Upload
vuonghuong
View
217
Download
0
Embed Size (px)
Citation preview
GF AgieCharmillesRoberto Perez
Innovation, R&D dept.
11 Juin 2013
Viser l‘excellence et le leadership grâce
aux projets européens
GF AgieCharmilles Immagine FOF 2020 212/06/2013
Outline
Introduction, GF Agie Charmilles
Technology and challenges
R&D organisation and collaboration frameworks
Collaborative project example: Fofdation
Conclusion
GF AgieCharmilles Immagine FOF 2020 312/06/2013
Activities :
Electroerosion machines (EDM)
Laser texturing machines
High speed milling machines (HSM)
High speed spindles for milling machines
Tooling, Automation, Software
Services and consummables : Agie Charmilles SA
Sales : Agie Charmilles Sales
GF AgieCharmilles
2012 :
• Employees : 2800
• Sales : CHF 850 millions
• CEO : Pascal Boillat
• www.agiecharmilles.com
One Brand. One Promise. Achieve more
GF AgieCharmilles Immagine FOF 2020 412/06/2013
Technology: GF AgieCharmilles Laser Highlights
Mechanical concept with 4th et 5th axes as
option
Fiber Laser 20W ou 50W
Automation solution with pallet changer
Specific CNC for Laser machining
Pack Software
GF AgieCharmilles Immagine FOF 2020 512/06/2013
3D IGES or DXF files
Import Rhino
Design office
Tool Path + .ALL,.MCL
Example: laser innovations (Mapping + texture)
Maya or Rhino
Mesh file triangle (.STL)
Image Texture ( .TIF,.BMP )
Design office
Rhino
+
GFAC LASER DESIGN
+ Mapping
UV Layout or
Maya
Mesh quad (.OBJ from Maya, UV Layout)
Checker
GF AgieCharmilles Immagine FOF 2020 612/06/2013
• Die sinking EDM reproduces on a
metallic workpiece the shape of the tool-
electrode.
• No mechanical contact between the part
and the electrode
• Electrode (+), Pièce (-), dielectric oil :
This configuration minimizes the tool
wear and keeps the shape of the
elctrode throughout the whole process
Die sinking electroerosion
GF AgieCharmilles Immagine FOF 2020 712/06/2013
Innovative pieces and Technology….. for standard & micro applications
Main sector involve
Medical instruments, implants,
High precision mould
Watch making
Microelectronics
Micro drilling
Light-emitting diode (LED)
applications.
Micro application
Micro connectors
Micro stamping dies
Micro assembly
Injection moulding
GF AgieCharmilles Immagine FOF 2020 812/06/2013
SF Module standard on FORM 1000
• SF Module „Super Finish“
• Generator-extension module for Surface finishes down to Ra 0.05 µm
• The key for autonomous machining of small high accurate cavities with smallest inside radius and finest surface finish.
• Minimum radius
Surface finish Ra 0.05 µm
r = 5 μm
GF AgieCharmilles Immagine FOF 2020 912/06/2013
Micro-Mechanics for highest precision
Piece for watch industry
Make impossible, possible !
GF AgieCharmilles Immagine FOF 2020 1112/06/2013
Developed in 1960. The cutting is performed through micro-second
duration sparks from a wire electrode in water dielectric
Cutting process scheme
Wire sparks at work
Wire electroerosion
GF AgieCharmilles Immagine FOF 2020 1212/06/2013
Precision aspects
• sharp angles
• taper cuts
• circularity
• distances
• parallelism
GF AgieCharmilles Immagine FOF 2020 1312/06/2013
Typical applications - Carbide
Carbide machining
Micro connectors
Lead frames
Punches and dies
Electronic die
Wire 0.05mm
Geometrical precision +/-1 µm
GF AgieCharmilles Immagine FOF 2020 1412/06/2013
Surface quality
High surface finish quality to meet today’s and tomorrow’s
manufacturing demands
2.5 1.58 1.26 0.5 0.32 0.2 0.1m Ra
Customer benefit: More flexibility in use.
• - Larger applications field.
- May eliminate the need for subsequent polishing.
GF AgieCharmilles Immagine FOF 2020 1512/06/2013
Surface integrity
Inconel 718 Ti-6Al-4V
Customer benefits:
Cut 200 is the right machine for industries where safety is critical.
(medical, aerospace) Prevents unexpected fatigue failure.
Programming the right sparking energy = respect the surface integrity
After roughing,
recast layer < 6 µm
Affected layer after the main cut
Inconel 718 Ti-6Al-4V
After 4 finishing
cuts, recast layer
is not visible
Affected layer after 4 skim cuts
Courtesy of Birmingham university
Inconel 718 Ti-6Al-4V
GF AgieCharmilles Immagine FOF 2020 1612/06/2013
Geometry
PCDThe use of anti-electrolysis generator settings from roughing to last finishing provides a perfect edge integrity while cutting sintered material:
•Tungsten carbide
•PCD
Customer benefits:
Maximize the service life of the
tools produced.
Magnification X1000
GF AgieCharmilles Immagine FOF 2020 1712/06/2013
R&D EDM major functions and groups
R&D EDM: 120 engineers with key functions:
Innovation (11 engineers)
• New technologies, feasibilities and University research
• System Engineering, Architecture and Technical Portfolio
PMO (Project Management Office)
• Project Management
• Application champions
Automation systems and segmentation
• Automation tools – SW, customer automation projects
• Customised products and applications (complex solutions, automation)
Customer oriented functions and HMI
• HMI Software and SQA
• Application development and testing
Base Development linked with production
• Machine design including Mechanics and electrics
– Includes customer special mechanics and mechanical tests
• RT SW/HW – CNC design
• Generator design and technology base
• R&D development processes (SAP, BOM, PDM)
1
3
2
4
5
GF AgieCharmilles Immagine FOF 2020 1812/06/2013
The two processes overlap against the axis of Technology Maturity Levels (TML)
EU collaborative research helps to reinforce Product Development Phase
through strong link with customers and adequate exploitation plans.
Technology
TXFR Period
Maturity
Product Development
(Engineering)
Technology Planning
PDP
TD
TML1
Technology Concept and/or
Application Formulated
TML2
R&D Proof of Concept
TML3
Individual System
Component Validated
TML4
Technology Prototyped in Operational Environment
TML5
Technology Qualified
through Client Operations
Technology and Product Development Processes are closely linked
UniversitiesTechnology Development
(Research)
Suppliers
Key customersPartner industries
GF AgieCharmilles Immagine FOF 2020 1912/06/2013
Collaborations for Innovation
And more… long term relationship and preferred partnership with most recognized Swiss and European research institutes for materials and production technologies, thanks to EU networking projects.
GF AgieCharmilles Immagine FOF 2020 2012/06/2013
Example : Towards the smart-machine – The Fofdation project ultimate goal
Industrial concerns• Global demand fluctuation • Greater product variability & quality (customer centric)• Productivity & time-to-market pressures• Growing complexity of machines & processes • Triple bottom-line responsibility
(economic, social, environmental)NC Program GenerationSimulationValidation
Optimisation
Our visionimagine...• All the factories sharing data seamlessly to design and produce
anywhere• All the people building a green planet• No pollution, no waste to clean, no smoke to destroy• The factory of the Future enabling a sustainable world and fair
trade
GF AgieCharmilles Immagine FOF 2020 2112/06/2013
Progress beyond the state of the art in the new concept around smart-machines
Top-down approach, disparate andincompatibles IT islands, lack ofinteroperability, point solution…
Holistic & bi-directional approach, end-to-end digitization,convergent and science-based process, interoperable ITmodules, plug-and-produce IT environment, lifecyclemanagement, sustainability monitoring,… all integrated !
Today, Tomorrow, powered by FOFdation …
GF AgieCharmilles Immagine FOF 2020 2212/06/2013
GFAC application: simplified smart CNC
Smart CNC: Introduction of complete geometries so to be able to
optimise the machining process following changing conditions
GF AgieCharmilles Immagine FOF 2020 2312/06/2013
Smart Management System: eTracking concept & architecture
Concept A new e-communication and control platform :
• Connected to the machine: smart execution activities
• Placed in the office: supervision and management activities
Functionalities to cover:
• Activities Before, during, and after machining
Architecture
Track & Trace level
Mode execution
Workshop supervision level
Mode management
eSupervisioneSupervision
m/c 1 m/c 2
Data Base
Global customer network level
Top level management
GF AgieCharmilles Immagine FOF 2020 2412/06/2013
Defining a model and communication channel to
close the loop with CADCAM
Machining Histograms, Energy cons.
Compare
Part #1
Check if part is correct
Detect where problems occur
Identify critical factors in part design
Assess energy consumption
Part signature
Reference
DataBase
(History
& Traceability)
Machine level smartness
3D CAD
model
ClassCad
Step-NC
model
GF AgieCharmilles Immagine FOF 2020 2512/06/2013
eTracking aero – Part monitoring
Monitoring of process signals correlated to axes position: quality
assurance
Préparation d’une piècePréparation d’une pièce
Machining process
KPI
Machining path
GF AgieCharmilles Immagine FOF 2020 2612/06/2013
eTracking – Shop monitoring
Dashboard of machine of the workshop
GF AgieCharmilles Immagine FOF 2020 2712/06/2013
eTracking – Shop monitoring
Associate users to each machine of workshop
GF AgieCharmilles Immagine FOF 2020 2812/06/2013
eTracking – Shop monitoring
Define periods when user can receive email
GF AgieCharmilles Immagine FOF 2020 2912/06/2013
eTracking – Shop monitoring
Define machine states (per user) that trigger sending email and states
contained in email
GF AgieCharmilles Immagine FOF 2020 3012/06/2013
Conclusion
GF Agie Charmilles works in a highly dynamic context requiring
multiple competencies and reduced time to market and
productivity
Collaborative projects are crucial to maintain level of excellence
through networking, access to leading edge resources, active
partnership with suppliers and customers: from sequential to
parallel development process
Fofdation project has helped to orient, develop and industrialise
our R&D efforts in the perspective of future manufacturing
systems
Open Innovation : Not all smart people work for us
(Henry Chesbrough)