AgieCharmilles DRILL 300 - Wire edm | die sinker edm · a new EDM drilling machine, the DRILL 300. This machine is manufactured in Switzerland to deliver top performance in machining

GF Machining Solutions

DRILL 300AgieCharmilles

2 AgieCharmilles DRILL 300

Swiss design and quality

The winning solution High-speed EDM drilling Fine hole qualityPowerful controlQuick preparationHigh degree of autonomy and AutomationGF Machining Solutions

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Contents

DRILL 300 The winning solution for cooling hole machining of components in aircraft enginesIn today’s aircraft engines, the temperature in the combus-tion chamber can be close to the melting point of the nickel alloy used. In order to create a film of cooling air on the surface of components to prevent the nickel alloy from melting, cooling holes are needed on the curved surface of components such as turbine blades, vanes, and shrouds. Machining these cooling holes with high quality and pro-ductivity is always the main concern for aircraft engine component manufacturers.


The DRILL 300 is equipped with GF Machining Solutions’ latest digital generator, allowing the drilling process to be continuously optimized with every pulse. As a result the machining speed has been increased significantly com-pared to conventional EDM drilling.

Technology is chosen according to the desired results. For example, by selecting “quality” technology, the electrode wear will automatically be reduced and the heat-affected layer is reduced to a few microns. Conversely, the operator can select “speed” technology to produce holes with the fastest possible erosion rate.

With six-axis configuration, holes with different positions and angles can be freely programmed and machined, al-lowing for greater part flexibility and design. Single setup machining reduces unproductive time.

By using the automatic electrode/guide changer (AEC/AGC), multiple holes with different diameters can be machined au-tomatically and the machine attains longest autonomy.

Due to wide range of optimized technologies for electrically conductive material like Inconel, steel and hard metal, the DRILL 300 is a winning solution for cooling hole machining in aerospace as well as other industrial applications such as cutting tools, automotive, medical and die plates.

The GF Machining Solutions’ answer


With 60 years of experience building Electrical Discharge Machines, GF Machining Solutions has developed a new EDM drilling machine, the DRILL 300. This machine is manufactured in Switzerland to deliver top performance in machining cooling holes for aircraft engine components.


100 mm

60 mm

High-speed EDM drilling

Increasing your productivityThe EDM generator has state-of-the art powerful electronics to increase production output by utilizing efficiently controlled EDM processes that include FPGA technology, digital data recording and fully digitized pulse control. The drilling process is continuously optimized with every pulse, thus the fastest drilling speed is achieved.

Drilling time

Without breaktrough detection

With advanced breaktrough detection

20 mm100 mm

48 s280 s

Depth

Electrode: brass, Ø 1.0 mmWorkpiece: steelSpeed technology

Conventionaldrilling time

28 s170 s

DRILL 300drilling time

DRILL 300up to 40% faster

Conventional EDM drilling

DRILL 300

Fast and reliable breakthroughWithout breakthrough detection, the machining time at breakthrough is even longer than the entire hole drilling time when the flushing process breaks down. With advanced breakthrough detection on the DRILL 300, the process is monitored in a real time; the technology is adapted automat-ically to exit technology; the reliable process is attained and the breakthrough time is shortened by 50-70 percent.


Steel

Hard metal

Inconel 718

Aluminium

Copper

5

5

5 510

20

510

20

40

10

20

40

60

40

80 80

10

20

40

10

20

40

60

80

10

40

60

80

10

40

5050

40

60

80

100

40

80

100

1010

202020

40

80

10

20

40

60

80

100

10

20

40

80

10

20

40

60

80 80

100

120

150

10

20

40

20

40

60

40

60

100

120

150 150

80

20

40

150

80

20

40

150

40

80

3 3

510

3

3

510

20

3

4040

10

20

10

31 31 31

49

31

49

1010

202020

5 510

3 3 3

40

20

3

10

53

0.1 0.15 0.2 0.3 0.4 0.5 0.6 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.00.8

0.1 0.15 0.2 0.3 0.5 1.0 1.5

0.3 1.5

2.0 3.0

Copper

Brass

Carbide

0.8

0.3 0.5 1.0

1.0

1.5 2.00.8

Optimal technologiesOne type of technology cannot meet all of your requirements. According to the workpiece material and your stringent met-allurgical requirements, the DRILL 300 has the optimized technologies to focus on either quality or speed. The quality technology achieves minimum heat-affected layer and bet-ter hole integrity, while the speed technology focuses on short drilling time.


Fine hole quality

The new standard in hole-drilling EDM

Minimum heat-affected layerHeated-affected layer has significant influence on the fatigue lifetime of components and the safety of aircraft engines. The DRILL 300 is designed for achieving the best result in terms of heat-affected layer and avoiding cracks in the components.The DRILL 300 digital generator allows the finest pulse dura-tion of a few microseconds. When quality technology is used, the heat-affected layer can be dramatically reduced to a few microns with a reasonable machining speed.


with FirstSpark

without FirstSpark

Electrode: brass, Ø 1.0 mmWorkpiece: steel, 20 mm heightQuality technology

Consistent hole dimensionWhen machining cooling holes with conventional EDM drill-ing, the spatters at the hole entrance are always a problem, especially if there is a small angle between the hole and surface of components. The DRILL 300 has a fine pulse ap-plied with the first spark function, then the technology is automatically adapted to the standard parameters. There-fore, the spatters in the hole entrance are avoidable and a perfect profile is achieved.

In order to optimize the machining of the most complex holes, the DRILL 300 provides the way of programming pa-rameters corresponding to the machining depth. Multi-parameters can be used in the same hole.

With advanced breakthrough detection “Breakthrough Strategy” on the DRILL 300, the hole exit technology is op-timized and the exit electrode length is programmable, and backstriking can be prevented. Meanwhile the quality technology also helps attain the right hole dimensions at the bottom of the hole.


Powerful control

To manage sophisticated hole machining

CNC controlIn order to meet the demands of different applications, the DRILL 300 can be configured with different kinematics: XYZW, XYZWBA, XYZWAB, XYZWB1C1, XYZWB1, XYZWAB1. With single setup the holes with different diameters, posi-tions and angles are freely programmable and machined.

Control unitThe graphical user interface is based on the Windows oper-ating system and allows real time control of the EDM pro-cess. The system works with descriptive picture symbols and conversational screen pages following one after another in a logical way. This allows even new users to understand the EDM principle quickly and means time to production is very short.


Manual operation – Easy DrillMain 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 preparationThe machine can import the entire work in the format of XML.NCC, ISO.NCC and PAT.NCC (compatible with AC CAM DRILL) directly or prepare the work manually with TEACH function. The parameters of every machining can be modi-fied with Edition. The work can be graphically checked.

Work executionThis page activates the work and executing measuring cy-cles. All machining, parameters and hole positions are monitored on this page.


Quick preparation

Single setup machiningWith different kinematics of six axes, holes with dif-ferent diameters, positions and angles can be freely programmable and machined even with single setup, allowing for greater part flexibility and design. Single setup machining eliminates the need for additional expensive fixtures and avoids multiple setups to re-duce unproductive time.

Reducing the un productive time

Fast setup cyclesThe universal console is equipped with the touchscreen based on the Windows operating system. The setup cycles probe, edge finding, corner finding, center finding, etc., help to prepare the job in a convenient way.

Less down timeTo ensure the longest life and reliability of the electronics, a closed water-air cooling circuit is contained within a dust-proof cabinet, in which the temperature is also monitored and stabilized with multi-sensors.With this design, the lifetime of the electronics is guaran-teed even in the most difficult conditions.


High degree of autonomy and Automation

Automatic filtration and conductivity controlWith the 200-liter water tank and a 10-liter resin bottle in a standard configuration, the water filtration and conductivity are automatically controlled and cycled.

For maximizing productivity

Automatic part changerWith the optional Automation kit, the DRILL 300 can connect to external robot to automatically manage part changing.

Automatic electrode/guide changerThe optional linear 16/4 electrode/guide changer and 50/8 ro-tary electrode/guide changer are available on the DRILL 300. AEC/AGC 16/4 is affordable solution and AEC/AGC 50/8 is a solution with the longest autonomy for max productivity.


DRILL 300

DRILL 300

MachineMachine dimensions (L x W x H) mm (in) 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)Net weight kg (lbs) 2500 (5512) without variants and options

Machining areaElectrode diameter mm

in0.3 ~ 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)

Max. workpiece dimension mm (in) 1000 x 700 x 500 (39.37 x 27.56 x 19.69)Max. workpiece dimensionwith tilting/rotary axes

mm (in) Ø x L = 350 x 320 (13.78 x 12.60)

Max. workpiece weight kg (lbs) 1000 (2205)Max. workpiece weight with tilting/rotary axes

kg (lbs) 25 (55) including clamping weight

Worktable dimension mm (in) 800 x 600 (31.50 x 23.62)Worktable type 4 bars (2 stationary, 2 adjustable)Distance from table surface to floor mm (in) 850 (33.46)Accessibility Front

AxesTravel X x Y axes mm (in) 600 x 400 (23.62 x 15.75)Travel W x Z axes mm

in450 x 450 (650 optional)17.72 x 17.72 (25.59 optional)

Tilting/rotary axes (option) º ± 100 / 0~360Max. axis motion speed m/min. (ft/min) 4 (13.12)Measuring system for Z, W axes EncoderMeasuring system for X, Y axes Encoder (linear glass scales optional)Lubrication Manual

Dielectric unitDielectric type Industrial water or civil waterDielectric capacity l (us gal) 200 (53)Max. flushing pressure bar (psi) 80 (1160)Filter accuracy µm 5Capacity of deionizing bottle l (us gal) 10 (2.6)Cooling system Water/water heat exchanger

Technical Data


DRILL 300

GeneratorGenerator type ISPGMax. mean working current A 60Cooling system inside cabinet Air/water heat exchanger

Numerical controlFlat screen 17” flat touchscreenKeyboard StandardMouse StandardStorage capacity > 230 GB HD, 1024 MB RamInterface port USB and EthernetMeasurement unit Metric/inchCommand format Absolute/incrementalCoordinates system Machine, partMax. number of machining in the program 500Servo controlled axes X, Y, Z, W, A, BImport files XML.NCC, ISO.NCC, PAT.NCCOnboard CAD/CAM AC CAM DRILL as standardFirst spark detection StandardElectrode wear compensation StandardBreakthrough detection StandardOnboard documentation Standard

Electricity supplyThree-phase input voltage V 380 or 400Permissible variations from +10% to -10%Main frequency Hz 50 or 60Power consumption kVA 4.2Nominal current A 6

Cooling water when heat exchanger usedFlow minimum required l/min (gal/min) 20 (5.2)Temperature °C

°F< Tworkshop – 9° C< Tworkshop – 18° F

Compressed airPressure range between bar (psi) 6 to 8 (85 to 113)Flow minimum required m3/h (yd3/h) 5 (6.54)Connection pipe external diameter mm (in) 10 (0.4)

Main optionsAutomatic electrode/guide changer AEC/AGC 16/4, AEC/AGC 50/8Tilting head ° Max. ~ ± 45 Large travel of Z axis mm (in) 650 (25.59)Rotary/tilting table


DRILL 300

DRILL 300

1400/55.12’’ 2375/93.5’’

800/31.5’’

Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 ’’

600/23.62’’

40/1.57’’

600/

23.6

2’’

400/

15.7

5

730/28.74’’ 1120/44.09’’

1998/78.66’’

700

27.56’’

1260/49.6’’

598

23.54’’

3393

/133

.58’

’

2280

/89.

76’’

100

3.94

’’

583

22.9

5’’

510

20.0

7’’

2375/93.5’’

800/31.5’’

Max. workpiece1000 x 700 x 50039.37 x 27.56 x19.68 ’’

600/23.62’’

40/1.57’’

600/

23.6

2’’

400/

15.7

5

730/28.74’’ 1120/44.09’’

2280

/89.

76’’

100

3.94

’’

1900/74.8’’

2248/88.5’’

250

9.84’’

1400/55.11’’

348

13.7’’

3392

/133

.54’

’

583

22.9

5’’

1270

/50’

’

510

20.0

7’’

tilting head


The DRILL 300 easily drills cooling holes in turbine blades. For this demo blade, 180 through holes and blind holes (Ø 0.5 mm and Ø 1.0 mm) were machined in only 75 minutes, using a single setup with the automatic electrode and guide changer.



Milling

High-speed and high-performance Milling centers. In terms of cutting speed, HSM centers are 10 times faster than con-ventional milling machines. Greater accuracy and a better surface finish are also achieved. This means that even tem-pered 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

Electrical Discharge Machines. EDM can be used to ma-chine conductive materials of any hardness (for example steel or titanium) to an accuracy of up to one one-thousandth 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.

Laser

Laser texturing. Laser texturing supplements and extends the technologies offered by GF Machining Solutions. With our Laser technology we enable you to produce texturing, engraving, microstructuring, marking and labeling of 2D geometries right through to complex 3D geometries. Laser texturing, compared to conventional surface treatment us-ing manual etching processes, offers economic, ecological and design advantages.

Automation

Tooling, Automation, Software. Tooling for fixing work-pieces and tools; Automation systems and system soft-ware for configuring machine tools and recording and exchanging data with the various system components and design advantages.

Customer Services

Operations, Machine and Business Support. Customer Services provides with three levels of support providing all kinds of services for GF Machining Solutions machines. Operations Support offers the complete range of original wear parts and certified consumables including wires, fil-ters, electrodes, resin and many other materials. Machine Support contains all services connected with spare parts, technical support and preventive services. Business Support offers business solutions tailored to the customer’s spe-cific needs.



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805.

752–

EN

At a glanceWe enable our customers to run their businesses efficiently and effectively by offering innovative Milling, EDM, Laser and Automation solutions. A comprehensive package of Customer Services completes our proposition.

www.gfms.com

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Documents

AgieCharmilles DRILL 300 - Wire edm | die sinker edm · a new EDM drilling machine, the DRILL 300. This machine is manufactured in Switzerland to deliver top performance in machining