copper, are ED wire cut on an Agiecut Evolution 2SF. A fully automatic handling device removes the finished clutch hubs from the sinter pressing tool. EDM programs are prepared externally After the receipt of the workpiece data for the clutch hub via IGES or DXF, the design of the sinter pressing tool is generated from this by ProEngineer. Special emphasis is placed here on designing correctly for the tool and using technologies adapted to the sintering process. When the parts to be machined using ED die sinking and wire cutting have once been defined, the EDM programs are prepared. Thanks to the Agievision PC software, this task is carried out externally at the pre-setting position, where the workpieces are also palletised, clamped and measured. The machining programs are then allotted to the pallets by means of Agie AV Manager. ED die sink punches in reverse procedure The following steps result for ED machining: - Preparation of the holder for the roughing electrode (graphite), the finishing electrode (copper) and fine finishing electrode (tungsten-copper). - ED wire-cutting of the electrodes as “dies” with the SF module for the finest surfaces. - Loading the electrode changer with the electrode families. - ED die sinking of the outside and inside form of the moulding plug from the material in automatic operation in which each electrode is called up with the machining technology and strategy allotted to it. Few machining steps increase the precision Sintered compacts pass through the following production processes: - pressing - sintering - possibly calibration in addition - if necessary, further finishing treatment. If the machining steps during the tool production are added to this, it becomes clear that the problem of positioning accuracy must not be underestimated either when ED machining or when sinter pressing. Because, with each reclamping, fixing or calibration operation, there is a risk of a loss of positioning precision, even if “only” in the tenth of a micron range. These minimal deviations can then quickly add together to 1 µm on the finished part. Thus at BTMT the foremost target, and also an integral part of the quality management, is to keep the number of machining and production steps as small as possible, and to document each machining and production step with measuring and test procedures. Precision which shows itself with a long working life, for example with clutch hubs. 19 AGIE experience No 23 October 2003 Already in 1998 with the Agietron Integral we were able to practically halve the times taken for ED machining and im- “ prove the surface quality to Ra 1.24 µm. Agietron Exact then brought a further improvement in EDM times of 20% and the positioning accuracy now lies in the tenth of a micron range. The Exact model in the Agietron series bears its name with real justification! Frank Pietzuch Toolmaking Manager of ” BT Magnet-Technologie GmbH We would like to thank BT Magnet-Technologie GmbH, in particular their Toolmaking Manager Frank Pietzuch, for their kind assistance and helpful collaboration with this report. Responsible Sales Engineer: Klaus Schmidt, AGIE GmbH A “die” serves as a mould electrode for the production of the outside contour of the clutch hub. The long travel paths of the Agiecut Evolution 2SF allow the working area to be optimally utilised, so that several workpieces can be placed there to then be processed autonomously. The basis for the constant quality of processes and products is certification in accordance with ISO/TS 16949 as well as VDA 6.1. In addition, the BTMT has the most modern measuring and testing systems at its disposal which are employed at all phases of production. Quality which proves itself millions of times daily with every gear-change using the clutch hub. The tool data Name Sinter pressing tool Name of finished part Clutch hub for passenger cars Moulding plug material Powder metallurgical tool steel Die material Hard metal Finished part material Sintered material Electrode material Graphite for roughing, copper for finishing and tungsten-copper for fine finishing Electrode production ED wire cutting with Agiecut Evolution 2SF EDM time EDM time: 70% ED die sinking and 30% ED wire cutting (incl. electrode production) Surface roughness Ra = 0,1 µm 20 AGIE experience No 23 October 2003 PNPPK Country Russia Production - Navigation instruments for aviation and shipping - Household and DIY appliances - Medical diagnosis instruments Target market International Employees 4200 Founded 1956 EDM systems 1 Agiecut Challenge 2 1 Agiecut Classic 2 1 Agiecut Classic 3 1 Agiecut 120F 1 Agiecut Sprint 70 1 Agietron Impact 2 1 Agietron Innovation 2 1 Agietron 3U 1 Agie Mondo Star 20 1 Agie Elox Mondo 1 1 Agie EDM-D Programming - Unicam - 2D and 3D-CAD/CAM systems - Agievision PC Clamping systems - System 3R Measuring testing - Global from DEA PNPPK – Perm Scientific Industrial Instrument Making Company 25.-Oktober-Strasse 106 Perm 614990 Russland The PNPPK company based in the Urals has 4200 people on its payroll and is the largest producer of household appliances and home working tools for the Russian market. In addition, the enterprise is known worldwide as the manufacturer of navigation instruments for the aviation and shipping fields. PNPPK has received awards on several occasions in Russia for the “Best Russian Product”, “Best Quality Production” and further prizes in various categories. Tel +007 (3432) 45 23 36 Fax +007 (3432) 45 12 19 [email protected] www.ppk.perm.ru Contact - Andrey Poloskov, Technical Director - Viatscheslav Bloch, Deputy Manager Manufacturing Technology 21 AGIE experience No 23 October 2003 Virtuoso use of ED die sinking and ED wire cutting High-tech in demand from Russia Two hours’ flying time from Moscow lies Perm in the foothills of the Urals, the home of PNPPK, the Perm Scientific-Industrial Instrument Making Company, founded in 1956. The company has 5000 employees on its payroll and is active in three business fields: - Navigation systems for die civil and military aviation, for sea and river shipping, as well as for terrestrial applications. - Household and DIY appliances. - Diagnosis instruments in the medical sector. PNPPK is not only a manufacturer here, but also has a large research and development department at its disposal, as well as an efficient tool and mould making facility with an ultra modern range of machines. With their repeatable precision results and their great autonomy, EDM systems are also held in high regard at PNPPK as important key stations in the manufacturing process. The EDM systems from Agie have proved themselves both in tool and mould making, and also in the series production of gyro compasses. Throughout controlled manufacturing is applied by PNPPK: Copper electrodes for the manufacturing of the housing for a percussion drill. A solid model of the percussion drill housing is generated on the CAD system. Insert for the plastic injection tool for the percussion drill housing. The most recent investments are an Agiecut Challenge 2 and an Agietron Impact 2, the performance spectrum of which is shown in this report with the production of an injection moulding tool for the casing of a percussion drill. 22 AGIE experience No 23 October 2003 PNPPK Combining complex forms on one electrode The CAD program was prepared on the basis of the design drawings for the percussion drill’s casing. From this PNPPK generated the electrodes, whereby as many mould geometries as possible were linked on one electrode, with the advantages: - fewer detail electrodes - less positioning - fewer co-ordinates - fewer measuring operations - fewer sources of errors. The electrodes and workpieces were plotted directly on the Agietron Impact 2 with Agiesetup 2D. Equidistant shaping for precise details The data input was carried out in accordance with the degree of difficulty of the machining target and was clearly structured thanks to the input pages Easywork, Easygeo and Easymachining. Orbit movements were also defined for various machining steps which were freely defined by means of Spacetrack. Agietron Impact calls up these parameters automatically for the machining step required so that filigree details can be shaped precisely equidistant, and sharp edges generated for webs and ribs. ED die sinking which is shown with outstanding quality on the percussion drill from PNPPK. The tool data An Agietron Impact is loaded with one mould half for the percussion drill casing. The electrodes milled from copper for the percussion drill. Copper electrodes were used even for the production of the shell halves for the accompanying tool case. Plotting a mould half on a Global measuring machine from DEA. Name Injection moulding tool Finished part name Percussion drill casing Mould insert material Steel 4X5 MFS Finished part material Polyamid Aramid PA-SW 30 Tool service life 1 million parts Electrode material Copper Electrode production Milling and ED wire cutting EDM time 72 hours ED die sinking 2,5 hours ED wire cutting Surface roughness Ra = 0,2 µm “ In country of the inventor of electrical discharge machining, Agie has the best name of all manufacturers in the field. The Russian husband and wife inventor team Lazarenko made the natural phenomenon of electrical discharge machining controllable. Agie has optimised the process over the decades and, in addition, was the first to bring ED wire cutting onto the market. For us technical competence that counts. Viatscheslav Bloch, Manager Manufacturing Technology PNPPK 23 AGIE experience No 23 October 2003 A further convincing example of the outstanding manufacturing technology of PNPPK is the series production of gyro compasses. The workpiece is made of a special alloyed steel and manufactured in over 30 single operations. Among other things, 11 slots are made by an Agiecut 120F and 40 slots by an Agie Elox Mondo 1. As one of the last machining steps, 4 separating slots are ED die sunk with an Agie Elox Mondo 1, by means of which the internal part of the compass becomes fully movable. The photos show the drawing and various stages of the manufacture of the gyro compass. We would like to thank PNPPK, in particular their Technical Director Andrey Poloskov and the Manager Manufacturing Technology Vyacheslav Bloch, for their kind support and helpful collaboration on this report. Responsible Sales Engineer for Russia: Hans Wyss