AgieCharmilles DRILL 300 - GFMS Opportunities

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GF Machining SolutionsAgieCharmillesDRILL 300

GF Machining Solutions : all about youWhen all you need is everything, it’s good to know that there is one company that you can counton to deliver complete solutions and services. From world-class Milling, electrical dischargemachines (EDM) and Laser texturing machine tools through to first-class Automation, Toolingand software systems — all backed by unrivaled Customer service and support — we, throughour Mikron, Liechti, AgieCharmilles and System 3R technologies help you raise your game andincrease your competitive edge.Swiss designand quality2AgieCharmilles DRILL 300

ContentsThe winning solutionHigh-speed EDM drillingFine hole qualityPowerful controlQuick preparationHigh degree of autonomy and AutomationGF Machining Solutions46810141618DRILL 300The winning solution for cooling hole machiningof components in aircraft enginesIn today’s aircraft engines, the temperature in the combustion chamber can be close to the melting point of the nickelalloy used. In order to create a film of cooling air on thesurface of components to prevent the nickel alloy frommelting, cooling holes are needed on the curved surface ofcomponents such as turbine blades, vanes, and shrouds.Machining these cooling holes with high quality and pro ductivity is always the main concern for aircraft enginecomponent manufacturers.

The GF Machining Solutions’answerThe DRILL 300 is equipped with GF Machining Solutions’latest digital generator, allowing the drilling process to becontinuously optimized with every pulse. As a result themachining speed has been increased significantly compared to conventional EDM drilling.Technology is chosen according to the desired results. Forexample, by selecting “quality” technology, the electrodewear will automatically be reduced and the heat-affectedlayer is reduced to a few microns. Conversely, the operatorcan select “speed” technology to produce holes with thefastest possible erosion rate.4AgieCharmilles DRILL 300With six-axis configuration, holes with different positionsand angles can be freely programmed and machined, allowing for greater part flexibility and design. Single setupmachining reduces unproductive time.By using the automatic electrode/guide changer (AEC/AGC),multiple holes with different diameters can be machined automatically and the machine attains longest autonomy.Due to wide range of optimized technologies for electricallyconductive material like Inconel, steel and hard metal, theDRILL 300 is a winning solution for cooling hole machining inaerospace as well as other industrial applications such ascutting tools, automotive, medical and die plates.

With 60 years of experiencebuilding Electrical DischargeMachines, GF MachiningSolutions has developeda new EDM drilling machine,the DRILL 300. This machineis manufactured in Switzerlandto deliver top performance inmachining cooling holes foraircraft engine components.5AgieCharmilles DRILL 300

High-speed EDM drillingIncreasingyour productivityThe EDM generator has state-of-the art powerful electronics to increase productionoutput by utilizing efficiently controlled EDM processes that include FPGA technology,digital data recording and fully digitized pulse control. The drilling process iscontinuously optimized with every pulse, thus the fastest drilling speed is achieved.Fast and reliable breakthroughWithout breakthrough detection, the machining time atbreakthrough is even longer than the entire hole drillingtime when the flushing process breaks down. With advancedbreakthrough detection on the DRILL 300, the process ismonitored in a real time; the technology is adapted automatically to exit technology; the reliable process is attained andthe breakthrough time is shortened by 50-70 percent.DepthConventionaldrilling timeDRILL 300drilling time20 mm100 mm48 s280 s28 s170 sElectrode: brass, Ø 1.0 mmWorkpiece: steelSpeed technologyWith advancedbreaktroughdetectionDrilling timeConventionalEDM drillingDRILL 300DRILL 300up to 40% faster60 mm100 mmWithout breaktroughdetection6AgieCharmilles DRILL 300

0202020202040404040405050Copper40BrassHard 1313149802.0510Inconel harmilles DRILL 300Optimal technologiesOne type of technology cannot meet all of your requirements.According to the workpiece material and your stringent metallurgical requirements, the DRILL 300 has the optimizedtechnologies to focus on either quality or speed. The qualitytechnology achieves minimum heat-affected layer and betterhole integrity, while the speed technology focuses on shortdrilling time.

Fine hole qualityThe new standardin hole-drilling EDMMinimum heat-affected layerHeated-affected layer has significant influence on the fatiguelifetime of components and the safety of aircraft engines. TheDRILL 300 is designed for achieving the best result in termsof heat-affected layer and avoiding cracks in the components.The DRILL 300 digital generator allows the finest pulse duration of a few microseconds. When quality technology is used,the heat-affected layer can be dramatically reduced to a fewmicrons with a reasonable machining speed.8AgieCharmilles DRILL 300

without FirstSparkwith FirstSparkConsistent hole dimensionWhen machining cooling holes with conventional EDM drilling,the spatters at the hole entrance are always a problem,especially if there is a small angle between the hole andsurface of components. The DRILL 300 has a fine pulse applied with the first spark function, then the technology isautomatically adapted to the standard parameters. Therefore, the spatters in the hole entrance are avoidable and aperfect profile is achieved.In order to optimize the machining of the most complexholes, the DRILL 300 provides the way of programmingparameters corresponding to the machining depth. Multiparameters can be used in the same hole.With advanced breakthrough detection “Breakthrough Strategy” on the DRILL 300, the hole exit technology is optimizedand the exit electrode length is programmable, and backstriking can be prevented. Meanwhile the quality technologyalso helps attain the right hole dimensions at the bottom ofthe hole.9AgieCharmilles DRILL 300Electrode: brass, Ø 1.0 mmWorkpiece: steel, 20 mm heightQuality technology

Powerful controlTo manage sophisticatedhole machiningCNC controlIn order to meet the demands of different applications, theDRILL 300 can be configured with different kinematics:XYZW, XYZWBA, XYZWAB, XYZWB1C1, XYZWB1, XYZWAB1.With single setup the holes with different diameters, positions and angles are freely programmable and machined.10 AgieCharmilles DRILL 300Control unitThe graphical user interface is based on the Windows operating system and allows real time control of the EDM process. The system works with descriptive picture symbolsand conversational screen pages following one after anotherin a logical way. This allows even new users to understandthe EDM principle quickly and means time to production isvery short.

Manual operation – Easy DrillMain functions include all setup cycles, easy and fast programming for single hole machining (one hole on one page)as well as electrode and guide management.Work preparationThe machine can import the entire work in the format ofXML.NCC, ISO.NCC and PAT.NCC (compatible with AC CAMDRILL) directly or prepare the work manually with TEACHfunction. The parameters of every machining can be modified with Edition. The work can be graphically checked.11 AgieCharmilles DRILL 300Work executionThis page activates the work and executing measuring cycles. All machining, parameters and hole positions aremonitored on this page.

Quick preparationReducing theun productive timeFast setup cyclesThe universal console is equipped with the touchscreenbased on the Windows operating system. The setup cyclesprobe, edge finding, corner finding, center finding, etc., helpto prepare the job in a convenient way.Single setup machiningWith different kinematics of six axes, holes with different diameters, positions and angles can be freelyprogrammable and machined even with single setup,allowing for greater part flexibility and design. Singlesetup machining eliminates the need for additionalexpensive fixtures and avoids multiple setups to reduce unproductive time.12 AgieCharmilles DRILL 300Less down timeTo ensure the longest life and reliability of the electronics,a closed water-air cooling circuit is contained within a dustproof cabinet, in which the temperature is also monitored andstabilized with multi-sensors.With this design, the lifetime of the electronics is guaranteedeven in the most difficult conditions.

High degree of autonomy and AutomationFor maximizingproductivityAutomatic electrode/guide changerThe optional linear 16/4 electrode/guide changer and 50/8 rotary electrode/guide changer are available on the DRILL 300.AEC/AGC 16/4 is affordable solution and AEC/AGC 50/8 is asolution with the longest autonomy for max productivity.Automatic filtration and conductivity controlWith the 200-liter water tank and a 10-liter resin bottle in astandard configuration, the water filtration and conductivityare automatically controlled and cycled.13 AgieCharmilles DRILL 300Automatic part changerWith the optional Automation kit, the DRILL 300 can connectto external robot to automatically manage part changing.

Technical dataDRILL 300DRILL 300MachineMachine dimensions (L x W x H)mm (in)Net weightkg (lbs)Without tilting head: 2320 x 1400 x 2180 (91.34 x 55.12 x 85.83)With tilting head: 2320 x 1900 x 2180 (91.34 x 74.8 x 85.83)2500 (5512) without variants and optionsmminmm (in)mm (in)0.3 3.0 (option: 0.1, 0.2, 4.0, 5.0, 6.0)0.012 0.12 (option: 0.004, 0.008, 0.16, 0.20, 0.24)1000 x 700 x 500 (39.37 x 27.56 x 19.69)Ø x L 350 x 320 (13.78 x 12.60)kg (lbs)kg (lbs)1000 (2205)25 (55) including clamping weightmm (in)800 x 600 (31.50 x 23.62)4 bars (2 stationary, 2 adjustable)850 (33.46)FrontMachining areaElectrode diameterMax. workpiece dimensionMax. workpiece dimensionwith tilting/rotary axesMax. workpiece weightMax. workpiece weightwith tilting/rotary axesWorktable dimensionWorktable typeDistance from table surface to floorAccessibilityAxesTravel X x Y axesTravel W x Z axesTilting/rotary axes (option)Max. axis motion speedMeasuring system for Z, W axesMeasuring system for X, Y axesLubricationDielectric unitDielectric typeDielectric capacityMax. flushing pressureFilter accuracyCapacity of deionizing bottleCooling system14 AgieCharmilles DRILL 300mm (in)mm (in)mminºm/min. (ft/min)l (us gal)bar (psi)µml (us gal)600 x 400 (23.62 x 15.75)450 x 450 (650 optional)17.72 x 17.72 (25.59 optional) 100 / 0 3604 (13.12)EncoderEncoder (linear glass scales optional)ManualIndustrial water or civil water200 (53)80 (1160)510 (2.6)Water/water heat exchanger

DRILL 300GeneratorGenerator typeMax. mean working currentCooling system inside cabinetANumerical controlFlat screenKeyboardMouseStorage capacityInterface portMeasurement unitCommand formatCoordinates systemMax. number of machining in the programServo controlled axesImport filesOnboard CAD/CAMFirst spark detectionElectrode wear compensationBreakthrough detectionOnboard documentationElectricity supplyThree-phase input voltagePermissible variationsMain frequencyPower consumptionNominal currentCooling water when heat exchanger usedFlow minimum requiredTemperatureCompressed airPressure range betweenFlow minimum requiredConnection pipe external diameterMain optionsAutomatic electrode/guide changerTilting headLarge travel of Z axisRotary/tilting table15 AgieCharmilles DRILL 300ISPG60Air/water heat exchanger17” flat touchscreenStandardStandard 230 GB HD, 1024 MB RamUSB and EthernetMetric/inchAbsolute/incrementalMachine, part500X, Y, Z, W, A, BXML.NCC, ISO.NCC, PAT.NCCAC CAM DRILL as standardStandardStandardStandardStandardVHzkVAA380 or 400from 10% to -10%50 or 604.26l/min (gal/min) C F20 (5.2) Tworkshop – 9 C Tworkshop – 18 Fbar (psi)m3/h (yd3/h)mm (in)6 to 8 (85 to 113)5 (6.54)10 (0.4) mm (in)AEC/AGC 16/4, AEC/AGC 50/8Max. 45650 (25.59)

1260/49.6’’7003.94’’DRILL ��’598600/23.62’’400/15.7540/1.57’’Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 .11’’3.94’’250100DRILL 300 tilting .95’’2248/88.5’’16 AgieCharmilles DRILL 0/23.62’’40/1.57’’Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 ’’

The DRILL 300 easily drillscooling holes in turbine blades.For this demo blade, 180 throughholes and blind holes (Ø 0.5 mmand Ø 1.0 mm) were machinedin only 75 minutes, using a singlesetup with the automaticelectrode and guide changer.17 AgieCharmilles DRILL 300

GF Machining SolutionsEDM (electrical discharge machining)MillingAgieCharmilles wire-cutting, die-sinkingand hole-drilling machines.For over 60 years we have been at the forefront of every EDM development: designing and refining the EDM process and building machinetools that deliver peerless part accuracies, surface finishes, cuttingspeeds and process reliability. Today, our AgieCharmilles wire-cutting, die-sinking and hole-drilling machines are recognized throughout the world as the best in the business. Our continuous research anddevelopment in digital generator technology, control systems and integrated Automation systems are evidence of our commitment tokeeping your EDM operations on the leading edge of technology.Mikron high-speed (HSM), high-

the EDM principle quickly and means time to production is very short. 11 AgieCharmilles DRILL 300 Manual operation – Easy Drill Main functions include all setup cycles, easy and fast pro-gramming for single hole machining (one hole on one page) as well as electrode and guide management. Work preparation The machine can import the entire work in the format of XML.NCC, ISO.NCC and