FORM 20 / FORM 30 - GF Machining Solutions
P_FORM 20-30ing
11.9.2007
8:36
Pagina 1
FORM 20 FORM 30
P_FORM 20-30ing
11.9.2007
8:36
Pagina 2
FORM 20 Simple data imput and low power consumption with FORM 20
2
P_FORM 20-30ing
11.9.2007
8:36
Pagina 3
Contents
Highlights The mechanism The generator The control Job preparation About GF Agiecharmilles
FORM 30 The ideal machine for big mould, with high performances: FORM 30
3
4 6-7 10 11-12 13 14-15
P_FORM 20-30ing
11.9.2007
Highlights
8:36
Pagina 4
Swiss top technology with best price-performance ratio
FORM 20 and FORM 30, simple handling combined with Swiss technology, with a price-performance ratio that is unequalled in this branch segment. - simple conversational programming system - ergonomic layout - wealth of technologies
P_FORM 20-30ing
11.9.2007
8:36
Pagina 5
5
P_FORM 20-30ing
11.9.2007
8:36
Pagina 6
Reliable design concept for longtime quality
The mechanism
The design concept of the FORM 20 and FORM 30 series is based on a tried and tested C-frame construction. The substructure of the machine, the column, table and quill are made from an ultra rigid cast iron in order to guarantee class leading stiffness and optimised thermal stability. The table and all major mechanical components, such as the recirculating ball screw and the guides for the axes, are over engineered, guaranteeing precision and repeatability and consequently ensuring years of trouble free service even in the toughest workshop environment.
Z
C
X
Y Thanks to the CNC controlled Caxis integrated into the quill of the Z-axis, FORM 20 and FORM 30 are incredibly flexible machines, with which 4 axes can be interpolated simultaneously. Allows curved recesses and undercuts by rotating the C-axis and 3D vector widening.
6
P_FORM 20-30ing
11.9.2007
8:37
Pagina 7
Electrode changer 4 electrode positions on FORM 20 and 6 electrode positions on FORM 30 for unattended machine operation.
7
P_FORM 20-30ing
11.9.2007
8:37
Achieve more...
Pagina 8
P_FORM 20-30ing
11.9.2007
8:37
Pagina 9
FORM 20 FORM 30
P_FORM 20-30ing
11.9.2007
8:37
Pagina 10
High performances with low power consumption
The generator
The FORM 20 and FORM 30 series are equipped with one of the most modern generators in the world for EDM die sinking. Thanks to its dynamic system, which is integrated into the intelligent part of the generator, the EDM process is continuously optimised with every impulse meaning electrode wear even under the finest finishes is dramatically reduced. Control of the process takes place in fractions of a second, and produces very homogeneous, uniform surface finish. State-of-the-art technology is employed so that energy consumption is as low as possible. As well as minimising cost of ownership it means the amount of heat dissipated into the workshop is dramatically reduced. Thanks to this approach, the FORM 20 and FORM 30 has the lowest energy consumption of any EDM machine worldwide, just 3.7 kW/h at full power. The high power generator has maximum output of 72A on FORM 20 and 104A on FORM 30. The generator's switchgear cabinet is equipped with a closed water-air cooling circuit which is controlled by the cooling unit within the system. To ensure the longest life and reliability of the electronics, they are contained within a dust proof cabinet, in which the temperature is also monitored and stabilized.
10
Technology: The FORM 20 and FORM 30 series encompass the most varied combinations of workpiece and electrode materials. All the technology series are present in the machine and can be called in for the most varied applications
P_FORM 20-30ing
11.9.2007
8:37
Pagina 11
Fast setup and easy operation
The Control
The numeric control of the FORM 20 and FORM 30 series is based on an industrial computer with an LCD-flat screen and works with the MS Windows XP operating system. The operator interface is operated with a mouse; in addition, a USB port is provided allowing easy transfer of data. The equipment can be integrated comfortably into a data network via LAN, for remote monitoring and data management from an external PC or send CMM coordinates from a measuring machine. The operator interface is designed with intuitive symbols and programming aids and can be easily operated even by less experienced users, however, it includes all the functions required for the creation of more complex moulds providing enough flexibility for the most experienced user. The FORM 20 and FORM 30 is the most user friendly and intuitive CNC EDM machine on the market.
Set-up page of workpiece and electrode
Graficheck of programmed Job
Detailed machining sequence
Process control and erosion optimizing
11
P_FORM 20-30ing
11.9.2007
8:37
Pagina 12
Simple and safe Job programming
With its AEP programming (Automatic Erosion Programming) a conversational type of data input takes place. The relevant instructions appear on the screen and the user is guided through all the phases of programming. This means that thanks to AEP simplicity the time to productivity is the absolute minimum and even new users can be programming complex forms within hours of delivery. From simple moulds with one electrode through to complex moulds with several cavities, the AEP system guarantees reliability and to ensure that the processed program is correct it can be graphically simulated. In addition to AEP programming, the system offers the possibility of using an advanced programming module with which the operator can retrieve records, run subroutines and freely program the machine. The control can also import ISO geometries for contours and data with reference points.
12
P_FORM 20-30ing
11.9.2007
8:37
Pagina 13
Easy setup for quick start of erosion
Job Preparation
D
C
C F
E D B D
A
Y
X
Measuring cycles A Corner touching B X/Y edge and Z finding C Internal centering D External centering E Alignement of the electrode F Angular position of the workpiece
The most common measuring cycles, from simple measuring of Z-level to rotating the workpiece around the C-axis, are integrated into the control. Thanks to these measuring cycles, the position of the workpiece is plotted, and the operator no longer has to adjust the workpiece. This means the time to erosion is minimised and the workpiece can be placed in the working area roughly. And then the operator can start the erosion.
13
The measuring cycles can be programmed and integrated into a job program. Allowing the unattended machining of multiple pieces, making out of hours operation a simple affair. The FORM 20 and FORM 30 series are ideal machines for inexperienced users in the field of general engineering and tool production. With FORM 20 and FORM 30, EDM die sinking is no longer reserved just for absolute experts.
Achieving the Highest Removal rates: Removal rates up to 1000 mm3/min. on FORM 30 with the 104A generator, roughness up to Ra 0.2 µm, just 3.7 kW/h power consumption on FORM 20, simple programming with AEP.
P_FORM 20-30ing
11.9.2007
8:37
Pagina 14
About GF AgieCharmilles
Milling
High-Speed and High-Performance Milling Centers In terms of cutting speed, HSM centers are 10 times faster than conventional milling machines. Greater accuracy and a better surface finish are also achieved. This means that even tempered materials can be machined to a condition where they are largely ready to use. One essential advantage of HSM is that with systematic integration, the process chain can be significantly shortened. HSM has developed alongside EDM into one of the key technologies in mold and tool making.
EDM
Electric Discharge Machines EDM can be used to machine conductive materials of any hardness (with the exception of steel or titanium) to an accuracy of up to onethousandth of a millimeter with no mechanical action. By virtue of these properties, EDM is one of the key technologies in mold and tool making. There are two distinct processes – wire-cutting EDM and die-sinking EDM.
Automation
Tooling, Automation, Software Tooling for fixing workpieces and tools; automation systems and system software for configuring machine tools and recording and exchanging data with the various system components.
Spindle
HSM Spindle Technology Development, production and sale of the motor spindles that form the core components of modern HSM centers. The spindles rotate at speeds between 10 000 and 60 000 rpm.
Service
Services and Consumables Service, maintenance, spare parts and consumables for EDM, milling and HSM systems as well as for other machine tools; consumables include filters, wire, graphite, copper electrodes and special resin.
P_FORM 20-30ing
11.9.2007
8:37
Pagina 15
© 2007 GF AgieCharmilles The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change.
259.804.512
P_FORM 20-30ing 11.9.2007 8:37 Pagina 16
Contact
www.gfac.com
Achieve more...
DT form 20-30 ing
12.9.2007
14:47
Pagina 2
Technical Data FORM 20 and FORM 30, die sinking machine in cast C frame and crosstable design FORM 20
FORM 30
X. Y. Z axes Travel X. Y. Z
mm
350 x 250 x 250
600 x 400 x 400
Positioning resolution
µm
0.5
0.5
Worktank size width x depth x height
mm
955 x 540 x 350
1200 x 800 x 500
Max. workpiece size
mm
800 x 500 x 265
1000 x 700 x 400
Manual bath level
mm
140-310
150-450
Door width
mm
830
1200/550
Worktable size width x depth Max. load
mm kg
630 x 400 200
800 x 600 1000
Distance floor to clamping level
mm
900
900
Max. electrode weight without C axis
kg
50
100
Max./Min. head to table distance chuck
mm
480/230
650/250
Max. electrode weight on automatic chuck
kg
50
50
Rotation speed
r.p.m.
0-55
0-55
Number of electrodes
pos
4
6
Max. electrode size
mm
75
75
Max. electrode length
mm
280
280
Max. electrode weight Weight total
kg kg
5 20
5 20
Worktank
Worktable
Z axis
Integrated C axis
Tool Changer
Generator Generator type
APG FORM
APG FORM
Max. machining current
A
72
104
Max. material removal
mm3/min
750 (gr-st)
1000 (gr-st)
Best surface finish Ra copper-steel
µm
0,2
0,2
Standard technology
Copper/Steel, Copper/Aluminum, Copper tungsten/carbide, Graphite/Steel...
Process adaptation according to the degree of difficulty
ACC/ACO automatic
Polarity
Programmable
Programmable
Electroerosive polishing
Agiebril
Agiebril
Flushing unit Injection
Through the workpiece and lateral
Suction
Through the workpiece
DT form 20-30 ing
12.9.2007
14:47
Pagina 3
FORM 20
FORM 30
Dielectric unit Capacity
l
270
750
Paper filteration cartridges
piece
2
6
Filter quality
µm
3-5
3-5
40 h at 32 A
100 h at 32 A
Filter autonomy
Cooling Integrated heat exchager air / wather for the cabinet Integrated heat exchager dielectricum / wather for the dielectricum
Machine Machine dimensions width x depth x height
mm
1300 x 1850 x 2500
2000 x 2600 x 2700
Cabinet dimension width x depth x height
mm
750 x 900 x 1915
750 x 900 x 1915
Cabinet weight Weight total without dielectric
kg kg
300 2000
300 3000
Floor space width x depth
mm
3000 x 3500
4500 x 4500
Power supply Standard voltage
3x380V/400V±10%. 50/60Hz (50Hz is standard)
Operator interface system Control unit integrated Remote control for manual axes movement X/Y/Z/C and general functions for work preparation
15” flat panel display, mouse JOGBOX with LCD Display
Operating system
Windows / multitasking
CPU’s
Pentium for CNC and operator interface
Storage capacity
> 20 GB HD, 512 MB Ram
Servo controlled axes
X/Y/Z/C axes
Units of measurement
mm/inch
Smallest programmable step X/Y/Z/C axes
0.001 mm / 0.001°
Visualisation of erosion data Program structure
Graphics display: power, stability, speed, depth Automatic Erosion Programing (AEP-guided)
Pickup cycles for automatic determination of workpiece position and electrode
Intuitive programming with icons
Orbital movement in space for every application
Ve c tor, circular, ve c tor 2D / 3D Equimode, continuous circular / spherical
Module for contouring
Geometry 3D
Help functions, explanations with text and graphics
Manual integrated in the operating system
Machining simulation and positioning
Program check without erosion
Languages Data storage media
EN,DE,CN,CZ,DK,ES,FR,IT,K,JP,NL,PL,PT,RU USB
Interfaces for external peripheries
1 x RS232C; 1 x Parallel; 1 x LAN; 2 x USB
Chiller included in standard configuration Chiller specifications Dimension: 450 x 500 x 1050 mm Cooling Capacity: 5 kW Power Supply: 3 x 380 V 50 Hz (60 Hz as option) Rated Power: 2.5 kW Rated Current: 7 A Controlled Temperature Range: 15~50o C, Control Accuracy +/- 1o C Minimum Flow Rate: 32 l/min. Ambient Temperature: 10~45o C, auto stop if temperature > 48o C
DT form 20-30 ing
12.9.2007
14:47
Pagina 4
626 670 730
FORM 20
1260
400
760
FORM 30
800 840 890
2000
600
760
626 670 730
DT form 20-30 ing
12.9.2007
14:47
Pagina 1
Achieve more...
11.9.2007
8:36
Pagina 1
FORM 20 FORM 30
P_FORM 20-30ing
11.9.2007
8:36
Pagina 2
FORM 20 Simple data imput and low power consumption with FORM 20
2
P_FORM 20-30ing
11.9.2007
8:36
Pagina 3
Contents
Highlights The mechanism The generator The control Job preparation About GF Agiecharmilles
FORM 30 The ideal machine for big mould, with high performances: FORM 30
3
4 6-7 10 11-12 13 14-15
P_FORM 20-30ing
11.9.2007
Highlights
8:36
Pagina 4
Swiss top technology with best price-performance ratio
FORM 20 and FORM 30, simple handling combined with Swiss technology, with a price-performance ratio that is unequalled in this branch segment. - simple conversational programming system - ergonomic layout - wealth of technologies
P_FORM 20-30ing
11.9.2007
8:36
Pagina 5
5
P_FORM 20-30ing
11.9.2007
8:36
Pagina 6
Reliable design concept for longtime quality
The mechanism
The design concept of the FORM 20 and FORM 30 series is based on a tried and tested C-frame construction. The substructure of the machine, the column, table and quill are made from an ultra rigid cast iron in order to guarantee class leading stiffness and optimised thermal stability. The table and all major mechanical components, such as the recirculating ball screw and the guides for the axes, are over engineered, guaranteeing precision and repeatability and consequently ensuring years of trouble free service even in the toughest workshop environment.
Z
C
X
Y Thanks to the CNC controlled Caxis integrated into the quill of the Z-axis, FORM 20 and FORM 30 are incredibly flexible machines, with which 4 axes can be interpolated simultaneously. Allows curved recesses and undercuts by rotating the C-axis and 3D vector widening.
6
P_FORM 20-30ing
11.9.2007
8:37
Pagina 7
Electrode changer 4 electrode positions on FORM 20 and 6 electrode positions on FORM 30 for unattended machine operation.
7
P_FORM 20-30ing
11.9.2007
8:37
Achieve more...
Pagina 8
P_FORM 20-30ing
11.9.2007
8:37
Pagina 9
FORM 20 FORM 30
P_FORM 20-30ing
11.9.2007
8:37
Pagina 10
High performances with low power consumption
The generator
The FORM 20 and FORM 30 series are equipped with one of the most modern generators in the world for EDM die sinking. Thanks to its dynamic system, which is integrated into the intelligent part of the generator, the EDM process is continuously optimised with every impulse meaning electrode wear even under the finest finishes is dramatically reduced. Control of the process takes place in fractions of a second, and produces very homogeneous, uniform surface finish. State-of-the-art technology is employed so that energy consumption is as low as possible. As well as minimising cost of ownership it means the amount of heat dissipated into the workshop is dramatically reduced. Thanks to this approach, the FORM 20 and FORM 30 has the lowest energy consumption of any EDM machine worldwide, just 3.7 kW/h at full power. The high power generator has maximum output of 72A on FORM 20 and 104A on FORM 30. The generator's switchgear cabinet is equipped with a closed water-air cooling circuit which is controlled by the cooling unit within the system. To ensure the longest life and reliability of the electronics, they are contained within a dust proof cabinet, in which the temperature is also monitored and stabilized.
10
Technology: The FORM 20 and FORM 30 series encompass the most varied combinations of workpiece and electrode materials. All the technology series are present in the machine and can be called in for the most varied applications
P_FORM 20-30ing
11.9.2007
8:37
Pagina 11
Fast setup and easy operation
The Control
The numeric control of the FORM 20 and FORM 30 series is based on an industrial computer with an LCD-flat screen and works with the MS Windows XP operating system. The operator interface is operated with a mouse; in addition, a USB port is provided allowing easy transfer of data. The equipment can be integrated comfortably into a data network via LAN, for remote monitoring and data management from an external PC or send CMM coordinates from a measuring machine. The operator interface is designed with intuitive symbols and programming aids and can be easily operated even by less experienced users, however, it includes all the functions required for the creation of more complex moulds providing enough flexibility for the most experienced user. The FORM 20 and FORM 30 is the most user friendly and intuitive CNC EDM machine on the market.
Set-up page of workpiece and electrode
Graficheck of programmed Job
Detailed machining sequence
Process control and erosion optimizing
11
P_FORM 20-30ing
11.9.2007
8:37
Pagina 12
Simple and safe Job programming
With its AEP programming (Automatic Erosion Programming) a conversational type of data input takes place. The relevant instructions appear on the screen and the user is guided through all the phases of programming. This means that thanks to AEP simplicity the time to productivity is the absolute minimum and even new users can be programming complex forms within hours of delivery. From simple moulds with one electrode through to complex moulds with several cavities, the AEP system guarantees reliability and to ensure that the processed program is correct it can be graphically simulated. In addition to AEP programming, the system offers the possibility of using an advanced programming module with which the operator can retrieve records, run subroutines and freely program the machine. The control can also import ISO geometries for contours and data with reference points.
12
P_FORM 20-30ing
11.9.2007
8:37
Pagina 13
Easy setup for quick start of erosion
Job Preparation
D
C
C F
E D B D
A
Y
X
Measuring cycles A Corner touching B X/Y edge and Z finding C Internal centering D External centering E Alignement of the electrode F Angular position of the workpiece
The most common measuring cycles, from simple measuring of Z-level to rotating the workpiece around the C-axis, are integrated into the control. Thanks to these measuring cycles, the position of the workpiece is plotted, and the operator no longer has to adjust the workpiece. This means the time to erosion is minimised and the workpiece can be placed in the working area roughly. And then the operator can start the erosion.
13
The measuring cycles can be programmed and integrated into a job program. Allowing the unattended machining of multiple pieces, making out of hours operation a simple affair. The FORM 20 and FORM 30 series are ideal machines for inexperienced users in the field of general engineering and tool production. With FORM 20 and FORM 30, EDM die sinking is no longer reserved just for absolute experts.
Achieving the Highest Removal rates: Removal rates up to 1000 mm3/min. on FORM 30 with the 104A generator, roughness up to Ra 0.2 µm, just 3.7 kW/h power consumption on FORM 20, simple programming with AEP.
P_FORM 20-30ing
11.9.2007
8:37
Pagina 14
About GF AgieCharmilles
Milling
High-Speed and High-Performance Milling Centers In terms of cutting speed, HSM centers are 10 times faster than conventional milling machines. Greater accuracy and a better surface finish are also achieved. This means that even tempered materials can be machined to a condition where they are largely ready to use. One essential advantage of HSM is that with systematic integration, the process chain can be significantly shortened. HSM has developed alongside EDM into one of the key technologies in mold and tool making.
EDM
Electric Discharge Machines EDM can be used to machine conductive materials of any hardness (with the exception of steel or titanium) to an accuracy of up to onethousandth of a millimeter with no mechanical action. By virtue of these properties, EDM is one of the key technologies in mold and tool making. There are two distinct processes – wire-cutting EDM and die-sinking EDM.
Automation
Tooling, Automation, Software Tooling for fixing workpieces and tools; automation systems and system software for configuring machine tools and recording and exchanging data with the various system components.
Spindle
HSM Spindle Technology Development, production and sale of the motor spindles that form the core components of modern HSM centers. The spindles rotate at speeds between 10 000 and 60 000 rpm.
Service
Services and Consumables Service, maintenance, spare parts and consumables for EDM, milling and HSM systems as well as for other machine tools; consumables include filters, wire, graphite, copper electrodes and special resin.
P_FORM 20-30ing
11.9.2007
8:37
Pagina 15
© 2007 GF AgieCharmilles The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change.
259.804.512
P_FORM 20-30ing 11.9.2007 8:37 Pagina 16
Contact
www.gfac.com
Achieve more...
DT form 20-30 ing
12.9.2007
14:47
Pagina 2
Technical Data FORM 20 and FORM 30, die sinking machine in cast C frame and crosstable design FORM 20
FORM 30
X. Y. Z axes Travel X. Y. Z
mm
350 x 250 x 250
600 x 400 x 400
Positioning resolution
µm
0.5
0.5
Worktank size width x depth x height
mm
955 x 540 x 350
1200 x 800 x 500
Max. workpiece size
mm
800 x 500 x 265
1000 x 700 x 400
Manual bath level
mm
140-310
150-450
Door width
mm
830
1200/550
Worktable size width x depth Max. load
mm kg
630 x 400 200
800 x 600 1000
Distance floor to clamping level
mm
900
900
Max. electrode weight without C axis
kg
50
100
Max./Min. head to table distance chuck
mm
480/230
650/250
Max. electrode weight on automatic chuck
kg
50
50
Rotation speed
r.p.m.
0-55
0-55
Number of electrodes
pos
4
6
Max. electrode size
mm
75
75
Max. electrode length
mm
280
280
Max. electrode weight Weight total
kg kg
5 20
5 20
Worktank
Worktable
Z axis
Integrated C axis
Tool Changer
Generator Generator type
APG FORM
APG FORM
Max. machining current
A
72
104
Max. material removal
mm3/min
750 (gr-st)
1000 (gr-st)
Best surface finish Ra copper-steel
µm
0,2
0,2
Standard technology
Copper/Steel, Copper/Aluminum, Copper tungsten/carbide, Graphite/Steel...
Process adaptation according to the degree of difficulty
ACC/ACO automatic
Polarity
Programmable
Programmable
Electroerosive polishing
Agiebril
Agiebril
Flushing unit Injection
Through the workpiece and lateral
Suction
Through the workpiece
DT form 20-30 ing
12.9.2007
14:47
Pagina 3
FORM 20
FORM 30
Dielectric unit Capacity
l
270
750
Paper filteration cartridges
piece
2
6
Filter quality
µm
3-5
3-5
40 h at 32 A
100 h at 32 A
Filter autonomy
Cooling Integrated heat exchager air / wather for the cabinet Integrated heat exchager dielectricum / wather for the dielectricum
Machine Machine dimensions width x depth x height
mm
1300 x 1850 x 2500
2000 x 2600 x 2700
Cabinet dimension width x depth x height
mm
750 x 900 x 1915
750 x 900 x 1915
Cabinet weight Weight total without dielectric
kg kg
300 2000
300 3000
Floor space width x depth
mm
3000 x 3500
4500 x 4500
Power supply Standard voltage
3x380V/400V±10%. 50/60Hz (50Hz is standard)
Operator interface system Control unit integrated Remote control for manual axes movement X/Y/Z/C and general functions for work preparation
15” flat panel display, mouse JOGBOX with LCD Display
Operating system
Windows / multitasking
CPU’s
Pentium for CNC and operator interface
Storage capacity
> 20 GB HD, 512 MB Ram
Servo controlled axes
X/Y/Z/C axes
Units of measurement
mm/inch
Smallest programmable step X/Y/Z/C axes
0.001 mm / 0.001°
Visualisation of erosion data Program structure
Graphics display: power, stability, speed, depth Automatic Erosion Programing (AEP-guided)
Pickup cycles for automatic determination of workpiece position and electrode
Intuitive programming with icons
Orbital movement in space for every application
Ve c tor, circular, ve c tor 2D / 3D Equimode, continuous circular / spherical
Module for contouring
Geometry 3D
Help functions, explanations with text and graphics
Manual integrated in the operating system
Machining simulation and positioning
Program check without erosion
Languages Data storage media
EN,DE,CN,CZ,DK,ES,FR,IT,K,JP,NL,PL,PT,RU USB
Interfaces for external peripheries
1 x RS232C; 1 x Parallel; 1 x LAN; 2 x USB
Chiller included in standard configuration Chiller specifications Dimension: 450 x 500 x 1050 mm Cooling Capacity: 5 kW Power Supply: 3 x 380 V 50 Hz (60 Hz as option) Rated Power: 2.5 kW Rated Current: 7 A Controlled Temperature Range: 15~50o C, Control Accuracy +/- 1o C Minimum Flow Rate: 32 l/min. Ambient Temperature: 10~45o C, auto stop if temperature > 48o C
DT form 20-30 ing
12.9.2007
14:47
Pagina 4
626 670 730
FORM 20
1260
400
760
FORM 30
800 840 890
2000
600
760
626 670 730
DT form 20-30 ing
12.9.2007
14:47
Pagina 1
Achieve more...
