die sinking of ED intelligent way The - GFMS · The intelligent way to manufacture moulds 2 ED die sinking is three-dimensional machining in space. The most reliable way from the

The intelligent wayof ED die sinking

PROS_HYPER 6.05 E 10.8.2006 11:38 Pagina 2

The intelligent way to manufacturemoulds

2

ED die sinking is three-dimensional machining

in space. The most reliable way from the work-

shop drawing to the finished workpiece.

Agietron Hyperspark HS uses the terminology of

tool and mould manufacturers. Clearly struc-

tured data input generates independently

machining technologies in accordance with the

targets set.


3

HS stands for High Speed

in the generator’s perform-

ance ranges. The new mod-

els, Agietron Hyperspark

HS and Exact HS in sizes 2

and 3, have new generator

technologies and modules,

resulting in a striking in-

crease in power during re-

moval, a reduction in wear

towards zero and optimum

EDM results with all work-

piece materials and

graphite grades of the elec-

trodes. Numerous modules

and functions reduce the

set-up and ED machining

time, and increase flexibili-

ty. Agietron Hyperspark HS

and Exact HS are thus the

ideal ED die-sinking ma-

chines from simple cavities

to highly complex multiple

moulds.


AGIETRON

Highlightsfor intelligent ED die sinking

4

Agietron Hyperspark HS ED die-sinking systems impress withunique characteristics:

High removal rates.The IPG generator achieves removalrates far above the average of otherproducts. Intelligent interaction ofvarious functions allow high perform-ance machining in all fields of appli-cation, from the narrowest slatsthrough pointed cone cavities to pre-milled moulds.

Flexible planning.Express orders can be inserted withPieceinsert without having to repro-gram the interrupted job. For this,the actual situation of the currentmachining job, including the com-plete machining sequences is record-ed. The Job will then resume at theidentical place of interruption.

Top results straight off.Best results are achieved straight offwith the Agievision control. Target-and object oriented input correspondperfectly to the required quality andprofitability criteria.

Long running times.The high autonomy, permits auto-mated machining already in standardconfiguration.

100 kg 100 kg

X 500

Y 350

Z 500X 350

Y 250

Z 350

5612

2 3

1000 mm3/min

Ra <0.1 µm

Workpiece dimensions

Workpiece weight

Electrode weight

Axes travel paths

Smallest roughness

Removal rate graphite/steel

Number of electrodes

Handling

AGIE WorkPal, AGIE WorkPartner and others

400 kg 800 kg

680 880

580

650

250 35

0

To



The Agietron Hyperspark 2 and 3 Exact HS models are designed

for highest precision requirements in ED die sinking:

Dual measuring system.

Two independent measuring systemsguarantee best positional accuracy.This combines high dynamism andoptimum process control. The µmrange is achieved on the workpiecewith the axis position, measured andcorrected continuously by means ofglass scales. Process control and dy-namism is warranted by high resolu-tion DC servo motors with encoderson all axes.

Maximum precisionAGIETRONHYPERSPARKE ACT HS

Exceptional positioning accuracy.Agietron Hyperspark Exact meets thehighest requirements of technicalmould making. Expect µm-accurateprecision on the workpiece for typicalapplications like multifunctionally de-signed plastic parts, containing webs,jaws, openings and cavities, e.g. forthe secure retention of electrical com-ponents in assembly. Conditions, re-quiring µm-accurate axis positionwhen ED machining.

Recorded care.Selection of all the precision givingcomponents and a comprehensivequality management for the AgietronHyperspark Exact , meet the high pre-cision demands required on a finishedED machined workpiece.

6

of the axis positions

CNC


For the highest positioning accuracy, the Exact models of the Agietron Hyperspark HSseries are equipped with a dual measuring system.


Above average autonomy.Agietron Hyperspark machines areperfectly suited for round the clock, 7 days/week operation. With elec-trode changers for 12, 24, 28, 50 or56 electrode positions and a dielec-tric unit with a filter performance forlong running times.

Agietron Hyperspark HS and Exact HSED die-sinking systems are de-signed for all the extension stagesof automation:

Optimal automatic actions.The lowerable work tank, ensuresgood accessibility for the setting-upof workpieces. Automated, the worktank is raised or lowered automati-cally in accordance with the machin-ing sequences for loading or unload-ing workpieces or pallets. Regulationof the bath level is adapted automati-cally to the workpieces.

Increased productivity through automation

AGIETRON

8Trouble-free automation interfaces.Agietron Hyperspark HS and Exact HSare ready for automation. Preparedfor various media with clearly definedcommunication interfaces. Thismakes it possible to connect han-dling devices, such as Agie WorkPal,Agie WorkPartner or master comput-ers simply for the interlacing of sev-eral machine tools.


Agietron Hyperspark HS and Exact HS

can be automated both with Agie WorkPal,

Agie WorkPartner and with every other

handling system.

9


The generatorfor above average performances

The Agie IPG (Intelligent Power Gen-eration) generator of all the AgietronHyperspark HS and Exact HS setsnew standards. This with patentedtechnologies for surfacequality,removal rate and shape accuracy.Electrode wear is reduced and theproductivity increased by 30% on av-erage with copper or graphite elec-trodes. In case of pre-milled mouldsby up to 100%. Even in the case ofdeep and narrow cavities with poorflushing conditions, an increase inEDM speed of 50% is achieved withconstant low electrode wear:

Fast to top results.Tectron generates the EDM technolo-gy adapted specifically and optimallyfor the application. Three databases,standard, ribs and pointed elec-trodes, guarantee super resultsstraight away.

Controlled process. React faster and also shape theprocess reliably. New, perfected algo-rithms have been implemented withACC (Adaptive Current Control) andACO (Adaptive Current Optimisation).They, even in the case of difficult EDMconditions, increase the productivity.

Low wear.Electrode wear is kept low even in thecase of high removal rates by fine ad-justment of the generator impulses.

10

AGIETRON

Predictive planetary EDM.Cavities are achieved fast and accu-rate. The PLS (Predictive LearningSystem) continuously monitors andanalyses the conditions in orbitalmovements. With every deflection,the process of planetary ED machin-ing is then optimised step by step.

Intelligent lift-off movements.Faster ED machining and optimisedsurface quality by dynamic accelera-tion and adaptive controlled lift-offmovements.

Intensified removal. Increased removal rate with isogeo-metric impulses. Electrode wear,spark gap, surface roughness andcrater geometry remain constant.The white coating on the ED ma-chined workpiece is reduced. As aresult, the removal is strikingly in-creased, especially in the case ofpremachined workpieces.


Highest process efficiency.Maximum EDM efficiency is achievedwith the Agie IPG Fuzzy generator.The servo system is constantly ad-justing to the EDM conditions.

Large surfaces.Dynamic acceleration and adaptivelycontrolled lift-off movements guaran-tee optimal EDM results also on largesurfaces.

Small and deep cavities.Optimum EDM results in small anddeep cavities. HVP (High Velocity Pul-sation) accelerates the axes dynami-cally with an extremely short reactiontime. Conversely slowing down dur-ing re-entry. Good flushing conditionsfor any type of cavity.

11

STANDARD

HYPERSPARK HS

With the SF module option, finest surface qualities can be achieved.


Agievision, the only control with inte-grated Job-management system. Devel-oped specially for electrical dischargemachining. Agievision is the control sys-tem that offers a nearly identical usersurface for both ED die-sinking andwire-cutting machines. Agievision has alarge number of shopfloor-orientedfunctions at its disposal. A flexible datamanagement allows machining se-quences to be changed, completed andsupplemented. Priorities of machiningsequences can be set individually in ac-cordance with profitability and qualityrequirements. Agievision gives completecontrol of the whole machining job.From data input to finished workpiece:

AGIEVISION

Data input adapted according to the organisation.Agievision, flexible data input in ac-cordance with the shopfloor infra-structure and its surroundings: - All the data are input directly on themachine.- Import electrode geometries andcomplete with the target data on themachine.- Import whole electrode geometriesand -positions and complete with thetarget data on board.

Direct import of electrode data.Import of Scriptfiles, an Agie exclu-sive in ED die sinking. Import thecomplete data of the electrode- andworkpiece data directly fromCAD/CAM system into Agievision. Nosources of errors, gives certainty andeliminates the manual data input of:- Positions in X, Y, Z and C with threedigit accuracy.- Starting point and filling level of thedielectric.- Workpiece and electrode names(designations).- Materials for electrodes and work-pieces.- Electrode size.

- Planetary or equidistant deflection.- Surface qualities in Ra or VDI.- Electrode assigning for roughingand finishing.- Electrode quantities according toroughing and finishing.- Electrode undersizes according toroughing and finishing.

Automatic technology generation.Automatic generating of technology.“Tectron” generates all technology inaccordance with given quality andmachining targets. The allocationof technology takes place,based on electrode shapes,number of electrodes, under-sizes and priorities, importedby Scriptfiles or manual input.

Trouble-free job insertion.Start another Jobwith “Piecein-sert” anytimeduring an ac-tive machiningJob. Suspend the active Job, insert anew Job; when finished, resume theprevious one without time consumingreprogramming.

Arranging of machining sequences.The module “Usersequence” allowsfree allocation of the machining se-quence, independent of the number ofworkpieces and electrodes.

Remote-controlled EDM.Control of the process from office orhome. “Agievision Contact” lets monitor

and control theED machiningon a PC, usingthe same

Userinterface ason the machine.

Identical data input on the PC.

Preparation of complete Jobswith “Agievision PC” in the office

or at home. Identical Userinterface ason the machine. Easy data transfer viaFloppy Disc or network to the AgietronHyperspark HS.

12

The controlwith integrated Job-management system

Elec.

Wp.

Elec.

Wp.

Elec.

Wp.


13

900 mm /min


AGIEVISION

Agievision saves time; by easy datainput and decreasing the machinesidletime. Simple or highly complexmould geometries, premachinedworkpieces, all the machinings areexcecuted without any interventionby an operator. Agievision has beenadapted to the new possibilities ofgenerator technologies:

Fast data input.“Easywork”, the fast way from orderto finished Job. Only minimum detailsof the workpiece and electrodes arerequired. An ED machining job canthus be generated quickly and reli-ably. A must for numerous machiningrequirements.

Selectable planetary strategies.Easygeo, with one click to the plane-tary strategies. The machining strat-egy is automatically activated andassigned to the required geometry.

Workpiece-oriented data input.“Pieceditor”, the interactive, graphi-cal defining of machining and work-piece. Particulars like dimension,material, roughness and tolerancesrelevant for the workpiece suffice forthis.

Simplify complex machining jobs.Simplified data input of complexmoulds and machining jobs with“Easymachining”, Following programscan be selected by a simple click:- Calibrate drill hole with orbiting- Drilling- Threading- Gates for injection moulds- Punches- UndercutsThe optimal technology for guaran-teed results is generated and execut-ed with maximum reliability.

Few electrode data.Few electrode data is required to de-scribe the electrodes. Input of Priori-ties, characteristics then grouped aselectrode family in Tooleditor.

14

The controlsystem for fast set-up

Direct geometry data input.Simple onboard generating of con-tours in two-and-a-half-dimensions.Import of VT/ISO code, manual modi-fication possible. The contour is rep-resented graphically.

No fine adjusting.No workpiece alignment required.Agiesetup 2D determines automati-cally the workpiece location in thework area with a touch probe. Thecontrol system takes account of anypossible rotation and allocates thenew reference values to the geometryprogram.


Optimised use of electrodes.Less electrodes for multiple cavitymachining. Toolmanager’s uniquefunction in ED die sinking usesfinishing electrodes again forpre-finishing, or pre-finishingelectrodes for roughing. Nonew assignment required.

Continuous data check.No missing data when starting theJob. Formalcheck verifies the data in-put continuously and automaticallychecks for completeness. Missing in-

puts are displayed in plain text andlead directly to the appropriate

input window. A data inputleaving no doubt about thecomplete Job.

Graphic machining check.

Two or three-dimensional presenta-tion of the Job to machine with Gra-ficheck. Machining sequences can besimulated, the feasibility verified andthe current state of machining visu-alised graphically.

15

EasyworkEasygeoEasymachiningPieceditor

Tooleditor

SpacetrackAgiepath

GeoeditorAgiesetup 2DFormalcheck

GraficheckToolmanager


Especially in the case of the produc-tion of mould inserts for tools andthe manufacture of valuable serialparts and prototypes, ED die sinkingis still the process with the widestspectrum of variety of forms with thehighest reproduction accuracy andfinest surface quality:

The freedomfor a boundless variety of forms

AGIETRON

- Triaxial and quadriaxial circular in-terpolations- Three-dimensional planetary move-ments with Agie Equimode- Circular drill holes- Triaxial vector ED machining- Quadriaxial linear interpolation- Two and three-dimensional paths- Undercuts- Draw-in and transition radii- Precise thread ED machining- Exactly shaped gear rods

16


Simply definable path ED machining.Geometrical contours can be execut-ed with variable cavity depths or ro-tating C-axis. “Agiepath” also allowsfreely definable orbit movements su-perimposed. External geometries canbe imported, modified with Geoeditorand easily supplemented with ma-chining technologies on the machine.

ED machining in every space vector.Vector or path ED machining can befreely defined with orbit movementssuperimposed. “Spacetrack” allowsevery orbital movement in any spacevector. In most cases, reclamping oraxis-parallel alignment is obsolete.

17


AGIETRON

18

The productionfor state-of-the-art EDM systems

With their mechanical concept, Agi-etron Hyperspark HS and Exact HSED die-sinking systems are designedfor high precision and for optimalprofitability. All the key components,decisive for the precision are manu-factured by Agie itself and thorough-ly checked:

Rigid construction.Guaranteed high static and dynamicrigidity. Assured by the stable castiron construction in C-frame.

Additional machining capabilities.Integrated thermally stable C-axis.Designed for helicoidal EDM, EDM inC-direction, indexing, drilling andpath EDM with a rotating round elec-trode.

Optimalthermal behaviour.All temperature relevant sources areinsulated by constructive measures.The dissipation of all the sources oc-curring in the system is madethrough the cooling water. The cool-ing of the generator, control systemand dielectric unit is regulated byheat exchangers.


Agietron Hyperspark HS and Hyper-spark Exact HS are manufactured inaccordance with state-of-the-artproduction and logistic methods,which are accompanied by a sensi-tive quality management at allstages:

Made in Switzerland.Inhouse manufacturing of all the me-chanical and electronic components,relevant for highest accuracy in AGIE’sultramodern production workshop.High precision, large-dimensioned re-circulating ball screws as well as pre-

tensioned, closed andalso oversized guides

on all axes en-sure a longworking liferesulting incontinous high

precision on the workpiece.

Pioneering production.

Configuration of all Agi-etron Hyperspark HS and

Exact HS in perfect accordance withcustomers requirements during as-sembly. Supported by powerful logis-tics. EDM systems and spare partscan be supplied within shortest time.

Machine-resident measurement data.All the measurement values and testresults of the assembly process arestored in the control system. They can be called up by specialists at anytime, anywhere.

Certified quality.Certification of the Agietron Hyper-spark HS and Exact HS requires al-most double as much time as that forthe actual assembly. Every AgietronHyperspark HS and Exact HS is laser-corrected. A pallet with practice-ori-ented inspection pieces is machined.The ED die-sinking machines aresupplied with an integrated qualitycertificate.

Exemplary compact construction.The machine, control system, genera-tor and dielectric unit are integrated,space saving in the fully encased sys-tem. Agietron Hyperspark HS ma-chines are delivered as a whole on aframe with rollers. The ED die-sink-ing machine can thus be manoeuvredwith minimum effort and, thanks toits small floor-space requirement, italso finds its space in narrow areas.Putting into service is extremely sim-ple with a total of just 4 connections.

19


20

Agietron Hyperspark HS are uniquein convenience, target oriented oper-ation and time-saving functions.

Maximum ergonomics.The striking Agie design, AgietronHyperspark HS and Exact HS com-bine functionality with aesthetics onsmallest footprint. Large slidingdoors allow convenient loading ofworkpieces and electrodes thanks tobest accessibility from two sides.

Electromagnetic screening.Agietron Hyperspark HS and ExactHS comply with all safety regulations.International and EU standards arefully met. Integrated in their fully en-closed casing, the machine, the di-electric unit, the control system andgenerator form a space-saving unit.

Ergonomic console.Non-fatiguing data input on the con-sole with their 15-inch LCD screen,keyboard and mouse. Flexibly instal-lable consoles of the Agietron Hyper-spark HS and Exact HS.

Convenient setting-up.With Agiejogger and Jogbox, themanual control units, all the set-upphases can be carried out conve-niently directly in the machine’s workarea. By means of the electronichandwheel, axes can be moved infi-nitely variable and at high speed.

Good accessibility.With the well designed layout, all thecomponents relevant for maintenance,service and wear can be easilyreached.

Exemplaryin operation and convenience

AGIETRON

The best of their category. Products

which received awards for the quality

of its design and finish. Functionality

and style elegantly combined.


21

Simple manoeuvring.The Agietron Hyperspark HS can beeasily transported. With its small di-mensions, delivered as a whole on aframe with rollers, the EDM systemcan be moved easily.

Optimum accessibility.Agietron Hyperspark HS and Exacts HSfor simple workpiece loading.


Agietron Hyperspark HS are automat-able ED die-sinking machines. Farabove the average with their standardscope of supply.

Pioneersin engineering and technology

22

AGIETRONHYPERSPARK HS

Axes travels X/Y/Z axesWorkpiece Max. dimensions Length x Width x Height

orMax. Workpiece weight

Electrode Max. Electrode weightTable to quill distance Minimal / Maximal

Work area Worktank type Automatic drop tankInternal worktank dimensionsAccessibilityProgrammable bath level

Machine table Clamping surface Length x WidthPlate with grid hole-pattern 50 mm grid hole patter

Integrated C axes Indexing, interpolation with X, Y and Z, rotation and spiral machining RotationMax. working current Rotating / StaticMax. Electrode weightProgrammable positioning brakeQuill equipment Integrated automatic chucks

Electrode changer ELW 12, ELW 24, ELW 28, ELW 50, ELW 56Workpieces / Electrodes changer AGIE WORKPAL, AGIE WORKPARTNER and othersHigh performance generator AGIE IPG "Intelligent Power Generation" with Hyperspark module Type

Mean discharge rateProcess monitoring and adaptation depending on the degree of machining difficulty Automatic ACC/ACOSelection and automatic adaptation of the technology depending on machining targets and electrodes data TECTRONAdaptive servo system for maximum ED machining efficiency AGIE IPG FuzzyTimer, gentle electrode return movements, for optimum EDM results on large surfacesHigh-speed timer, high-speed return movements, for optimum EDM results in small and deep moulds HVP “High Velocity Pulsation”

Performances Removal rate ◆ Cupper / steel a 72ARemoval rate ◆ Graphite / steel a 72ABest roughness ◆ RaBest surface finish with SF Module, power module for finest finishing ◆ RaEDM-Polishing AGIEBRILAdditional power unit 32A for optimum utilisation of the equipment with graphite electrodes ◆ Expansion at 104 A, removal rate Gr/Ac

Flushing Number of connections Tank / QuillProgrammable flushing, suction

Dielectric unit Integrated Charge volumeInterface for central DA connection or other systems

Filtration Cartridge filters 4 canisters with 8 cartridge filtersFiltrate qualityFilter autonomy

System System dimensionsLength x Width x HeighDistance floor / Clamping level

Weight Net weightWeight ready-to-run

Cooling Cooling with heat exchanger air / water for generator, control, dielectric / water for dielectricStandards and directives Directives 98/37/CE “Safety and Health”, Directives 89/336/CEE “Electromagnetic compatibility”


1m

AGIETRON HYPERSPARK 2 HS AGIETRON HYPERSPARK 3 HS

23

2 3

Operation and data inputRemote control for manual axes movement X/Y/Z/C ■ JOGBOX with electronic handwheelRemote control for manual axes movement X/Y/Z/C with ▲ AGIEJOGGER with electronic handwheel and LCD displaysetup functions for electrode, worktank and pickup cyclesOperator interface system ■ 15"-LCD-display, keyboard and mouseControl unit integrated ■ AGIEVISION object oriented man-machine interfaceOperating system ■ Multitasking OS/2Operating mode ■ MultiprocessorCPU’s ■ Pentium for CNC and operator interfaceServocontrolled axes ■ X/Y/Z/C axesSupplementary servocontrolled axis ▲ A axisUnits of measurement ■ mm/inchCommand format ■ Absolute / incrementalSmallest programmable step X/Y/Z/C axes ■ 0.0001 mm / 0.0001° (0.000004 in)Modules and functions Simple realisation of basic applications ■ EASYWORKSimple realisation of complex applications ■ EASYGEO / EASYMACHININGPickup cycles for automatic determination of workpiece and electrodes position ■ AGIESETUP 2DFree combination of orbital moves and erosion formes ■ SPACETRACKPath controle module ● AGIEPATH 3DSimple 2D geometry programming ● GEOEDITOROptimisation of electrode utilisation ● TOOLMANAGERPredefined and user defined machining strategies ■ USERSEQUENCEQuickly insert rush orders without effort ■ PIECEINSERTDNC port with Xon/Xoff and LSV2 protocols ■ DNCHelp functions, explanations with text and graphics ■ HELP and online manualMachining simulation 2D and 3D view ■ GRAFICHECKMaximum safety through continuous data input ■ FORMALCHECK and data input ProtocolEasy preparation of job templates ■ WORKMODELAutomatic instructions and commands execution ■ EASYRUNAutomatic machining sequence definitionfor multiple workpieces clamping ■ LOTTO

Languages ■ English, CN, CZ, DE, DK, ES, FR, HU, IT, JP, NL, PL, RU, SE, USStorage capacity ■ > 40 GB HD, 128 MB RamInterfaces ■ 2 x RS232C, 1 x Parallel, 1 LAN (Local Area Network)Data storage media ■ CD-ROM for updates and on line manual, 31/2"-floppy-diskInterface for automationBasic equipment for handling devices ▲ AUTOMATIONCommunication interface for handling devices ● ROBOTCOMMANDCommunication interface for cell computer connection ● HOSTCONTROLUtilitiesLine power ■ 8.3 kVALine voltage ■ 3 x 400 VCompressed air ■ 7 bar, 5 m3/hCooling capacity required ■ 1.5-6 kW

◆ According to AGIE setting values■ Standard▲ Variant: Not retrofittabe● Option

350 x 250 x 350 mm (13.77x9.84x13.77 in) 500 x 350 x 500 mm (19.7x13.77x19.7 in)650 x 580 x 250 mm (25.6x22.85x9.85 in) 880 x 680 x 350 mm (34.65x26.75x13.77 in)820 x 420 x 250 mm (32.3x16.5x9.85 in) 1070 x 530 x 350 mm (42.12x20.9x13.77 in)400 kg (880 lbs) 800 kg (1760 lbs)100 kg (220 lbs) 100 kg (220 lbs)170 - 520 mm (6.7 - 20.5 in) 200 - 700 mm (7.9 - 27.5 in)■ ■

860 x 620 x 360 mm (33.8x24.4x14.2 in) 1090 x 730 x 490 mm (43x28.7x19.3 in)from 3 sides from 3 sides0-290 mm (0 - 11.40 in) 0-390 mm (0 - 15.35 in)600 x 450 mm (23.6 - 17.7 in) 800 x 600 mm (31.5 - 23.6 in)■ ■

0-60 rpm 0-60 rpm72 A / 104 A 72 A / 104 A50 kg (110 lbs) 50 kg (110 lbs)■ ■

▲ ▲

▲ ▲

▲ ▲

integrated integrated72 A 72 A■ ■

■ ■

■ ■

■ ■

up to 7 m/min (22 ft/min) up to 7 m/min (22 ft/min)550 mm3/min (0.033 in3/min) 550 mm3/min (0.033 in3/min) 600 mm3/min (0.037 in3/min) 600 mm3/min (0.037 in3/min) 0.2 µm (RMS 7.9 µin) 0.2 µm (RMS 7.9 µin)▲ < 0.1 µm (RMS < 3.9 µin) ▲ < 0.1 µm (RMS < 3.9 µin)■ ■

● 1000 mm3/min (0.055 in3/min) ● 1000 mm3/min (0.055 in3/min) 4/2 4/2■ ■

415 l (109 gal) 620 l (164 gal)● ●

■ ■

3 - 5 µm (0.00020 in) 3 - 5 µm (0.00020 in)160 Hrs. at 32 A 160 Hrs. at 32 A■ ■

2689 x 1855 x 2593 mm (106.35x73x102.1 in) 2855 x 2135 x 2965 mm (112.9x84.05x116.75 in)884 mm (34.8 in) 884 mm (34.8 in)3200 kg (7040 lbs) 3900 kg (8580 lbs)appr. 4200 kg (9240 lbs) appr. 5500 kg (12100 lbs)■ ■

■ ■


Axes travels X/Y/Z axesDual Measuring System for the X/Y/Z axes

Workpiece Max. dimensions Length x Width x Heightor

Max. Workpiece weightElectrode Max. Electrode weight

Table to quill distance Minimal / MaximalWork area Worktank type Automatic drop tank

Internal worktank dimensionsAccessibilityProgrammable bath level

Machine table Clamping surface Length x widthPlate with grid hole-pattern 50 mm grid hole patter

Integrated C axes Indexing, interpolation with X, Y and Z, rotation and spiral machining RotationMax. working current Rotating / staticMax. Electrode weightProgrammable positioning brakeQuill equipment Integrated automatic chucks

Electrode changer ELW 12, ELW 24, ELW 28, ELW 50, ELW 56Workpieces / Electrodes changer AGIE WORKPAL, AGIE WORKPARTNER and othersHigh performance generator AGIE IPG "Intelligent Power Generation" with Hyperspark module Type

Mean discharge rateProcess monitoring and adaptation depending on the degree of machining difficulty Automatic ACC/ACOSelection and automatic adaptation of the technology depending on machining targets and electrodes data TECTRONAdaptive servo system for maximum ED machining efficiency AGIE IPG FuzzyTimer, gentle electrode return movements, for optimum EDM results on large surfacesHigh-speed timer, high-speed return movements, for optimum EDM results in small and deep moulds HVP “High Velocity Pulsation”

Performances Removal rate ◆ Cupper / steel a 72ARemoval rate ◆ Graphite / steel a 72ABest roughness ◆ RaBest surface finish with SF Module, power module for finest finishing ◆ RaEDM-Polishing AGIEBRILPower unit 32A for optimum utilisation of the equipment with graphite electrodes ◆ Expansion at 104 A, removal rate Gr/Ac

Flushing Number of connections Tank / quillProgrammable flushing, suction

Dielectric unit Integrated Charge volumeInterface for central DA connection or other systems

Filtration Cartridge filters 4 canisters with 8 cartridge filtersFiltrate qualityFilter autonomy

System System dimensionsLength x Width x HeighDistance floor / Clamping level

Weight Net weightWeight ready-to-run

Cooling Cooling with heat exchanger air / water for generator, control, dielectric / water for dielectricStandards and directives Directives 98/37/CE “Safety and Health”, Directives 89/336/CEE “Electromagnetic compatibility”

Above averagein precision and operating convenience

24

Agietron Hyperspark Exact HS under-line their top position in ED die sink-ing with numerous features placing itfor tomorrow’s challenges.

AGIETRONHYPERSPARKE ACT HS


350 x 250 x 350 mm (13.77x9.84x13.77 in) 500 x 350 x 500 mm (19.7x13.77x19.7 in)■ ■

650 x 580 x 250 mm (25.6x22.85x9.85 in) 880 x 680 x 350 mm (34.65x26.75x13.77 in)820 x 420 x 250 mm (32.3x16.5x9.85 in) 1070 x 530 x 350 mm (42.12x20.9x13.77 in)400 kg (880 lbs) 800 kg (1760 lbs)100 kg (220 lbs) 100 kg (220 lbs)170 - 520 mm (6.7 - 20.5 in) 200 - 700 mm (7.9 - 27.5 in)■ ■

860 x 620 x 360 mm (33.8x24.4x14.2 in) 1090 x 730 x 490 mm (43x28.7x19.3 in)from 3 sides from 3 sides0-290 mm (0-11.40 in) 0-390 mm (0-15.35 in)600 x 450 mm (23.6 x 17.7 in) 800 x 600 mm (31.5 x 23.6 in)■ ■

0-60 rpm 0-60 rpm72 A / 104 A 72 A / 104 A50 kg (110 lbs) 50 kg (110 lbs)■ ■

▲ ▲

▲ ▲

▲ ▲

integrated integrated72 A 72 A■ ■

■ ■

■ ■

■ ■

up to 7 m/min (22 ft/min) up to 7 m/min (22 ft/min)550 mm3/min (0.033 in3/min) 550 mm3/min (0.033 in3/min)600 mm3/min (0.037 in3/min) 600 mm3/min (0.037 in3/min)0.2 µm (RMS 7.9 µin) 0.2 µm (RMS 7.9 µin)▲ < 0.1 µm (RMS < 3.9 µin) ▲ < 0.1 µm (RMS < 3.9 µin)■ ■

● 1000 mm3/min (0.055 in3/min) ● 1000 mm3/min (0.055 in3/min)4/2 4/2■ ■

415 l (109 gal) 620 l (164 gal)● ●

■ ■

3 - 5 µm (0.00020 in) 3 - 5 µm (0.00020 in)160 Hrs. at 32 A 160 Hrs. at 32 A■ ■

2689 x 1855 x 2593 mm (106.35x73x102.1 in) 2855 x 2135 x 2965 mm (112.9x84.05x116.75 in)884 mm (34.8 in) 884 mm (34.8 in)3200 kg (7040 lbs) 3900 kg (8580 lbs)appr. 4200 kg (9240 lbs) appr. 5500 kg (12100 lbs)■ ■

■ ■

1m

AGIETRON HYPERSPARK 2 EXACT HS AGIETRON HYPERSPARK 3 EXACT HS

25

Operation and data inputRemote control for manual axes movement X/Y/Z/C with ■ AGIEJOGGER with electronic handwheel and LCD displaysetup functions for electrode, worktank and pickup cyclesOperator interface system ■ 15"-LCD-display, keyboard and mouseControl unit integrated ■ AGIEVISION object oriented man-machine interfaceOperating system ■ Multitasking OS/2Operating mode ■ MultiprocessorCPU’s ■ Pentium for CNC and operator interfaceServocontrolled axes ■ X/Y/Z/C axesSupplementary servocontrolled axis ▲ A axisUnits of measurement ■ mm/inchCommand format ■ Absolute / incrementalSmallest programmable step X/Y/Z/C axes ■ 0.0001 mm / 0.0001° (0.000004 in)Modules and functions Simple realisation of basic applications ■ EASYWORKSimple realisation of complex applications ■ EASYGEO / EASYMACHININGPickup cycles for automatic determination of workpiece and electrodes position ■ AGIESETUP 2DFree combination of orbital moves and erosion formes ■ SPACETRACKPath controle module ■ AGIEPATH 3DSimple 2D geometry programming ■ GEOEDITOROptimisation of electrode utilisation ■ TOOLMANAGERPredefined and user defined machining strategies ■ USERSEQUENCEQuickly insert rush orders without effort ■ PIECEINSERTDNC port with Xon/Xoff and LSV2 protocols ■ DNCHelp functions, explanations with text and graphics ■ HELP and online manualMachining simulation 2D and 3D view ■ GRAFICHECKMaximum safety through continuous data input ■ FORMALCHECK and data input ProtocolEasy preparation of job templates ■ WORKMODELAutomatic instructions and commands execution ■ EASYRUNAutomatic machining sequence definitionfor multiple workpieces clamping ■ LOTTO

Languages ■ English, CN, CZ, DE, DK, ES, FR, HU, IT, JP, NL, PL, RU, SE, USStorage capacity ■ > 40 GB HD, 128 MB RamInterfaces ■ 2 x RS232C, 1 x Parallel, 1 LAN (Local Area Network)Data storage media ■ CD-ROM for updates and on line manual, 31/2"-floppy-diskInterface for automationBasic equipment for handling devices ▲ AUTOMATIONCommunication interface for handling devices ● ROBOTCOMMANDCommunication interface for cell computer connection ● HOSTCONTROLUtilitiesLine power ■ 8.3 kVALine voltage ■ 3 x 400 VCompressed air ■ 7 bar, 5 m3/hCooling capacity required ■ 1.5-6 kW

◆ According to AGIE setting values■ Standard▲ Variant: Not retrofittabe● Option

2 3


Electrical erosion, also called EDM –Electric Discharge Machining, is ayoung technology. Over 50 years old.Just as young as Agie. A technology,which has been decisively influencedand shaped by Agie. What is EDM? Byusing electrical discharge machining,conducting materials of any hardnesscan be machined with an accuracy ofdown to one thousandth of a millime-tre, practically without mechanicalinfluence. This makes EDM the keytechnology for the manufacture of thedemanding moulds and puncheswhich are used for the mass pro-duction of parts made of plastic,metals and glass. Objects fromour everyday life: toothbrush-es, mobiles, PET bottles,computers, cutlery, skiboots, ballpoint pens, carcomponents, toys, implants,instruments – the series couldbe continued at will, provingimpressively that EDM is a dy-namic technology with unlim-ited potential for the future.

PARTNER TO THE BEST

26

The addressfor over 50 years of ED machining


27

Advice. Competent and experiencedsales engineers, who are in yourvicinity, consult you in all topics of EDmachining. No questions are leftopen.

Information. Agie updates its web sitewww.agie.com continuously, publishesinteresting customer applications inits magazine “experience” and, evenafter the sale, informs about the latestproducts with brochures and flyers.

Customer care. Agie has specialistconsultants deployed worldwide, whorealise practice-oriented application,automation, hardware and softwaresolutions, and also make the entry in-to ED machining easier.

Training. Agie prepares individual in-structions for every EDM system sothat productive EDM jobs can bestarted shortly after commissioning.

Documentation. Agie supports theuser effectively with practice-orienteduse and maintenance documentationin printed and electronic form.

Help line. Agie routinely solves ap-prox. 90% of all problems directly onthe phone.

Service. Agie ensures the optimalfunctioning and utilisation of its AgieEDM systems worldwide with its con-tinuously trained service engineers.

Readiness for delivery. Agie offers a24-hour service on workdays andholds a large stock for fast deliveries,with 97 percent availability of originalspare and wear parts, consumablesand additional equipment.

Original parts. Agie guarantees thebest EDM results with its originalspare and wear parts. All machiningtechnologies and factory data arebased on this.


AGIE SACH - 6616 LOSONETELEPHONE +41 (0)91 806 91 11TELEFAX +41 (0)91 806 92 [email protected]

All rights to changes reserved.

© AGIE. The machine design is registered, 1997.

500.029.838August 2006Printed in Switzerland.

AGIE CHARMILLES LTDNORTH VIEWUK-COVENTRY CV2 2SJUNITED KINGDOMTEL +44 2476 538 666FAX +44 2476 530 [email protected]

AGIE [email protected]

AGIE SALES LTDCH - 6616 LOSONETEL +41 (0)91 806 90 30FAX +41 (0)91 806 90 [email protected]

MIKRON AGIE CHARMILLES SALES LTDWWW.AGIE.COM

AGIE CHARMILLES [email protected]

AGIE CHARMILLES MAKINE TICARETLIMITED [email protected]

AGIE CHARMILLES SPA BU [email protected]

AGIE CHARMILLES [email protected]

AGIE CHARMILLES SA [email protected]

AGIE LTD575 BOND STREETLINCOLNSHIREILLINOIS 60069 - USATEL +1 800 438 50 21FAX +1 847 478 57 [email protected]

ON THE WEB SITE:WWW.AGIE.COM

GREAT BRITAINNORTHERN IRELAND

GERMANY

SWITZERLANDAUSTRIABENELUXSCANDINAVIASLOVENIACENTRAL AND EASTERN EUROPEBALKANSMIDDLE EASTSOUTH AFRICA

CIS

POLAND

TURKEI

ITALY

FRANCE

SPAINPORTUGAL

USACANADASOUTH AMERICAMEXICO

JAPANSINGAPOREINDIAPAKISTANCHINAKOREA

EUROPE NORTH

EUROPE SOUTH

AMERICA

ASIA


Documents

die sinking of ED intelligent way The - GFMS · The intelligent way to manufacture moulds 2 ED die sinking is three-dimensional machining in space. The most reliable way from the