laser line ultra - United Grinding
Creating Tool Performance
A member of the UNITED GRINDING Group
LASER LINE ULTRA A quantum leap in the production of ultra-hard tools
Key parameters The LASER LINE ULTRA replaces previous methods for grinding and eroding ultra-hard materials such as CVD and PCD through the use of lasers. It produces rotationally symmetrical tools with up to 150 mm circle of rotation diameter and up to 200 mm length, and indexable cutting inserts from 3 mm incircle diameter and up to 50 mm circumcircle diameter. The maximum weight for a tool including the clamping system is 15 kg.
Grinding
Eroding
Laser
Measuring
Software
Customer Care
Ewag AG The origins of Ewag AG date back to 1946 when the company delivered precision tool grinding machines for the Swiss watch industry. Today the EWAG product range includes manual machines for grinding and regrinding tools as well as the production of small precision parts, CNC tool grinding machines for grinding as well as a laser machine for replaceable cutting inserts and rotationally symmetric tools made from carbides. Ewag AG is part of the UNITED GRINDING Group within Körber AG which has significant financial strength and well tested processes. Together with our sister company, Walter Maschinenbau GmbH, we consider ourselves to be a supplier of systems and solutions for the complete machining of tools and can offer a wide range of products, including grinding, rotary eroding, laser machining, measurement and software. Our customer focus and our global sales and service network of company-owned locations and employees has been appreciated by our customers for decades.
LASER LINE ULTRA The LASER LINE ULTRA produces extremely complex geometries of rotationally symmetric tools and indexable cutting inserts in just one clamping. With five CNC machine axes and three overlaid laser beam guide axes, a total of eight CNC axes are available. Complex geometries including cuts and cavities are mastered with precision thanks to the kinematics. LASER LINE ULTRA works force-free and without altering the material characteristics.
Laser
Software
4
EWAG LASER LINE ULTRA
LASER LINE ULTRA at a glance Application
The machine
•
• • • • • • • • • • •
• • • • • •
All-in-one, productivity and precision at its best: outer contour, chip breaker and negative chamfer followed by marking in one clamping 3D shaping of all popular cutting materials Ultimate surface quality for longer tool life Indexable cutting inserts from 3 mm incircle diameter and up to 50 mm circumcircle diameter. Rotationally symmetric tools 0.5 to 150 mm diameter and up to 200 m length. Maximum piece weight 15 kg Materials include TC, cermet, ceramic, CBN, PCD, CVD-D and MCD/ND
Industrial ultra-short pulse laser Low-vibration cast-iron machine bed 5-axis CNC tool machine plus overlaid 3-axis CNC laser beam guide Direct drives for for linear axis Torque motors for B and C axes Shielded laser chamber – beam guiding in protective atmosphere Integrated laser performance measurement and control (IPC) Automatic HSK 63 tool interface Integrated 3D measuring probe FANUC control unit, world standard Automation peripheral equipment such as 6-axis CNC robots
LASER LINE ULTRA – pioneering performance through laser technology! EWAG, the original machine manufacturer, combines complete machining of cutting edges and chip breakers using the latest ultra-short pulse laser technology for optimal surface qualities in a compact laser machining system for all popular cutting materials.
EWAG LASER LINE ULTRA
5
Software • • • •
EWAG LaserSoft combines laser and machine control Direct 3D CAD/CAM interface Simplest definition of laser removal path using the 3D model Standardised user philosophy on all EWAG CNC machines: HMI machine and laser, CNC program with wizard technology, laserwatch management, hardware/tool management, production management and job management
Zusatzbild
Ultra-short pulse laser with direct vaporisation without any significant heat input obtains material properties EWAG uses an ultra-short pulse laser for the removal process. This operates in picosecond intervals in the direct vaporisation process without any heat input (cold ablation). The material properties are fully retained while the tool life is extended. Furthermore, combined with the high repetitive rates, the ultra-short pulses result in high-quality surface characteristics. The unique 8-axis kinematics concept enables LASER LINE ULTRA to machine extremely complex geometries in one clamping. In conjunction with a 6-axis CNC robot, multi shift production can be handled only with minimal interaction of the operators. LASER LINE ULTRA and robots are coordinated via FANUC control technology.
6
EWAG LASER LINE ULTRA
Ultimate surface quality for all materials
EWAG LASER LINE ULTRA
Conventional machining Material ILJIN CXL-II 2 µm – 40 µm mixed grain
Laser machining Material ILJIN CXL-II 2 µm – 40 µm mixed grain
10 x
10 x
40 x
40 x
Comparison of cutting quality: The excellent cutting quality achieved through the high-performance picosecond laser does not reveal any chips on the cutting edge because of the force-free laser removal. The geometric flexibility is increased even further, such as for concave forms. 3D machining in diamond or tungsten carbide can be introduced easily for enhanced tool functionality. Another benefit of laser removal is that all materials can easily be machined. Modern material CVC-D, which is used as a preferred alternative for machining contemporary materials such as carbon fibres and aluminium alloys, can also be machined superbly using LASER LINE ULTRA.
TC applications
CBN applications
PCD applications
CVD-D applications
7
8
EWAG LASER LINE ULTRA
Kinematics and laser pulses shape each geometry 2
1
• High removal rates • Ultimate surface quality • Unique kinematics
High-end laser source The high-performance picosecond laser generates the ultimate removal performance and surface quality with minimal thermal influence to the material that is to be removed. Stable beam environment The professional beam guide ensures ultimate process stability and constant beam properties. The beam path is fully encapsulated and is guided into a protective atmosphere under excess pressure. Deflection mirrors are monitored and sensitive optical components are integrated into the cooling circuit. Unique machine concept The clever kinematics concept using 5-axis machine kinematics and an overlaid 3-axis laser beam guide ensures ultimate flexibility when machining extremely complex tools.
1 Workroom
2 Flute groove machining
EWAG LASER LINE ULTRA
1
9
2
3
4
5
Modern direct/torque drives The modern drive concept using low-maintenance direct drives and torque axes is an optimal extension of the unique machine concept.
3D measurements Brazing errors are recorded via the integrated 3D measuring probe and the plate position is automatically compensated in LaserSoft. Recording the exact plate height is equally important for ensuring the correct focus position during laser machining.
Customer-specific tool holders In order to satisfy the variety of customer-specific tool holders, EWAG uses the HSK63 interface as a basis that can be adapted in line with the required clamping solution in each case.
1 HSK 63 interface 2 3D measurements
3 Integrated power control 4 Hydraulic expansion chuck for rotationally symmetric tools
5 Clamping solution for replaceable cutting inserts
• Low-maintenance linear drives • Individual tool holders • 3D measuring probe
10
EWAG LASER LINE ULTRA
Flexible automation
Robot integration The efficient EWAG rotating drum solution for robot integration is required for multiple shift operation with few operators. Laser machining cells and robot cells are beam-proof and are integrated to save space.
EWAG LASER LINE ULTRA
• Place-saving robot integration • Customer-specific tool handling • Profitability, even for small batch sizes
Triple gripper The triple gripper on the FANUC robot minimises changeover times. Once the tool and allocated clamping system are recognised, the gripper takes the tool from the pallet and forwards it in the correct, precise machining position to the clamping station.
11
Customer-specific tool handling The customer’s requirements remain EWAG’s priority. Rotationally symmetric tools, indexable cutting inserts, in series or in changing series. Tool handling is superbly integrated in the LASER LINE ULTRA machining centre. The diversity of the 6-axis FANUC robot fulfils this goal in combination with the triple gripper. Handling stations and automatic part recognition support the automation process.
12
EWAG LASER LINE ULTRA
EWAG LaserSoft with plug-in LaserPro 3D LaserSoft – more than just software! Innovation calls for innovative software. LaserSoft is a customer-focused software package from EWAG that will fully satisfy even your most challenging expectations. Programs can be created quickly and easily on all EWAG CNC machines in accordance with the standard philosophy. Input screens are supported through 3D graphics. The machines can be integrated to your company network via Ethernet. Our specialists also have access for carrying out diagnostics and maintenance.
ESAF – EWAG Standard Application Framework • Human Machine Interface HMI • Laser administration • Production • CNC programming
LASER LINE ULTRA LaserSoft laser software with plug-in LaserPro 3D
• Hardware • Job management
EWAMATIC LINEAR ProGrind grinding software with plug-in NUMROTOplus
COMPACT LINE ProGrind grinding software with plug-in CyberGrinding
INSERT LINE ProGrind HSM grinding software with plug-in EWAG Insert HMI
EWAG LASER LINE ULTRA
13
Human Machine Interface HMI HMI contains all relevant data views. It supports the user when setting up production orders while informing him of production-related facts in real-time.
Direct programming via the 3D model In order to machine complex 3D structures, the tool geometries are read in a popular 3D data format and are broken up into removal layers. The machining strategy and scanner parameters for the layer removal can be defined and stored in a machining file. Tool laser marking can also be defined in accordance with the same procedure and can be integrated into the program tree.
• Modular software modules • A program for the entire value-adding chain • 3D interface • Lettering add-on
Proven program tree structure Programs in LaserSoft can be easily and flexibly created using a range of program modules. Laser commands can be executed within the program tree and machining functions can be loaded into the program tree. The monitoring and control of the laser source as well as job administration and robot programming for production operation are fully integrated in LaserSoft.
14
EWAG LASER LINE ULTRA
FANUC control unit, the global standard
• Multi-processor system – high system security • FANUC bus for digital drives – fault-free communication • CNC and robots from a single manufacturer – no interface problems
With the FANUC control unit, EWAG relies on the global standard of control technology. For the user, this means the highest degree of reliability, availability and operating comfort.
EWAG LASER LINE ULTRA
Customer Care WALTER and EWAG deliver systems and solutions worldwide for all areas of tool machining. Our leadership is based on ensuring maximum availability of our machines over their entire service life. For this we have thus bundled numerous services in our customer care program. From “Start up” through “Prevention” to “Retrofit”, our customers enjoy tailor made services for their particular machine configuration. Around the world, our customers can use helplines, which can generally solve a problem using remote service. In addition to that, you will also find a competent service team in your vicinity around the world. For our customers, this means: • • • •
Our team is close by and can quickly be with you. Our team will support you to improve your productivity. Our team works quickly, focuses on the problem and its work is transparent. Our team solves every problem in the field of machining tools, in an innovative and sustainable manner.
Start up
Commissioning Extension of the guarantee
Qualification
Training Support for production
Prevention
Maintenance Inspection
Service
Customer service Customer advice Helpline Remote service
Material
Spare parts Replacement parts Accessories
Rebuilt
Machine overhauling Refurbishing of assemblies
Retrofit
Conversions Retrofitting parts Taking machines back
15
16
EWAG LASER LINE ULTRA
Technical data, dimensions Mechanical axes X axis Y axis Z axis Rapid motion B axis C axis
Tool data 440 mm 140 mm 170 mm 15 m/min ± 110 ° ∞
Optical axes Max. scanning field size Automatic focus position displacement Max. beam deflection speed
Laser source Industrial high-performance ultra-short pulse laser Wave length Repetition rate Pulse duration Beam profile and quality
100 x 100 mm2 ± 11 mm 10 m/s
Automatic clamping system for indexable cutting inserts Min. incircle of replacement cutting insert1) Max. circumcircle of replaceable cutting insert1) Automatic clamping system for rotationally symmetric tools Interface Max. circle of rotation diameter2) Max. tool length2)
Options
• • • 50 W •
1,064 nm 400 – 1,000 kHz < 15 ps TEM00 (M2 < 1.5)
Water reverse-flow cooling unit Smoke gas suction with HEPA filter system Automation with FANUC robots Robot cell with 2 pallets
Accuracy Linear resolution Radial resolution
0.0001 mm 0.0001 °
Smoke gas suction/filter system Volume flow Low pressure F9 bag prefilter/prefilter pad/HEPA H13 dust filter
170 m3/h 2,800 Pa filter module F2
Others Power consumption at 400 V/50 Hz Weight incl. robot cell
The maximum tool dimensions depend on the type of tool and its geometry, as well as the type of machining. 2) From the theoretical disk diameter of the workpiece carrier. 1)
3 mm 50 mm
approx. 11 kVA approx. 4,000 kg
Subject to modifications due to technical progress and errors. No guarantee is provided for this information.
HSK 63 A 150 mm 200 mm
EWAG LASER LINE ULTRA
17
Creating Tool Performance WALTER and EWAG are globally leading market-oriented technology and solutions for practically all tool types and materials typical for the market service companies, and are system and solution partners for all areas of with a high degree of added value in terms of quality, precision, durability tool machining. Our range of services is the basis for innovative machining and productivity.
Grinding – Grinding of rotation symmetrical tools and workpieces
Grinding – Grinding of indexable inserts
Use
Materials
Tool dimensions 1) max. length 2) / diameter
EWAG machines
Use
Materials
HELITRONIC ESSENTIAL
P R
HSS TC C/C CBN
255 mm / Ø 1 – 100 mm
EWAMATIC LINEAR
P R
HSS TC C/C CBN PCD
Ø 3 mm / Ø 50 mm
HELITRONIC MINI POWER
P R
HSS TC C/C CBN
255 mm / Ø 1 – 100 mm
COMPACT LINE
P R
HSS TC C/C CBN PCD
Ø 3 mm / Ø 50 mm
HELITRONIC MINI AUTOMATION
P R
HSS TC C/C CBN
255 mm / Ø 1 – 100 mm
INSERT LINE
P R
HSS TC C/C CBN
Ø 3 mm / Ø 75 mm
HELITRONIC BASIC
P R
HSS TC C/C CBN
350 mm / Ø 3 – 320 mm
RS15
P R M HSS TC C/C CBN PCD
HELITRONIC POWER
P R
HSS TC C/C CBN
350 mm / Ø 3 – 320 mm
HELITRONIC VISION
P R
HSS TC C/C CBN
370 mm / Ø 3 – 320 mm
HELITRONIC VISION 700 L
P R
HSS TC C/C CBN
700 mm / Ø 3 – 200 mm
WALTER machines
P R
HSS TC C/C CBN
370 mm / Ø 3 – 315 mm
HELITRONIC MICRO
P
HSS TC C/C CBN
120 mm / Ø 0,1 – 12,7 mm
R
HSS TC C/C CBN
120 mm / Ø 3 – 12,7 mm
EWAG machines
Use
EWAG machines
Use
Materials
Tool dimensions 1) max. length / diameter
LASER LINE ULTRA
P
EWAMATIC LINEAR
P R
HSS TC C/C CBN PCD
200 mm / Ø 0,2 – 200 mm
EWAG machines
Use
WS11/WS11-SP
P R M HSS TC
- / bis Ø 25 mm
RS15
- / bis Ø 25 mm
LASER LINE ULTRA
P
P R M HSS TC C/C CBN PCD
Eroding – Electrical discharge machining and grinding of rotation symmetrical tools
Materials
HELITRONIC POWER DIAMOND
P R
HSS TC C/C CBN PCD
HELITRONIC DIAMOND
P R
HSS TC C/C CBN PCD
P
Production
Materials: MCD/ND
1) 2)
HSS
R
Regrinding
High speed steel
M TC
TC C/C CBN PCD CVD-D MCD/ND
Materials
C/C
Indexable inserts 1) Inscribed / circumscribed circle Ø 3 mm / Ø 50 mm
TC C/C CBN PCD CVD-D MCD/ND
Use
Tool dimensions 1) max. length 2) / diameter
350 mm / Ø 3 – 320(400) mm
HELICHECK PRECISION
M
420 mm / Ø 1 – 220 mm
370 mm / Ø 3 – 320(400) mm
HELICHECK ADVANCED
M
420 mm / Ø 1 – 100 mm
HELICHECK PRO
M
300 mm / Ø 1 – 150 mm
HELICHECK PRO LONG
M
730 mm / Ø 1 – 150 mm
HELICHECK PLUS
M
300 mm / Ø 0,1 – 25,4 mm
HELICHECK PLUS LONG
M
730 mm / Ø 0,1 – 110 mm
HELICHECK 3D
M
HELISET UNO
M
400 mm / Ø 1 – 150 mm
HELISCALE
M
300 mm / Ø 2 – 25 mm
Customer Care – Comprehensive range of services
Measuring Tungsten carbide
200 mm / Ø 0,1 – 150 mm
WALTER machines
Software – The intelligence of tool machining and measuring for production and regrinding
Use:
Tool dimensions 1) max. length / diameter
Materials
Measuring – contactless measurement of tools, workpieces and grinding wheels
Tool dimensions 1) max. length 2) / diameter
Use
- / bis Ø 25 mm
Laser – Laser machining of indexable inserts and/or rotation symmetrical tools
HELITRONIC VISION 400
WALTER machines
Indexable inserts 1) Inscribed / circumscribed circle
Cermet/ceramics
CBN
Cubic boron nitride
PCD
Monocrystalline diamond/natural diamond
Maximum tool dimensions are dependent on the tool type and geometry, as well as the type of machining. From the theoretical taper diameter of the workpiece holder.
Polycrystalline diamond
CVD-D
Chemical vapour deposition
For worldwide contact details, please visit www.ewag.com
LASER LINE ULTRA · Subject to alterations · Printed in Germany · V3 · 08/2014 · en
Ewag AG Industriestrasse 4 · CH-4554 Etziken Tel. +41 32 613 3131 Fax +41 32 613 3115 [email protected]
A member of the UNITED GRINDING Group
LASER LINE ULTRA A quantum leap in the production of ultra-hard tools
Key parameters The LASER LINE ULTRA replaces previous methods for grinding and eroding ultra-hard materials such as CVD and PCD through the use of lasers. It produces rotationally symmetrical tools with up to 150 mm circle of rotation diameter and up to 200 mm length, and indexable cutting inserts from 3 mm incircle diameter and up to 50 mm circumcircle diameter. The maximum weight for a tool including the clamping system is 15 kg.
Grinding
Eroding
Laser
Measuring
Software
Customer Care
Ewag AG The origins of Ewag AG date back to 1946 when the company delivered precision tool grinding machines for the Swiss watch industry. Today the EWAG product range includes manual machines for grinding and regrinding tools as well as the production of small precision parts, CNC tool grinding machines for grinding as well as a laser machine for replaceable cutting inserts and rotationally symmetric tools made from carbides. Ewag AG is part of the UNITED GRINDING Group within Körber AG which has significant financial strength and well tested processes. Together with our sister company, Walter Maschinenbau GmbH, we consider ourselves to be a supplier of systems and solutions for the complete machining of tools and can offer a wide range of products, including grinding, rotary eroding, laser machining, measurement and software. Our customer focus and our global sales and service network of company-owned locations and employees has been appreciated by our customers for decades.
LASER LINE ULTRA The LASER LINE ULTRA produces extremely complex geometries of rotationally symmetric tools and indexable cutting inserts in just one clamping. With five CNC machine axes and three overlaid laser beam guide axes, a total of eight CNC axes are available. Complex geometries including cuts and cavities are mastered with precision thanks to the kinematics. LASER LINE ULTRA works force-free and without altering the material characteristics.
Laser
Software
4
EWAG LASER LINE ULTRA
LASER LINE ULTRA at a glance Application
The machine
•
• • • • • • • • • • •
• • • • • •
All-in-one, productivity and precision at its best: outer contour, chip breaker and negative chamfer followed by marking in one clamping 3D shaping of all popular cutting materials Ultimate surface quality for longer tool life Indexable cutting inserts from 3 mm incircle diameter and up to 50 mm circumcircle diameter. Rotationally symmetric tools 0.5 to 150 mm diameter and up to 200 m length. Maximum piece weight 15 kg Materials include TC, cermet, ceramic, CBN, PCD, CVD-D and MCD/ND
Industrial ultra-short pulse laser Low-vibration cast-iron machine bed 5-axis CNC tool machine plus overlaid 3-axis CNC laser beam guide Direct drives for for linear axis Torque motors for B and C axes Shielded laser chamber – beam guiding in protective atmosphere Integrated laser performance measurement and control (IPC) Automatic HSK 63 tool interface Integrated 3D measuring probe FANUC control unit, world standard Automation peripheral equipment such as 6-axis CNC robots
LASER LINE ULTRA – pioneering performance through laser technology! EWAG, the original machine manufacturer, combines complete machining of cutting edges and chip breakers using the latest ultra-short pulse laser technology for optimal surface qualities in a compact laser machining system for all popular cutting materials.
EWAG LASER LINE ULTRA
5
Software • • • •
EWAG LaserSoft combines laser and machine control Direct 3D CAD/CAM interface Simplest definition of laser removal path using the 3D model Standardised user philosophy on all EWAG CNC machines: HMI machine and laser, CNC program with wizard technology, laserwatch management, hardware/tool management, production management and job management
Zusatzbild
Ultra-short pulse laser with direct vaporisation without any significant heat input obtains material properties EWAG uses an ultra-short pulse laser for the removal process. This operates in picosecond intervals in the direct vaporisation process without any heat input (cold ablation). The material properties are fully retained while the tool life is extended. Furthermore, combined with the high repetitive rates, the ultra-short pulses result in high-quality surface characteristics. The unique 8-axis kinematics concept enables LASER LINE ULTRA to machine extremely complex geometries in one clamping. In conjunction with a 6-axis CNC robot, multi shift production can be handled only with minimal interaction of the operators. LASER LINE ULTRA and robots are coordinated via FANUC control technology.
6
EWAG LASER LINE ULTRA
Ultimate surface quality for all materials
EWAG LASER LINE ULTRA
Conventional machining Material ILJIN CXL-II 2 µm – 40 µm mixed grain
Laser machining Material ILJIN CXL-II 2 µm – 40 µm mixed grain
10 x
10 x
40 x
40 x
Comparison of cutting quality: The excellent cutting quality achieved through the high-performance picosecond laser does not reveal any chips on the cutting edge because of the force-free laser removal. The geometric flexibility is increased even further, such as for concave forms. 3D machining in diamond or tungsten carbide can be introduced easily for enhanced tool functionality. Another benefit of laser removal is that all materials can easily be machined. Modern material CVC-D, which is used as a preferred alternative for machining contemporary materials such as carbon fibres and aluminium alloys, can also be machined superbly using LASER LINE ULTRA.
TC applications
CBN applications
PCD applications
CVD-D applications
7
8
EWAG LASER LINE ULTRA
Kinematics and laser pulses shape each geometry 2
1
• High removal rates • Ultimate surface quality • Unique kinematics
High-end laser source The high-performance picosecond laser generates the ultimate removal performance and surface quality with minimal thermal influence to the material that is to be removed. Stable beam environment The professional beam guide ensures ultimate process stability and constant beam properties. The beam path is fully encapsulated and is guided into a protective atmosphere under excess pressure. Deflection mirrors are monitored and sensitive optical components are integrated into the cooling circuit. Unique machine concept The clever kinematics concept using 5-axis machine kinematics and an overlaid 3-axis laser beam guide ensures ultimate flexibility when machining extremely complex tools.
1 Workroom
2 Flute groove machining
EWAG LASER LINE ULTRA
1
9
2
3
4
5
Modern direct/torque drives The modern drive concept using low-maintenance direct drives and torque axes is an optimal extension of the unique machine concept.
3D measurements Brazing errors are recorded via the integrated 3D measuring probe and the plate position is automatically compensated in LaserSoft. Recording the exact plate height is equally important for ensuring the correct focus position during laser machining.
Customer-specific tool holders In order to satisfy the variety of customer-specific tool holders, EWAG uses the HSK63 interface as a basis that can be adapted in line with the required clamping solution in each case.
1 HSK 63 interface 2 3D measurements
3 Integrated power control 4 Hydraulic expansion chuck for rotationally symmetric tools
5 Clamping solution for replaceable cutting inserts
• Low-maintenance linear drives • Individual tool holders • 3D measuring probe
10
EWAG LASER LINE ULTRA
Flexible automation
Robot integration The efficient EWAG rotating drum solution for robot integration is required for multiple shift operation with few operators. Laser machining cells and robot cells are beam-proof and are integrated to save space.
EWAG LASER LINE ULTRA
• Place-saving robot integration • Customer-specific tool handling • Profitability, even for small batch sizes
Triple gripper The triple gripper on the FANUC robot minimises changeover times. Once the tool and allocated clamping system are recognised, the gripper takes the tool from the pallet and forwards it in the correct, precise machining position to the clamping station.
11
Customer-specific tool handling The customer’s requirements remain EWAG’s priority. Rotationally symmetric tools, indexable cutting inserts, in series or in changing series. Tool handling is superbly integrated in the LASER LINE ULTRA machining centre. The diversity of the 6-axis FANUC robot fulfils this goal in combination with the triple gripper. Handling stations and automatic part recognition support the automation process.
12
EWAG LASER LINE ULTRA
EWAG LaserSoft with plug-in LaserPro 3D LaserSoft – more than just software! Innovation calls for innovative software. LaserSoft is a customer-focused software package from EWAG that will fully satisfy even your most challenging expectations. Programs can be created quickly and easily on all EWAG CNC machines in accordance with the standard philosophy. Input screens are supported through 3D graphics. The machines can be integrated to your company network via Ethernet. Our specialists also have access for carrying out diagnostics and maintenance.
ESAF – EWAG Standard Application Framework • Human Machine Interface HMI • Laser administration • Production • CNC programming
LASER LINE ULTRA LaserSoft laser software with plug-in LaserPro 3D
• Hardware • Job management
EWAMATIC LINEAR ProGrind grinding software with plug-in NUMROTOplus
COMPACT LINE ProGrind grinding software with plug-in CyberGrinding
INSERT LINE ProGrind HSM grinding software with plug-in EWAG Insert HMI
EWAG LASER LINE ULTRA
13
Human Machine Interface HMI HMI contains all relevant data views. It supports the user when setting up production orders while informing him of production-related facts in real-time.
Direct programming via the 3D model In order to machine complex 3D structures, the tool geometries are read in a popular 3D data format and are broken up into removal layers. The machining strategy and scanner parameters for the layer removal can be defined and stored in a machining file. Tool laser marking can also be defined in accordance with the same procedure and can be integrated into the program tree.
• Modular software modules • A program for the entire value-adding chain • 3D interface • Lettering add-on
Proven program tree structure Programs in LaserSoft can be easily and flexibly created using a range of program modules. Laser commands can be executed within the program tree and machining functions can be loaded into the program tree. The monitoring and control of the laser source as well as job administration and robot programming for production operation are fully integrated in LaserSoft.
14
EWAG LASER LINE ULTRA
FANUC control unit, the global standard
• Multi-processor system – high system security • FANUC bus for digital drives – fault-free communication • CNC and robots from a single manufacturer – no interface problems
With the FANUC control unit, EWAG relies on the global standard of control technology. For the user, this means the highest degree of reliability, availability and operating comfort.
EWAG LASER LINE ULTRA
Customer Care WALTER and EWAG deliver systems and solutions worldwide for all areas of tool machining. Our leadership is based on ensuring maximum availability of our machines over their entire service life. For this we have thus bundled numerous services in our customer care program. From “Start up” through “Prevention” to “Retrofit”, our customers enjoy tailor made services for their particular machine configuration. Around the world, our customers can use helplines, which can generally solve a problem using remote service. In addition to that, you will also find a competent service team in your vicinity around the world. For our customers, this means: • • • •
Our team is close by and can quickly be with you. Our team will support you to improve your productivity. Our team works quickly, focuses on the problem and its work is transparent. Our team solves every problem in the field of machining tools, in an innovative and sustainable manner.
Start up
Commissioning Extension of the guarantee
Qualification
Training Support for production
Prevention
Maintenance Inspection
Service
Customer service Customer advice Helpline Remote service
Material
Spare parts Replacement parts Accessories
Rebuilt
Machine overhauling Refurbishing of assemblies
Retrofit
Conversions Retrofitting parts Taking machines back
15
16
EWAG LASER LINE ULTRA
Technical data, dimensions Mechanical axes X axis Y axis Z axis Rapid motion B axis C axis
Tool data 440 mm 140 mm 170 mm 15 m/min ± 110 ° ∞
Optical axes Max. scanning field size Automatic focus position displacement Max. beam deflection speed
Laser source Industrial high-performance ultra-short pulse laser Wave length Repetition rate Pulse duration Beam profile and quality
100 x 100 mm2 ± 11 mm 10 m/s
Automatic clamping system for indexable cutting inserts Min. incircle of replacement cutting insert1) Max. circumcircle of replaceable cutting insert1) Automatic clamping system for rotationally symmetric tools Interface Max. circle of rotation diameter2) Max. tool length2)
Options
• • • 50 W •
1,064 nm 400 – 1,000 kHz < 15 ps TEM00 (M2 < 1.5)
Water reverse-flow cooling unit Smoke gas suction with HEPA filter system Automation with FANUC robots Robot cell with 2 pallets
Accuracy Linear resolution Radial resolution
0.0001 mm 0.0001 °
Smoke gas suction/filter system Volume flow Low pressure F9 bag prefilter/prefilter pad/HEPA H13 dust filter
170 m3/h 2,800 Pa filter module F2
Others Power consumption at 400 V/50 Hz Weight incl. robot cell
The maximum tool dimensions depend on the type of tool and its geometry, as well as the type of machining. 2) From the theoretical disk diameter of the workpiece carrier. 1)
3 mm 50 mm
approx. 11 kVA approx. 4,000 kg
Subject to modifications due to technical progress and errors. No guarantee is provided for this information.
HSK 63 A 150 mm 200 mm
EWAG LASER LINE ULTRA
17
Creating Tool Performance WALTER and EWAG are globally leading market-oriented technology and solutions for practically all tool types and materials typical for the market service companies, and are system and solution partners for all areas of with a high degree of added value in terms of quality, precision, durability tool machining. Our range of services is the basis for innovative machining and productivity.
Grinding – Grinding of rotation symmetrical tools and workpieces
Grinding – Grinding of indexable inserts
Use
Materials
Tool dimensions 1) max. length 2) / diameter
EWAG machines
Use
Materials
HELITRONIC ESSENTIAL
P R
HSS TC C/C CBN
255 mm / Ø 1 – 100 mm
EWAMATIC LINEAR
P R
HSS TC C/C CBN PCD
Ø 3 mm / Ø 50 mm
HELITRONIC MINI POWER
P R
HSS TC C/C CBN
255 mm / Ø 1 – 100 mm
COMPACT LINE
P R
HSS TC C/C CBN PCD
Ø 3 mm / Ø 50 mm
HELITRONIC MINI AUTOMATION
P R
HSS TC C/C CBN
255 mm / Ø 1 – 100 mm
INSERT LINE
P R
HSS TC C/C CBN
Ø 3 mm / Ø 75 mm
HELITRONIC BASIC
P R
HSS TC C/C CBN
350 mm / Ø 3 – 320 mm
RS15
P R M HSS TC C/C CBN PCD
HELITRONIC POWER
P R
HSS TC C/C CBN
350 mm / Ø 3 – 320 mm
HELITRONIC VISION
P R
HSS TC C/C CBN
370 mm / Ø 3 – 320 mm
HELITRONIC VISION 700 L
P R
HSS TC C/C CBN
700 mm / Ø 3 – 200 mm
WALTER machines
P R
HSS TC C/C CBN
370 mm / Ø 3 – 315 mm
HELITRONIC MICRO
P
HSS TC C/C CBN
120 mm / Ø 0,1 – 12,7 mm
R
HSS TC C/C CBN
120 mm / Ø 3 – 12,7 mm
EWAG machines
Use
EWAG machines
Use
Materials
Tool dimensions 1) max. length / diameter
LASER LINE ULTRA
P
EWAMATIC LINEAR
P R
HSS TC C/C CBN PCD
200 mm / Ø 0,2 – 200 mm
EWAG machines
Use
WS11/WS11-SP
P R M HSS TC
- / bis Ø 25 mm
RS15
- / bis Ø 25 mm
LASER LINE ULTRA
P
P R M HSS TC C/C CBN PCD
Eroding – Electrical discharge machining and grinding of rotation symmetrical tools
Materials
HELITRONIC POWER DIAMOND
P R
HSS TC C/C CBN PCD
HELITRONIC DIAMOND
P R
HSS TC C/C CBN PCD
P
Production
Materials: MCD/ND
1) 2)
HSS
R
Regrinding
High speed steel
M TC
TC C/C CBN PCD CVD-D MCD/ND
Materials
C/C
Indexable inserts 1) Inscribed / circumscribed circle Ø 3 mm / Ø 50 mm
TC C/C CBN PCD CVD-D MCD/ND
Use
Tool dimensions 1) max. length 2) / diameter
350 mm / Ø 3 – 320(400) mm
HELICHECK PRECISION
M
420 mm / Ø 1 – 220 mm
370 mm / Ø 3 – 320(400) mm
HELICHECK ADVANCED
M
420 mm / Ø 1 – 100 mm
HELICHECK PRO
M
300 mm / Ø 1 – 150 mm
HELICHECK PRO LONG
M
730 mm / Ø 1 – 150 mm
HELICHECK PLUS
M
300 mm / Ø 0,1 – 25,4 mm
HELICHECK PLUS LONG
M
730 mm / Ø 0,1 – 110 mm
HELICHECK 3D
M
HELISET UNO
M
400 mm / Ø 1 – 150 mm
HELISCALE
M
300 mm / Ø 2 – 25 mm
Customer Care – Comprehensive range of services
Measuring Tungsten carbide
200 mm / Ø 0,1 – 150 mm
WALTER machines
Software – The intelligence of tool machining and measuring for production and regrinding
Use:
Tool dimensions 1) max. length / diameter
Materials
Measuring – contactless measurement of tools, workpieces and grinding wheels
Tool dimensions 1) max. length 2) / diameter
Use
- / bis Ø 25 mm
Laser – Laser machining of indexable inserts and/or rotation symmetrical tools
HELITRONIC VISION 400
WALTER machines
Indexable inserts 1) Inscribed / circumscribed circle
Cermet/ceramics
CBN
Cubic boron nitride
PCD
Monocrystalline diamond/natural diamond
Maximum tool dimensions are dependent on the tool type and geometry, as well as the type of machining. From the theoretical taper diameter of the workpiece holder.
Polycrystalline diamond
CVD-D
Chemical vapour deposition
For worldwide contact details, please visit www.ewag.com
LASER LINE ULTRA · Subject to alterations · Printed in Germany · V3 · 08/2014 · en
Ewag AG Industriestrasse 4 · CH-4554 Etziken Tel. +41 32 613 3131 Fax +41 32 613 3115 [email protected]
