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Achieve more...
TODAY
THE GF AgieCharmilles CUSTOMER NEWSPAPER
DEAR READERS,
I am pleased to be able to
introduce to you the fi rst edition
of our new customer magazine
«Results today». «Results today»
came about by merging the
former customer magazines
«Experience» (Agie) and «HSM
today» (Mikron). «Results today»
documents the pooling of all the
assets of our company, through
the amalgamation on 1 July 2007
of the traditional brands Agie,
Charmilles and Mikron into the
single brand GF AgieCharmilles.
«Results today» is published twice
a year and introduces new prod-
ucts, looks into industrial methods
in the EDM and milling fi elds and
gives you a better understanding,
in a concise way, of the advantag-
es of working in cooperation with
GF AgieCharmilles, with which you
can quickly and precisely achieve
success.
GF AgieCharmilles has pooled
its extensive market know-how
and the proven innovation of its
former brands, in order to create
real added value for you, its
customers. So we are now in a
position to be able to offer you a
one-stop comprehensive range of
products and services.
GF AgieCharmilles is presenting
itself to the world for the fi rst time
with a new image and a range of
new, innovative products. In this
way we our bringing to life our
«Achieve more» brand promise.
We hope to continue to «Achieve
more» together with you in the
future.
Yours sincerely,
Dr. Jürg Krebser,
CEO GF AgieCharmilles
EDM AND HSC – SYNERGY INTOOL AND MOLD MAKING
A drastic change has taken place in tool and mold making.
In practically no other area are the traces of globalization as
obvious as in this branch of industry. Many wage-intensive
jobs have been transferred to Eastern Europe and Asia and
new technologies have been introduced. Purposefully utiliz-
ing the key technologies, electrical discharge machining and
milling, is therefore equally relevant for manufacturers and
users of such machines.
The FORM 2000 is one of many novelties GF AgieCharmilles.
DR. JÜRG KREBSER
The HPM is one of many milling novelties GF AgieCharmilles.
Pelton turbine blades are piece by piece milled precision.
A milled axis shows innovation for race bicycles.
The GF AgieCharmilles coin.
3
4-5
6-7
10-11
14-15
ENGLISH EDITION
01
MAGNETFABRIK 12
CAMPAGNOLO 10
BRÄM 8
OMB 6
KEY TECHNOLOGIES
EDM and high-speed cutting
(HSC) are among today’s key
technologies for classic tool
and mold machining. While the
electrical discharge machin-
ing method works by thermal
removal, high-speed cutting is
a method of cutting with a geo-
metrically defi ned cutting edge.
Even from this simple and hardly
noteworthy comparison it can be
seen that there are characteris-
tics, which determine the basic
suitability of the method for
certain applications.
HIGH-SPEED CUTTING (HSC)
The term high-speed cutting
typically means machining with
a geometrically defi ned cutting
edge, which enables the maxi-
mum possible cutting speed of
modern tool materials and coat-
ings in the various workpiece
materials. In relation to tool and
mold making, the main focus
is on the machining of easily
machinable materials for model
and electrode production (cut-
ting speeds 800 – 2000 m/min-1)
as well as the machining of
tempered and hardened tool
steels (cutting speeds 100 to 500
m/min-1). Modern fi nest carbide
grade hard metals with coatings
suited to the workpiece material
are used as tools. Typical tool di-
ameters in tool and mold making
range from D = 0.2 mm to D = 16
mm, whereby a maximum ratio
of cutting length to diameter of
L/D = 10 to L/D = 15 is possible.
ELECTRICAL DISCHARGE MACHINING (EDM)
With the EDM method, two
charged electrodes in an electri-
cally insulated fl uid (dielectric)
approach each other, until
sparkover occurs between the
tips, and, as a result, a plasma
channel forms between the
electrodes. The charge carri-
ers, which are impinging on the
electrode surfaces at high speed,
convert their kinetic energy into
heat, causing local melting of the
electrode material on the contact
surfaces between the plasma
channel and the electrodes. Due
to the impinging of the charge
carriers, a part of the melted
electrode material is already
vaporized or fl ung out of the
existing crater. If, subsequently,
the power supply is interrupted,
the plasma channel collapses
at high speed. The resulting low
pressure increases the effi ciency
of the process, in which addi-
tional melted electrode material
is removed from the crater by
the high/low pressure effect.
By sequential repetition of this
process, considerable material
volumes can be removed from
almost all electrically conductive
electrode materials.
The processes of die sinking
EDM and wire EDM are differ-
entiated. In the fi rst case, one
of the electrodes corresponding
to the required end geometry of
the typically three-dimensional
cavity, is sunk into the workpiece
material, and in the second case
a maximum two-dimensional ge-
ometry is cut out of a workpiece
with a retracting wire electrode.
In principle, almost all electri-
cally conductive materials can be
machined by the EDM process.
On the basis of the underly-
ing functional principle, the
EDM process is independent
of material hardness and, to a
large extent, is independent of
the material composition of the
workpiece. In combination with
negligible machining power, this
results in particular characteris-
tics, which have predestined the
process for tool and mold mak-
ing in the past and for which up
until now no alternative method
has been found.
COMPARISON OF METHODS
The methods that really compete
with each other in tool and mold
making are die sinking EDM and
high-speed milling. Both meth-
ods can be used primarily to pro-
duce complex three-dimensional
cavities and mold cores for injec-
tion or die casting molds as well
as for the manufacture of forging
punches and dies, compression
molds, forming punches, sinter-
ing press molds and blow molds.
High-speed machining has
become particularly established
in the production of graphite and
copper electrodes and is, from
this point of view, also a comple-
mentary method to die sinking
EDM.
The operating costs of die sink-
ing EDM machines are largely
the same as those of high-speed
milling machines, provided that
machines of the same category
are compared with each other.
An important factor in this com-
parison is taking into considera-
tion the costs of tools (milling
tools, electrode production),
auxiliary materials (dielectric, oil
for minimum quantity lubrica-
tion) replacement and exchange
parts (spindles), waste disposal
(dielectric, chips, sludge, etc.).
While wire cutting EDM with ex-
ecuted cutting electrodes is now
to a great extent unrivalled in
the production of punching and
cutting dies, die sinking EDM
and high-speed milling meet
each other directly as compet-
ing production methods in many
areas of application. Neverthe-
less, the question of advantages
and disadvantages of die sinking
and high-speed milling in tool
and mold making can not be
answered conclusively. Despite
the massive advantages of high-
speed milling, special geometry
elements remain, which limit
this method. In this respect, both
state-of-the-art methods should
be regarded as complementing
each other.1997
20%
40%
60%
80%
100%
2002 2007
EDM
Laser sintering
HSC
Conventional Milling
Form
HSC HSC
EDM
Time advantage
TimeForm
Electrode
Electrode
High-speed cutting is executed with 3, 4 or 5 axes. Wire EDM is performed with 3 axes and can also be tapered through
defl ection of the U and V-axis. Special machining can be carried out by
extension with the A and B-axis.
Die sinking EDM occurs on 3 axes and can be extended with the C-axis.
Simple shapes take less time to machine with HSC than EDM – however
with complex shapes EDM tends to come out on top. Market shares of forming processes in the mould and die industry.
EDM HSC3 and 5 axis
Max. precision (form error)
2 – 10 μm 5 – 10 μm (3 axis)10 – 20 μm (5 axis)
Max. removal rate 900 mm3/min 2500 – 3500 mm3/min
Max. surface to machine dependent of roughness unlimited
Prozess indirect direct
Max. hardness of material to machine (steel)
unlimitted ≤ 60 HRC ensured process60 – 65 HRC short tool life
Max. toughness of material to machine
unlimitted linked with high hardness problematical
Max. relation of depth to width for nutes
unlimitted ≤ 7 ensured process7 – 10 possible> 10 dependent of the case
Min. radii of inside corners Gap Radii of endmillLimitation through relation of length to diameter
Comparison of EDM with HSC in relation to performance and geometry results.
GF AgieCharmilles | Results TODAY | 01
ERODING – MILLING | COMPARISON 2
UNIQUE PRECISION AND AUTONOMY
The mechanics of the FORM 2000/3000
series are designed for extremely high
speeds and accelerations and, with high
precision, meet the requirements of
specifi c market segments, which want to
«Achieve more». The FORM 2000 and 3000
enable users to produce extremely ac-
curate, perfectly shaped geometries with
a very fi ne surface quality. The new die
sinking EDM series also combines perfect
precision and high autonomy in environ-
ments without air conditioning.
At the heart of the FORM 2000/3000 series
is a generator with the most modern,
state-of-the-art EDM strategies, technolo-
gies and functions, which enable these die
sinking EDM machines to predictably and
consistently achieve remarkable perform-
ances.
The FORM 2000/3000 series offers two
exclusive user interfaces, Agievision
and Dynamic Process Control (DPC),
which have been proven in practice and
are appreciated by customers. A further
highlight of the FORM 2000/3000 is pallet
and electrode changing systems that can
be integrated, which stand out due to
their exceptional modularity and competi-
tive prices, enabling this new die sinking
EDM series to be adapted to the individual
production cells of every customer.
NEW DIE SINKING AND WIRE EDM MACHINESFORM 2000 AND 3000. This die sinking EDM se-
ries from GF AgieCharmilles redefi nes precision
and performance boundaries in die sinking EDM.
FORM 2000 and 3000 are specially geared towards
the requirements of exacting manufacturers, who
produce everything from micro-electronic parts
and complex telecommunications components to
connector assemblies requiring extreme precision
and multiple cavities.
Process routes (X, Y and Z) mm 350 x 250 x 350 600 x 400 x 500
Max. electrode weight kg 100 100
Max. electrode weight (with C-axis) kg 50 50
Max. workpiece weight kg 800 2000
Table/clamping chuck distance mm 170/520 200/700
Table dimensions mm 600 x 400 850 x 600
Max. workpiece dimensions mm 820 x 580 x 250 1200 x 800 x 350
Worktank dimensions mm 900 x 630 x 350 1280 x 1040 x 450
Machine dimensions mm 1410 x 2460 x 2660 1790 x 2790 x 3110
Machine weight (without dielectric) kg 3830 5900
Machine name FORM 2000 FORM 3000
High precision and modularity of the pallet and electrode
changing systems are the outstanding features of the new
FORM 2000 and 3000 die sinking EDM series.
GF AgieCharmilles | Results TODAY | 01
NEW PRODUCTS | GF AgieCharmilles 3
ALWAYS ON THE SAFE SIDE
The mechanical construction of the FORM
20 and FORM 30 is a C-frame type with
a cross table. The machine base, col-
umns, cross table and Z-axis are made
of cast iron and offer optimum rigidity
and thermal stability. The cross table and
other mechanical components such as
axis guides and recirculating ball screws
are generously sized and ensure good
positioning accuracy and reproducibility of
EDM results in the workshop environment.
An integrated C-axis and an electrode
magazine make the FORM 20 and FORM
30 a profi table production center with high
autonomy.
The FORM 20 and FORM 30 series offers
a large working area, which is optimally
suited to multiple clampings, without
restrictions having to be imposed due to
positional deviation errors. With the FORM
20 and FORM 30 there are no surprises:
predictable results are the hallmark of
this new die sinking EDM machine series,
so that a job can be programmed and
the required geometrical results quickly
achieved without previous knowledge.
FORM 20 AND 30. GF AgieCharmilles takes a great
interest in ensuring the success of its custom-
ers and this is emphasized by the introduction of
the new FORM 20 and FORM 30 die sinking EDM
machine series. The main focus is on production
effi ciency, reliability and user-friendliness.
EDM KNOW-HOW COMBINED WITH SWISS VALUES
Incorporated into the new CUT 20 wire
EDM machine are both EDM know-how
from GF AgieCharmilles research and
development as well as Swiss values, to
which the company feels bound. In this
way we meet the market demand for
affordable wire EDM solutions for a wide
variety of applications – from the produc-
tion of precision parts and electrodes to a
wide range of cutting tools.
Like all GF AgieCharmilles machines,
the CUT 20 is equipped with quality glass
scales on all axes, outstanding ergonom-
ics, an extremely accessible working area
and a very well designed control panel.
Based on proven technology, the CUT 20
provides a reliable EDM process, fl exibil-
ity, uncomplicated programming, easy to
operate job preparation and an aesthetic
design – all at an attractive price.
A further important advantage of the CUT
20 is its intuitive user interface and its
complete range of software functions,
which enable fast preparation of wire EDM
jobs and achieve optimum results straight
off. Due to its user-friendliness, operation
of the CUT 20 can be learnt quickly and
full production can be attained quickly
after installation.
CUT 20. The new wire EDM machine gives prior-
ity to machining speed and cost effectiveness and
offers a standard level of accuracy and surface
quality for applications, for which production costs
are frequently a more important criterion than
extreme precision.
Process routes (X, Y and Z) mm 350 x 250 x 250 600 x 400 x 400
Max. electrode weight kg 50 100
Max. electrode weight (with C-axis) kg 25 50
Max. workpiece weight kg 200 1000
Table/clamping chuck distance mm 480/230 650/250
Table dimensions mm 630 x 400 800 x 600
Max. workpiece dimensions mm 800 x 500 x 265 1000 x 700 x 400
Worktank dimensions mm 955 x 540 x 350 1200 x 800 x 500
Machine dimensions mm 1300 x 1850 x 2500 2000 x 2600 x 2700
Generator dimensions mm 750 x 900 x 1915 750 x 900 x 1915
Machine weight (without dielectric) kg 2000 3000
Machine name FORM 20 FORM 30
Process routes (X, Y and Z) mm 350 x 250 x 250
Process routes (U and V) mm 90 x 90
Max. workpiece weight kg 400
Table dimensions mm 700 x 480
Max. workpiece dimensions mm 900 x 680 x 250
Worktank dimensions mm 1050 x 765
Machine dimensions mm 3500 x 3500
Machine weight (without dielectric) kg 3000
Wire diameter mm 0.15 to 0.30
Max. taper ° 25° with 80 mm
Machine name CUT 20
The FORM 20 and FORM 30 die sinking EDM range is
impressive due to its robust construction, simple operation
and large working area.
The new CUT 20 wire EDM machine offers proven technol-
ogy, high ergonomics and easy to operate programming at
an extremely attractive price.
GF AgieCharmilles | Results TODAY | 01
NEW PRODUCTS | GF AgieCharmilles 4
NEW MIKRON HPM MILLING MACHINE SERIESMIKRON HPM 600, 900 UND 1200. The newly de-
veloped, three-axis machining centers are, due to
their strong and robust construction, particularly
well suited to machining in the HPC (High Per-
formance Cutting) fi eld and stand out due to their
less than 2-second tool change.
FLEXIBLE CONFIGURATION AS REQUIRED
The new HPM series is designed, due to
its modular construction, for all applica-
tion areas from prototyping, to tool and
mold making, to fully automated produc-
tion; this is due to the large number of
options and their compatibility. There are
several automation alternatives available
– from the established Mikron solution
in-house pallet magazine to robot as-
sembly by well-known manufacturers. All
machine components are logically syn-
chronized with each other and enable very
effi cient machine use around the clock.
NOT ONLY FAST FOR MILLING
The new HPM series also wants for
nothing with regard to tool quantities. The
customer can choose between the two
solutions integrated into the machine for
either 30 or 60 tools, and the externally
linked storage tower (ATC) for 120, 170 or
220 tools. Due to the double arm gripper
system exceptionally fast tool changes of
less than two seconds can be achieved.
The new Step-Tec 15 000 min-1 and
20 000 min-1 inline motor spindles,
available with or without inner cooling
lubricant supply, are designed with
high torque capacity for removing large
volumes of chips. This type of spindle is
characterized by its easy-to-maintain
construction and its automatically
lubricated hybrid metal bearing systems.
In addition, the 30 000 min-1 and
42 000 min-1 Step-Tec motor spindles,
which are custom-designed through
incorporating HSC (High Speed Cutting)
milling strategies, are also available. All
the spindles are vector controlled, making
rigid tapping possible.
CHIPS SAFELY DISPOSED OF
The accumulation of chips in the work-
ing area can consistently be avoided. With
sophisticated detailed engineering of the
raised machine tray, chip build-ups are
avoided and the accrued chips are safely
and economically separated from the
cooling lubricant and disposed of. There
are various construction variations avail-
able for this. With the simplest variation,
the chips are collected in baskets and the
cooling lubricant is drained off. A reliable
chip conveyer can be used for auto-
matic swarf removal, in automated mode
amongst others.
USER-FRIENDLY IN EVERY DETAIL
The two light, waist-high doors that close
above the corner, can be opened at a
distance by the operator and enable free
access to the working area. Large panes
of glass give a clear view of the machining
process. Regardless of which options the
Mikron HPMs are equipped with, per-
fect accessibility can always be taken for
granted. The work table, pallet and tool
magazine, as well as the swarf removal
system can be reached just as easily as
the maintenance units. The work table and
pallet magazine can of course be loaded
using the crane. The effi ciency-increasing
«smart machine» module is of course also
available on the new HPM series.
INSTALLATION SIZES FOR VOLUMINOUS PARTS
The three-axes HPM series comes in three
sizes – with an X working range of 650,
900 or 1200 millimeters. The maximum,
manually loadable workpiece weight is
1200 kilograms on a work table of 1400 x
600 millimeters. All three machine sizes
have a Y working range of 600 millimeters
and a working range in the Z direction of
500 millimeters. Consequently, machining
is problem free.
Process routes
Longitudinal X mm 650 900 1200
Lateral Y mm 600 600 600
Vertically Z mm 500 500 500
Work table
Slot table mm 800 x 600 1100 x 600 1400 x 600
Maximale Tischbeladung kg 500 800 1200
Clamping system
EROWA UPC mm 320 x 320 320 x 320 320 x 320
System 3R Dynafi x mm 280 x 280 280 x 280 280 x 280
System 3R GPS mm 240 x 240 240 x 240 240 x 240
MIKRON HPM mm 600 x 600 600 x 600 –
MIKRON HPM mm 800 x 600 800 x 600 –
Max. workpiece weight kg 80/500 80/800 80
Spindle
15 000 min-1 Inline motor spindle
20 000 min-1 Inline motor spindle
30 000 min-1 Motor spindle
42 000 min-1 Motor spindle
Tool magazine Number of tools
Control system
Machine name MIKRON MIKRON MIKRON HPM 600 HPM 900 HPM 1200
The three-axis Mikron HPM 600, HPM 900
and HPM 1200 machining centers are new developments
of GF AgieCharmilles for machining in the HPC fi eld.
SK40 or BT40-CAT40
HSK-A63
HSK-A63 or HSK-E40
HSK-E40
30 / 60 / 120 / 170 / 220
Heidenhain iTNC 530
GF AgieCharmilles | Results TODAY | 01
NEW PRODUCTS | GF AgieCharmilles 5
EASY TO GENERATE MILLING STRATEGIES
OMB, whose registered offi ce is
in Bütschwil in Switzerland, re-
ceived an order to produce Pel-
ton turbines on demand. These
consist of the basic wheel with
cover, the quick shaft, clamping
nut, as well as the 21 Pelton
blades. In accordance with the
CAD data from the customer,
the machining technologies are
drawn up for turning and milling
using Mastercam. Due to the
iTNC 530 control system from
Heidenhain, the data could be
taken over by the Mikron UCP
600 Vario without any problem.
EFFICIENT SERIES PRODUCTION
The preformed blanks made
from 1.4021, a martensitic
stainless steel, are delivered
externally and clamped on GPS
240 workpiece pallets from
System 3R. The integrated
automation system of the Mikron
UCP 600 Vario can accom-
modate up to 10 pallets and be
loaded randomly. Depending
on priority, the workpieces are
then executed automatically,
whereby the likewise integrated
tool changer can accommodate
30 to 220 HSK-clamped cutters.
Different modules of the «smart
machine» modular design, which
is standard for the universal
high-performance Mikron UCP
600 Vario machining center,
guarantee an optimum process:
more precision, increased sur-
face quality and contouring accu-
racy as well as improved safety,
which is especially appreciated
for machining without an opera-
tor, since at OMB one shift in 3 is
currently unmanned.
RANDOM LOADING – ORGANIZED MACHINING
For OMB, the randomly loadable
workpiece pallet changer en-
sures the necessary fl exibility, in
order to quickly be able to fi t in a
rush order during series produc-
tion. Via the Sigma FMC software
program from Mikron, produc-
tion sequences can quickly be
established and also modifi ed as
necessary. Although random, the
operator maintains an overview
of the workpiece loading, and
can manage the work fl ow de-
pending on the priority of orders.
OMB was a new customer of
Mikron, so the operators re-
ceived one-to-one training on the
two UCP and VCE milling ma-
chines. The learning curve went
into a steep climb, so that after
a short time, both Mikron milling
machines could be incorporated
into daily production.
«The Mikron UCP 600 Vario with
its automatic pallet loading and
unloading system gives us the
fl exibility to organize and imple-
ment both series and single part
production».
Markus Wick, manager of OMB
Oberdorfer Maschinenfabrik AG
PIECE BY PIECE MACHINED PRECISIONFor over 25 years, Oberdorfer Maschinenfabrik AG has developed, produced and assembled prototypes,
devices, parts, components and fi nished appliances. The company from Toggenburg is a professional
partner for CNC-manufactured turning workpieces made from all materials as well as for cubic work-
pieces in small, medium to large series production, which OMB produces ready-to-install on the most
up-to-date CNC machining centers. For implementation of demanding projects, it has an innovative
design department and a highly-productive jig and prototype manufacturing department.
The 3D volume model and the design of a Pelton turbine blade show the complexity of
machining and the milling strategies.
Pre-machined Pelton turbine blades have a surface roughness of Ra 1.6 μm and show a toler-
ance of ± 0.05 mm over the whole workpiece.
GF AgieCharmilles | Results TODAY | 01
MILLING CUSTOMER | OMB 6
www.omb.ch
Industrie Hofacker
CH-9606 Bütschwil
Switzerland
Phone: +41-(0)71-982 72 72
Fax: +41-(0)71-982 72 90
Contact
Markus Wick
www.omb.ch
Chip-forming machining
1 Mikron UCP 600 Vario 5-axis
milling center
1 Mikron VCE 800 W Pro vertical
machining center
1 5-axis milling center
5 horizontal machining centers
1 vertical machining center
7 turning machines
Clamping systems
GPS 240 from System 3R
Programming
Mastercam VX 3D
Measuring, checking
Zeiss Eclipse 700
If workpiece production exceeds 5
parts, we can begin to talk about
small series or production. During the
«Prototype» stage, both CAD and CAM
programs are optimized, the best, most
suitable clamps for machining are
decided on and, last but not least, the
most economic machining technology
is established. If the customer gives
the green light, the fi nal modifi cations
with regard to the tool, material and
machine can be made. Therefore, OMB
has designed a holder specifi cally for
the series production of mechanical
components for these parts, which cor-
responds to the machine properties of
the Mikron UCP 600 Vario with regard
to the working ranges of all 5 axes. In
this way, fi rstly the full potential of the
machine can be tapped and secondly
the self-designed holder makes quick
clamping easier. By taking just a few
measures, OMB can adapt to economic
series production, without having to be
equipped with all the usual resources.
Markus Wick, manager of OMB Oberdorfer
Maschinenfabrik AG, with a pre-machined
Pelton turbine blade.
KEYWORDMACHINED PRODUCTION PARTS
THE COMPANYOBERDORFER MASCHINENFABRIK AG
The fl exibility of
the Mikron UCP 600 Vario
enables, due to the pallet
changer, autonomous machin-
ing of workpieces of different
shapes and materials.
Specifi cally for the fi nishing
process of die casting parts
for medical technology, OMB
built a holder itself, to enable
machining in a clamp.
In parallel with the milling process, workpieces can be loaded and unloaded at any time.
In the same way, in multitasking mode, new milling work can be prepared on the control system.
The pre-assembled Pelton turbine blade wheel is used in the hydropower industry and
consists of 21 blades, a basic wheel with cover, a quick shaft and a clamping nut.
The preformed blank made from X20Cr13
steel weighs 8 kg. After milling, the weight
reduced to 1.3 kg. This created many chips,
which were reliably discharged by the
Mikron UCP 600 Vario.
The pre-machined Pelton turbine blade
can be unloaded and unclamped by the auto-
mation system of the Mikron UCP 600 Vario.
The Pelton turbine blade clamped on the
GPS 240 workpiece pallet in the Mikron UCP
600 Vario.
GF AgieCharmilles | Results TODAY | 01
MILLING CUSTOMER | OMB 7
LEADING TECHNOLOGY FROM THE START
Investment in the most recent
technologies runs like a thread
through the development history
of the company, which now has 35
employees. The fi rst EDM machine
was installed at the end of the 60s.
Now, with fi ve die sinking and fi ve
wire-EDM machines, the EDM de-
partment is the largest production
department of the Bräm fi rm.
STEP BY STEP TO AUTOMATION
Through continuous analysis of
production costs, management
saw machine set-up times as a
suitable beginning for reducing
processing time and increasing
productivity. By the end of the
90s, the fi rst loading stations for
EDM and milling had already been
installed, and consequently the
preliminary stage for part auto-
mation through pallet systems
was completed. At this time, the
decision was also made to use
Charmilles EDM machines, which
impressed Gebr. Bräm AG both by
their quality and performance and
by the advisory skills and service
offered.
TWO SYSTEMS LINKED WITHOUT DIFFICULTY
In mid-November 2005 a Robofi l
440 CC wire-EDM machine was
installed. At the same time, work
also began on the new production
cell from the existing Roboform
350 die sinking EDM machine and
the WorkMaster handling robot
from System 3R. A further step to-
wards automation followed shortly
afterwards with the commission-
ing of a milling cell. For clamping
and automation systems, System
3R proved its worth, since the
structure, handling and network-
ing capability of the software of
the swedish automation specialist
was the best suited to the existing
systems and in-house processes
of Gebr. Bräm AG. The clamping
systems of a third supplier were
kept.
AUTOMATIZATION ON ALL LEVELS
Production cells enable automa-
tion with palletized workpiece
and tool change regardless of
quantity. For this purpose, each
workpiece and each electrode is
palletized, clamped, measured on
the presetting station and given a
chip ID number, which is managed
in the System 3R «Cell Manager»
databank. All data such as dimen-
sioning, 0-point reference and ma-
chining progress are stored in the
«Cell Manager» and can be called
up fl exibly and individually. Conse-
quently, roughing and preliminary
fi ne machining are often carried
out unmanned during the night, so
that operator-intensive measuring
and fi ne machining can be carried
out during the day. At the same
time as automation, the technical
data of further internal processes
and other CNC machines were
networked and connected to the
overall design. Thus, continuous
process chains could be formed
from planning to completion and
data from Inventor 11 and Autocad
2002 exchanged with customers
through interfaces even during the
development phase.
EDM CELL FREES UP TIME
Even before automation by the
pallet changer, WorkMaster was
already used with pallets, the
increase in machine hours for
the Roboform 350 die sinking
EDM machine did not turn out to
be as impressive as with milling.
However, with an increase of
around 36 percent, Gebr. Bräm AG
does feel that it made the right
decision. Whereas previously EDM
orders had to be put back due
EDM CELL FREES UP TIMEThe production range of Gebr. Bräm AG encompasses prototype manufacturing, production of single
and series production parts as well as cutting dies, molds, devices and special purpose machines, for
which the Swiss company uses EDM cells as the key technology for precision.
With wire and die sinking EDM, multiaxis
milling, circular and surface grinding,
turning, extrude honing and polishing, Gebr.
Bräm AG can carry out all the most impor-
tant machining processes in-house. Future
technologies such as laser cutting, welding
and marking, electro chemical machin-
ing and micro-vortex cutting round off the
machining range.
GF AgieCharmilles | Results TODAY | 01
EDM CUSTOMER | BRÄM 8
www.gebrbraem.ch
Lerzenstrasse 4
CH-8953 Dietikon
Switzerland
Phone: +41-(0)44-746 46 46
Fax: +41-(0)44-746 46 47
Contact
Martin Bräm
www.gebrbraem.ch
Non-cutting machining
– Roboform 200
– Roboform 350 with Workmaster
from System 3R
– Roboform 31
– 2 Robofi l 200
– Robofi l 2000
– Robofi l 4020 SI
– Robofi l 440 CC
– HD 30
Chip-forming machining
Multiaxis milling machines
Circular grinding
Surface grinding machines
CNC turning centers
Extrude honing
Other machining
Electro Chemical Machining
Micro vortex cutting
Laser
Clamping systems
System 3R
Programming
Integrated CIM system
Inventor 7
Autocad
Measuring, checking
DEA Global Image 3D coordinate
measuring machine
The ECM method is an electro chemi-
cal die sinking method with a vibrating
electrode and controlled work edge.
A pulsed direct current is applied
between the electrode and workpiece.
The workpiece is dissolved anodi-
cally according to the geometry of the
retracting electrode. This results in
complex geometrical shapes in almost
any metal, such as tempered steels,
ball bearing steels, powder metallurgy
steels as well as super alloys. ECM
opens up applications, which previously
could not or could not economically be
developed.
A multiple machining job is changed
on the ECM machine.
KEYWORDECM – ELECTRO CHEMICAL MACHINING
THE COMPANYGEBR. BRÄM AG
ECM is a recent machining method at Gebr.
Bräm AG and is used by the company from
Dietikon mainly for series EDM parts with fl at
or open contours.
to a lack of capacity, today the
company can, due to automation,
make better use of its strengths
and appeal to new customers. The
increase in productive hours has
freed up the capacity of the other
EDM machines, which has granted
employees additional room for
maneuver, for example by having
100 percent control of their work
results. With a capacity of 60 to 80
electrodes and around 40 work-
piece pallets in the «WorkMaster»,
the work, which is mostly against
high-pressure deadlines, can be
very effectively organized and
the machining priorities for a job
can be easily changed. Modular
software for fl exible automa-
tion ensures that the machin-
ing program changes the right
electrode and the right tool at the
right time and stores them again,
even with random loading. Error
transmission by SMS provides
additional safety for unmanned
shifts. The operator in charge can
then access the control system via
the Internet, facilitating the deci-
sion as to whether the fault can
be remedied remotely or on-site
intervention is necessary.
Designed in accordance with the CAD
data from the customer and machining
technologies are defi ned according to cost
effectiveness and quality criteria.
Pre-loaded workpieces on the Erowa pal-
let systems are measured on the presetting
station.
Job results are checked and documented
in a 100% check by the machine operator
in charge.
Workpiece pallets and electrodes are
automatically changed with «WorkMaster»,
enabling the machine time of the «Roboform
350» to be doubled.
GF AgieCharmilles | Results TODAY | 01
EDM CUSTOMER | BRÄM 9
A RENOWNED NAME IN CYCLE RACING
Campagnolo S.r.l. was founded
in Vicenza in 1933 by Com-
mendatore Tullio Campagnolo,
and did not take long to grow.
Three basic concepts have al-
ways distinguished the company
and will continue to do so in the
future: Technological innovation,
impeccable after-sale service
and addressing the emotions of
customers thanks to the strong
character of its products.
As in the aviation industry,
Campagnolo work mainly with
aluminium alloys. These are
needed for manufacturing com-
ponents that combine extremely
high reliability with the typical
light weight of professional
racing bicycles. The hot-forged
parts are processed in so-called
«machining centres» or on
automatic processing lines with
automatic static dimensional
testing, carried out «in proc-
ess» or «post process» even on
each and every piece for critical
elements. Many of the items of
equipment and systems used
have been developed directly
by Campagnolo, who have also
developed their own produc-
tion technology alongside their
technical product innovations.
The numerical controls present
on each machine enables quality
control throughout every single
step of the manufacturing proc-
ess. Camapgnolo have a Mikron
UCP 600 Vario 5-axis machining
centre at their disposal for
production parts but also for
producing tool inserts. By way
of example, the moulds and dies
for manufacturing cranksets
by means of a fi ne-blanking
tool were manufactured on this
machine.
FLEXIBLE MILLING APPLICATIONS
Making copper electrodes, alu-
minium-alloy hardware or tool
inserts made of various grades
of steel are the day-to-day
machining tasks undertaken on
the Mikron UPC 600 Vario. This
requires great fl exibility in terms
of both loading options and
control as well as a comprehen-
sive technological performance
range of the machine. Thus,
the built-in workpiece-changer
can be loaded or unloaded at all
times during while machining is
going on.
The latest-generation Heiden-
hain iTNC 530 digital numerical
control and a clearly structured
control desk make the Mikron
UCP 600 Vario a process-safe
and user-friendly machining
centre. Simple, dialogue-driven
programming, parallel program-
ming, free contour programming
and freely defi nable sub-pro-
gramming do justice to the
variety of milling jobs needed at
Campagnolo.
A stable, trouble-free milling
process features the typical char-
acteristics of the UCP 600 Vario:
Direct measuring systems on the
current axis, centric arrange-
ment of the circular axis in rela-
tion to the swivelling axis, good
transmission of forces and full
torque in the lower speed ranges
with the Steptec high-tech spin-
dle, no reversing backlash, wide
slewing range also for machining
recesses and high speeds of
rotation and slew rates.
«The machining spectrum of the
Mikron UPC 600 Vario enables
us to put this machine to use
on a universal basis, both for
the production of parts made of
aluminium alloys and also for
machining tool inserts made of
hardened and tempered steels.»
Giovanni Borga,
workshop manager at Campagnolo S.r.l.
NEW DEFINITION OF CRANKSETSTHROUGH INNOVATIONThe company Campagnolo S.r.l. develops, produces and sells top-of-the-range components for rac-
ing bicycles. It is represented in over 30 countries by fi ve branch offi ces and nine agencies. About 400
people are employed at the headquarters in Vicenza. Since March 2003 the group also includes the
company Campagnolo Sportswear S.r.l., which designs, develops, manufactures and markets technical
sportswear bearing the Campagnolo trademark for cyclists.
Campagnolo S.r.l. always employ highly innovative technology for manufacturing its prod-
ucts, and use only fi rst-class raw materials such as carbon fi bres, titanium and aluminium
alloys originally created for aeronautical engineering applications.
GF AgieCharmilles | Results TODAY | 01
MILLING CUSTOMER | CAMPAGNOLO 10
www.campagnolo.com
The palletised and clamped die is returned automatically to the workpiece-changer
after machining.
Via della Chimica, 4
I-36100 Vicenza
Italy
Phone: +39-0444-22 55 00
Fax: +39-0444-22 54 00
Contact
Giovanni Borga
www.camapgnolo.com
Non-cutting machining
1 Agietron Mondo Star 20
1 Roboform 20
1 Robofi l 4020
Chip-forming machining
1 Mikron UCP 600 Vario
Cylindrical grinding
Flat grinding
Turning
Hardening
Honing
Welding
Clamping systems
Erowa (EDM and milling)
System 3R (EDM and milling)
Programming
Sulfcam (eroding)
Sulfcam, Unigraphics (CAM milling)
Unigraphics (CAD milling)
Measuring, checking
Mitutoyo CNC measuring machine
Optical measuring system
Right from the planning stage, which
is developed using CAD techniques
and with the help of FEM analysis, it
is possible to determine the optimum
cross-sections for the various parts
concerned. The Campagnolo engineers
use highly sensitive instruments
to check the starting materials,
unmachined parts and semi-fi nished
products at the time of acceptance and
after the planned processing cycles in
order to check that the parts match the
design exactly.
Campagnolo has now developed the
innovative «Ultra-Torque» system, with
the aim of improving existing systems.
The system for fi xing the crankset in
place has been simplifi ed and requires
practically no checking. It is now
quicker and simpler to take to pieces
and put back together again. The tech-
nical system used for inserting the ball
bearing was originally invented for the
engine shafts of aeroplane propulsion
systems: it consists of an inside bear-
ing shaft made up of two semi-axes
coupled fi rmly to one another by means
of Hirth toothing.
A prototype is created from a piece of solid
aluminium alloy, fi rst by turning after which
the fi ne details and recesses are milled on the
Mikron UCP 600 Vario.
The semi-axis, part of the «Ultra-Torque»
system, with Hirth toothing, was milled from
alloyed steel alloy by indexing.
Giovanni Borga, workshop manager at
Campagnolo S.r.l., with the milled sprocket
wheel die.
KEYWORDULTRA-TORQUE
THE COMPANYCAMPAGNOLO S.R.L.
A new wheel hub and the «Ultra-Torque» system were designed and optimised using CAD methods.
The complete fi ne-blanking tool with the milled cutting inserts for burr-free cutting.
The fi nish-milled die insert for the fi ne-
blanking tool and a copper electrode for a
forming tool show just what chaotic loading
can do.
With the Heidenhain numerical control of
the Mikron UCP 600 Vario, the user can fall
back on tried and tested milling strategies
and adapt them easily to a new application
when needed.
Before machining starts, a measuring
probe that carries out automatic measuring
cycles is put to work in order to determine
the workpiece location and position.
GF AgieCharmilles | Results TODAY | 01
MILLING CUSTOMER | CAMPAGNOLO 11
IN THE LEAD WITH PERMANENT MAGNETS
With its over 300 employees and
its approximately 5000 custom-
designed articles Magnetfabrik
Schramberg, which occupies
a surface area of about 17 000
square metres, develops and
produces permanent magnets
and sub-assemblies for many
different branches of industry
such as the automotive industry,
motive-power engineering, sen-
sor technology, measuring and
control technology, equipment
and machine construction, pow-
er tools, household appliances,
the textile industry and medical
technology.
The best application solution
starts with the choice of raw
materials, which is the basis for
the development of any magnet.
In order to guarantee that the
materials always have the nec-
essary properties, Magnetfabrik
Schramberg manufacturers its
magnetic materials itself and is
the only company in Europe to
offer such a wide range of in-
house manufactured materials
and to handle the associated
machining and processing. The
most commonly used processes
for manufacturing permanent
magnets and sub-assemblies
are pressing and powder metal-
lurgy in an oxidising atmos-
phere and in inert gas; single
and multi-component injection
moulding; over-moulding and in-
jection moulding onto or around
inserts; bonding and jointing
techniques such as US-welding,
clipping, etc.
PROGRESS WITH EDM
Magnetfabrik Schramberg
have their own tool-making
shop specifi cally for the press
and injection-moulding proc-
esses, enabling them to have
the necessary technology and
skills available in house. EDM
is a key technology for complex
shapes and cavities with the very
fi nest surface quality. In order to
cater effectively for the increas-
ingly strict demands in terms
of precision, time and costs, in
2006 Magnetfabrik Schram-
berg started to implement the
«manufacturing cell» project
under the overall guidance of the
general manager Heimo Hübner
and with the sound advice of
Charmilles. The machine run-
ning times (24 hours a day, 7
days a week), capacity, fl exibility
of the machines and the surface
quality, too, needed to be raised.
The availability of the machines
and their precision even after
long running times (temperature
variations) had to be guaranteed.
Last but not least, the program-
ming and preparation times
needed to be cut.
The fi rst stage of its implemen-
tation was a «small die sinking
EDM manufacturing cell» con-
sisting of a Roboform 350 with
a hard-metal box and a Tool-
master Version 2.1 Duo Package
handling system by System 3R
including a tilting station and
Dynafi x clamping chucks for
12 pallets and 216 electrode
positions. After a successful
trial phase lasting six months,
the project was completed and
the second stage implemented
with a Roboform 350 MicroTEC,
so that automated die-sinking
work can now be carried out now
at Magnetfabrik Schramberg
on a Roboform 350 and a 350
MicroTEC – served simultane-
ously by the «ToolMaster». The
same principle was applied to
wire EDM in 2007 with a Robofi l
240 CC served by a 3R Workpal
workpiece-handling system.
MANUFACTURING CELLS IN PRACTICE
The integration of both manu-
facturing cells can be explained
clearly by following the proce-
dure for manufacturing a car
component. The article was
developed jointly by the customer
and Magnetfabrik Schramberg,
giving rise to a rudimentary 3D
model. The operating principle
was checked, 2D and 3D ver-
sions were investigated using the
fi nite-element method and it was
then optimised from the point
of view of magnet technology.
The article was then designed
as a complete sub-assembly,
this being the core competence
at Magnetfabrik Schramberg,
then came the prototype injec-
tion-moulding die. Functional
tests, climatic, corrosion and
machining tests followed as the
next steps. Based on the number
of pieces required, the die was
then designed with two quadru-
ple cavities. The shapes of the
electrodes were based on the
design of the injection-moulding
die, and were then manufactured
in copper, clamped to electrode
holders, calibrated on the basis
of the preliminary setting sta-
tion, equipped with recognition
chips and put away chaotically
DIE SINKING AND WIRE CUTTING EDMMANUFACTURING CELLSMagnetfabrik Schramberg is one of the leading manufacturers in Europe of permanent magnets and
sub-assemblies used in motorcars, in household appliances and in measuring, control, adjustment and
motive-power engineering applications. The company, based in the Black Forest, promotes integrated
solutions that include in-house tool-making using cost-lowering automated EDM.
With its over 6000 custom-designed articles, this company based in the Black Forest is the
manufacturer with the broadest product range in Europe in the fi eld of permanent magnets.
GF AgieCharmilles | Results TODAY | 01
EDM CUSTOMER | MAGNETFABRIK 12
www.magnete.de
Max-Planck-Strasse 15
D-78713 Schramberg
Germany
Phone: +49-(0)7422-519-0
Fax: +49-(0)7422-519-260
Contact
Dietmar Schwegler, Dipl.-Ing. (FH)
www.magnete.de
Non-cutting machining
– Roboform 350, 350 S and 350
with ToolMaster by System 3R
– Robofi l 4020 SI with WorkPal
by System 3R
– Robofi l 240 SL
– Robofi l 240 CC with WorkPal
by System 3R
Chip-forming machining
Grinding, turning, milling
Clamping systems
System 3R Macro
Hirschmann 4000
Programming
ProEngineer (CAD)
Peps (milling)
DPC, Sigma (die sinking EDM)
Peps (wire cutting EDM)
Measuring, checking
Zeiss Vista CNC measuring machine
Microscopes
Wolpert hardness-testing system
With the «ToolMaster» handling system
by System 3R for 216 electrodes and
12 workpiece pallets, Magnetfabrik
Schramberg accomplished the leap
towards the automated manufacturing
cell, thereby increasing their capacity
by one third and the maching running
time to 13 000 (2 x 6500) hours a year.
Now everything seems to indicate
that similar results can be expected
also from the wire cutting EDM manu-
facturing cell. The fl exibility of these
manufacturing cells enables them to
be enlarged at any time by including
additional die-sinking or wire-cutting
EDM machines, and even integrating
milling machines is not a problem. This
concept is «future-proof», since it can
be expanded in steps and Magnetfabrik
Schramberg have found it so convinc-
ing that they have already ordered
another «small» manufacturing cell
consisting of a Roboform 350 die sink-
ing EDM machine with electrode and
workpiece shelves.
A «ToolMaster» serves two Charmilles die
sinking EDM machines, which allows fl exibel
machining around the clock.
KEYWORDMANUFACTURING CELL
THE COMPANYMAGNETFABRIK SCHRAMBERG GMBH& CO. KG
Charmilles EDM
machines enable key
mould-making technol-
ogy at Magnetfabrik
Schramberg GmbH & Co.
KG and have been devel-
oped step-by-step into
manufacturing cells.
Special pulses achieve very fi ne surface quality on the workpiece with little electrode wear,
so that the mould insert for the injection-moulding is ready for installation.
in the «ToolMaster». Alongside
this procedure, palletised and
clamped workpieces were also
measured, marked with the rec-
ognition chip and placed in the
«ToolMaster» or the «WorkPal».
wire cutting and die sinking
EDM EDM manufacturing cells
then worked their way reliably
through all the batches provided.
Powder-metallurgy steel, special
steels and carbide were used
to make the injection-mould-
ing die. The stampings were
delivered and then extruded with
high-performance thermoplastic
material. The mould core had a
surface roughness of VDI 20-0
and the tolerance throughout the
whole die amounted to ± 5 μm.
The key technology was EDM,
which was used for about 45% of
all the processing.
In the EDM shop, the mould insert for
an injection-moulding die for making car
components is being prepared. Several
copper mould electrodes are calibrated at
the preliminary setting station.
3 die-sinking EDM and 3 wire cutting
EDM systems explain the great considera-
tion in which Charmilles machines are
held at Magnetfabrik Schramberg GmbH
& Co. KG.
Thanks to the microtechnology of the
Roboform 350 MicroTEC die sinking EDM
machine, high process and temperature
stability are guaranteed and long running
times are possible.
The fi rst stage of the set-up die sinking
EDM consisted of a Roboform 350 and a
«ToolMaster».
The fi nal stage was implemented with the
«ToolMaster» used for the fi rst stage, that
now serves both die sinking machines, the
Roboform 350 and the 350 MicroTEC.
GF AgieCharmilles | Results TODAY | 01
EDM CUSTOMER | MAGNETFABRIK 13
ONE-STOP KEY TECHNOLOGIES
Economic criteria were at the
forefront when planning the die,
in order to get as close as possi-
ble to how you as our customers
proceed in actual practice. For
production of the zinc die-cast-
ing die, HSC hard material
milling, wire and die sinking
EDM as well as HSC-milling of
graphite and copper electrodes
was used. Franz-Josef Send-
ler, Head of product marketing
and communication at Agie
Charmilles GmbH, was in charge
of this «production project» and
took on the role of coordinator
and technical supervisor. The
coin was based on a design by
Roberto Grizzi, graphic designer
of the MarCom EDM department,
which was then converted into
CAD and CAM programs.
MACHINING PROCESS PREDETERMINED BY GEOMETRY
On the front of the coin, where
the «one» is depicted, concise
and feather-edged circular lay-
ers are specifi ed by the design.
What is distinctive about the
«one» is the clear outside edges.
The design specifi cation to
concisely shape the symbols to
the right and left of the «one»
was a challenge from a produc-
tion point of view. It was decided
to use the symbols as the core;
the openings for the symbols
were cut using wire EDM. In this
way the geometry of the symbols
on the front sides of the cores
cut using wire EDM, could be
HSC-milled economically on a
high-speed Mikron XSM 400U
machining center.
The design elements on the back
of the coin were created from
different levels. The three-di-
mensional impression results
from the layers of 0.05 mm each,
which lead from the highest to
the lowest level and back again.
These staggered levels are all
plane-parallel. The radial layers
are HSC-milled. Since the layers
adjoin the contour elements of
the «outline of Switzerland» and
milling radii were not required,
the «Swiss cross» was cut out
and reinserted as the core. In
this way the layers could be
milled, tapering in the opening of
the «Swiss cross».
The copy of the Swiss map
was HSC-milled as a graphite
electrode on the Mikron HSM 300
Graphite Master and then ma-
chined using die sinking EDM in
the mold with the perfectly fi tting
built-in core of the Swiss cross.
All the elements together re-
sulted in an «intertwining» of the
layers, which were represented
on the front and back of the
coin. What is more, the planning
complexity resulting from this,
in order to use the technologies
economically and to match the
planned design, could not be
estimated from the fi rst. Since
pushers always reproduce the
part (in our case the back of the
coin), the usual round pushers
would have been too simple.
Therefore, they were specifi cally
molded as coats of arms with
the Swiss cross.
A dozen departments of GF Agie-
Charmilles contributed towards
the success of this fi nely shaped
coin. Evidence that the coopera-
tion of the group’s employees
is just as outstanding as the
interaction of GF AgieCharmilles
technologies. Coined for you.
COINED FOR YOUThe ambiguity is intentional. On the one hand, GF AgieCharmilles has produced this coin especially for
customers and, on the other hand, our customers receive an enduring symbol of the key technologies
of EDM and high-speed milling, which were used to produce the zinc die casting mold for this coin.
Only with the combination of EDM and
HSC technologies the design engineers
and process planners were able to fi nd
the most economical way to produce the
geometries specifi ed by the design.
On the fi nished back of the coin, the
various levels of the design elements can
be clearly made out. This required an
approach using combined manufacturing
methods.
GF AgieCharmilles | Results TODAY | 01
GF AgieCharmilles | THE COIN 14
The R8710 graphite electrode for the
«one» was produced on a Mikron HSM
300 Graphite Master by roughing and
fi nishing with a surface quality of VDI 7.
The outline of Switzerland was created
as an electrode from R8710 graphite on a
Mikron HSM 300 Graphite Master. The fi nal
roughness was Ra 0.4 μm.
The openings for the 4 cores were
machined using wire EDM on a precisely
tailored AC Challenge 3V with a surface
roughness of Ra 0.6 μm and a contour toler-
ance of ± 2 μm.
The «Swiss cross» was machined as a
core using wire EDM on an FI 440 CC with a
surface quality of Ra 0.6 μm and a contour
tolerance of ± 2 μm.
The 4 cores, into which the symbols were
milled using a Mikron XSM 400U.
After wire cutting of the openings fi nest
details were milled with a Mikron XSM 400U.
For all further machining steps, the mold
cores of the front and back of the coin were
created with CAD programs.
The inscription was incorporated into the
copper electrodes by means of technical
engraving. A centuries-old craft, which –
as can be seen – is still applicable in the
21st Century.
For high detail reproduction, the cores
of the die-casting die were produced from
1.2767 steel hardened to HRC 54.
The coins were actually produced on a zinc die casting machine
by the Föhl company in Rudersberg, Germany.
On the precast coins it can be seen that the zinc die-casting die was
designed with a double mold for high quantities.
GF AgieCharmilles | Results TODAY | 01
GF AgieCharmilles | THE COIN 15
Achieve more...
GF AgieCharmilles today offers
the industry’s most compre-
hensive service package and is
committed to delivering an even
greater range of services. In the
coming months, GF Agie-
Charmilles Customer Services
will introduce new wires avail-
able exclusively to GF AgieC-
harmilles customers, expand
its Club Privilege customer
incentive program to include
Germany and other key markets,
and launch an online knowledge
database and e-shop and a
parts hub in Asia. In addition, GF
AgieCharmilles will fi ne-tune
its logistics services to expedite
urgent orders, making overnight
and weekend delivery of parts
possible for many customers.
GF AgieCharmilles is uniquely
positioned, with more than 700
engineers worldwide, more than
10 000 combined years of market
experience and the world’s best-
structured sales and service
organization, to support custom-
ers’ business performance.
PREVENTIVE MAINTENANCE
Seventy percent of machine
downtime can be avoided by pre-
ventive maintenance contracts,
which have been extremely
popular with customers. Pre-
ventive maintenance supports
customers’ competitiveness with
increased equipment productiv-
ity, enhanced performance and
long-term cost savings.
With a preventive maintenance
contract, customers receive
planned visits from highly-
trained GF AgieCharmilles
personnel who check each
machine thoroughly and provide
them with a detailed list of rec-
ommended measures to ensure
failure-free operation.
TRAINING
Training is key to realizing
the full potential of GF Agie-
Charmilles EDM and milling
machines. Research shows that
lack of training can limit a ma-
chine’s potential by 50 percent.
GF AgieCharmilles training is
available at basic, advanced
and expert levels, and allowing
customers to choose the training
modules that suit their specifi c
needs and motivates machine
operators with opportunities to
become better qualifi ed.
ORIGINAL PARTS AND CERTIFIED CONSUMABLES
Using GF AgieCharmilles
original spare and wear parts
and certifi ed consumables can
increase machine productivity by
20 percent, extending equipment
life and ensuring that GF Agie-
Charmilles machines operate at
peak precision and performance.
Even for machines 15 years old
and older, GF AgieCharmilles
has the market’s highest avail-
ability of original parts.
GF AgieCharmilles understands
that reliable delivery of parts is
central to customers’ success.
Each machine has up to 2000
parts and, while most of those
parts will never need replace-
ment, the company’s spare parts
hub in Geneva has stands ready
to quickly deliver more than
21 000 different parts. More than
95 percent of available GF Agie-
Charmilles parts are shipped the
same day that they are ordered.
THE HOTLINE
GF AgieCharmilles’ experts are
able to resolve 70 percent of
equipment-related problems
over the phone. The hotline team
has a single goal: customer
support.
THE CLUB
Every GF AgieCharmilles cus-
tomer can join the Privilege Club
and gains access to exclusive ad-
vantages. Customers in France,
Italy, the United Kingdom and
the United States already benefi t
from the Privilege Club. Privilege
Points accrue with each purchase
of GF AgieCharmilles wear parts
and certifi ed consumables at a
rate of one point for each Euro,
dollar or pound spent, giving
customers value-added access to
a wide range of opportunities.
The Privilege Club allows
customers to benefi t from 100
percent service, including pre-
ventive maintenance and training
at lower costs, and special pre-
ferred-customer access to other
valuable services and events.
CUSTOMER SERVICES ENABLESCUSTOMERS’ SUCCESS
GF AgieCharmilles Customer Services is accelerating its effort
to make its customers more successful than their competitors
by introducing a range of enhanced services and products, all
designed to increase customers’ productivity and knowledge,
as well as the lives of their GF AgieCharmilles machines.
© 2007 GF AgieCharmilles.
The technical data and illustrations are not binding.
They are not warranted characteristics and are subject to change.
259.804.582
Imprint
Publisher
GF AgieCharmilles
www.gfac.com
Editor
Michael Katz
Pictures
Marinus van Breugel
Michael Katz
Graphic Designer
David Hirsbrunner
Copies
140 000
Appearance
Twice a year in English,
German, French,
Italian, Spanish and
Chinese
Printing
Poncioni SA,
6616 Losone,
Switzerland
No 1,
© GF AgieCharmilles
2007
GF AgieCharmilles | Results TODAY | 01
CUSTOMER SERVICES | GF AgieCharmilles 16
