Aerospace Manufacturing Solutions

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GF AgieCharmilles Your partner in constant innovation

Aerospace manufacturing encompasses a wide variety of parts, diverse in shape, size, design and material. To meet the complex needs of the industry, GF AgieCharmilles offers complete turnkey manufacturing solutions built around the world’s most advanced high-speed and high-performance machines. From turbine blade repair to heavy milling of titanium alloys to production of very large components, our array of machine and automation technologies offers unmatched precision and productivity.

All GF AgieCharmilles machines are backed by Uptime+, the industry’s strongest, all-encompassing customer service and support program. Our highly qualified and experienced engineers provide training, technical information and expert application advice on the selection, implementation and optimization of equipment. Whatever aerospace manufacturing challenges you face, our team of experts works ceaselessly to overcome them.

With uncompromised machine performance, turnkey solution productivity and unmatched Uptime+ service and support, GF AgieCharmilles can meet all of your aerospace manufacturing needs.

Complex aerospace parts require flexible, reliable machines with impeccable precision and backed by the best service and support program in the industry.

Message from the PresidentAerospace and aeronautic manufacturing has long been a core expertise of GF AgieCharmilles. Therefore, we understand that high precision machining and stringent manufacturing requirements are extremely critical components of this quickly evolving industry.

As a result, we remain committed to understanding your manufacturing processes, and working closely with your team to ensure you receive the highest level of accuracy and productivity when using our milling machines and EDM solutions to produce intricate, complex parts.

In fact, you’ll find our diverse portfolio of standard-setting, high-speed and high-performance solutions can take on difficult-to-machine materials in a wide variety of applications, from turbine blade repair to heavy milling of titanium. And if you’re not sure what machine is right for you, we have application engineers that can help select, implement and optimize your equipment.

Furthermore, our source of strength doesn’t end with our machines. Through our Uptime+ program, we provide customers with the world-class service, support and training needed to ensure your manufacturing processes run smoothly well into the future.

We appreciate your support of GF AgieCharmilles and look forward to doing business with you.

Sincerely,

Glynn Fletcher, PresidentAgie Charmilles LLC

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HPM 800UHPM 450U HPM 1350U HPM 1850U

Work AreaWork Area

Swiveling AxisTilting AxisSpindle Options

Feed RateX/Y/Z Feed RateX/Y/Z Rapid Traverse RateAxis Feed Rate

Axis Rapid Traverse Rate

Work TableClamping SurfaceMax Table LoadPallet Changer

Tool Changer Options

CNC Control Options

Smart Machine Features

800 x 800 x 550 mm31.5 x 31.5 x 21.65 in+91°/-121°360°20 000 RPM, 52.3 hp HSK-A63

60 m/min (2362 ipm)60 m/min (2362 ipm)60 rpm (Rotary)50 rpm (Tilting)60 rpm (Rotary)50 rpm (Tilting)

Ø 630 mm (24.8 in)500 kg (1100 lbs)7, 9, 12 pallets up to 610 x 508 mm (24 x 20 in)30-tool HSK-A6360-tool HSK-A63115-tool HSK-A63165-tool HSK-A63210-tool HSK-A63

iTNC 530 HeidenhainSiemens 840D-APS, APS Extended, ITC, ITC 5X, RNSCAMplete Post Processorand Machine Simulation

1350 x 1150 x 895 mm53.15 x 45.28 x 35.24 in+16°/-120°360°15 000 RPM, 50.96 hp HSK-A6315 000 RPM, 50.96 hp ISO 4024 000 RPM, 40.23 hp HSK-A63

15 m/min (590 ipm)32 m/min (1260 ipm)40 rpm (Rotary)11 rpm (Swiveling)40 rpm (Rotary)20 rpm (Swiveling)

Ø 1100 mm (43.31 in)1600 kg (3520 lbs)3 pallets up to 1016 x 838 mm (40 x 33 in)30-tool HSK-A6346-tool HSK-A6392-tool HSK-A6330-tool ISO 4046-tool ISO 4092-tool ISO 40

iTNC 530 HeidenhainSiemens 840DAPS, APS Extended, ITC, ITC 5X, RNSCAMplete Post Processorand Machine Simulation

1850 x 1400 x 905 mm72.83 x 55.12 x 35.63 in+20°/-120°360°10 000 RPM, 45.59 hp HSK-A10015 000 RPM, 50.96 hp HSK-A6324 000 RPM, 40.23 hp HSK-A63

15 m/min (590 ipm)40 m/min (1575 ipm)30 rpm (Rotary)11 rpm (Swiveling)30 rpm (Rotary)20 rpm (Swiveling)

Ø 1600 mm (63 in)4000 kg (8800 lbs)3 pallets up to 1245 x 1016 mm (49 x 40 in)30-tool HSK-A100175-tool HSK-A10046-tool HSK-A63120-tool HSK-A63210-tool HSK-A63

iTNC 530 HeidenhainSiemens 840DAPS, APS Extended, ITC, ITC 5X, RNSCAMplete Post Processorand Machine Simulation

600 x 450 x 450 mm23.62 x 17.72 x 17.72 in+45°/-120°360°12,000 RPM, 20.12 hp ISO-B4020,000 RPM, 40.23 hp HSK-A63

15m/min (590 ipm)22m/min (866 ipm)50 rpm (Rotary)

140 rpm (Rotary)

Ø 450 mm (17.72 in)150 kg (330 lbs)7, 8 pallets up to 350 x 350 mm (13.8 x 13.8 in)30-tool ISO-B4060-tool ISO-B4030-tool HSK-A6360-tool HSK-A63120-tool HSK-A63170-tool HSK-A63220-tool HSK-A63iTNC 530 Heidenhain

APS, APS Extended,ITC, ITC 5X, RNSCAMplete Post Processorand Machine Simulation

Aerospace components are often made of hard-to-machine materials that necessitate a unique approach to manufacturing. GF AgieCharmilles excels in meeting this challenge. Our robust spindles provide the power and speed needed to maintain high productivity while milling difficult materials.

Milling Tough Materials

Milling

HPM Series High-performance 5-axis machining for complex aerospace parts of all sizes. The HPM (High-Performance Milling) Series offers reliable accuracy with high removal rates, even in difficult-to-machine materials. Perfect for aerospace production, these machines feature state-of-the-art motor spindles, glass scales for precision machine positioning, direct drive swiveling and tilting axes for full 5-axis simultaneous machining and uncompromised, rigid and ergonomic machine body designs.

Whether machining airframe components, landing gear parts or turbine blades, HPM Series machines offer turnkey automated system capability for every aerospace part application. Through pallet changers and tool magazine options, this series of machines allows for considerable customization to meet specific production needs and lights-out operations.

HPM 450U HPM 800U HPM 1350U HPM 1850U

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HSM 400U LP HSM 600U LP

HSM Series High-speed 5-axis machining for unmatched productivity.Every aspect of an HSM (High-Speed Milling) Series machine is designed around high-speed machining to maximize productivity of aerospace part processing operations. Rigid structural machine designs, high-speed spindles, advanced control systems, powerful feed drives and axis mechanisms, together with integrated automation features, all combine to deliver unparalleled HSM Series machine performance.

For high-speed, full, simultaneous 5-axis machining to achieve superior contoured part surface finishes, the HSM Series machine features spindle speeds up to 54,000 RPM and feed rates on linear motor machine axes.

HSM 400U LP HSM 600U LP Work AreaWork Area

Swiveling AxisTilting AxisSpindle Options

Feed RateX/Y/Z Rapid Traverse RateAxis Rapid Traverse Rate

Work TableClamping SurfaceMax Table LoadPallet Changer

Tool Changer Options

CNC Control Options

500 x 240 x 360 mm19.69 x 9.45 x 14.17 in+110°/-110°360°54,000 RPM, 11.4 hp HSK-E3242,000 RPM, 18.1 hp HSK-E4030,000 RPM, 18.1 hp HSK-E40

60m/min (2,362 ipm)165 rpm (Swiveling)250 rpm (Turning)

in accordance with pallet size25 kg (55 lbs)M.M. 156/18XITS 148/20X20-tool HSK-E3240-tool HSK-E3218-tool HSK-E4036-tool HSK-E4068-tool HSK-E40168-tool HSK-E40308-tool HSK-E40

iTNC 530 Heidenhain

800 x 600 x 500 mm31.5 x 23.6 x 19.7 in+30°/-110°360°42,000 RPM, 18.1 hp HSK-E4030,000 RPM, 18.1 hp HSK-E4036,000 RPM, 46.9 hp HSK-E50

60m/min (2,362 ipm)60 rpm (Swiveling)150 rpm (Turning)

in accordance with pallet size120 kg (265 lbs)UPC/Dynafix/7XGPS 240/10X18-tool HSK-E4036-tool HSK-E4068-tool HSK-E40168-tool HSK-E40308-tool HSK-E4015-tool HSK-E5030-tool HSK-E5060-tool HSK-E50120-tool HSK-E50170-tool HSK-E50220-tool HSK-E50iTNC 530 Heidenhain

Milling

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1 2 3

4 5

8

1 2 3

1 Between machined and molded

components, an airplane cockpit contains

a host of components that benefit from

the efficient and accurate performance on

GF AgieCharmilles EDMs, HSMs and HPMs.

2 This electronic component housing

demonstrates the performance of MIKRON

machining centers.

3 Productivity and efficiency are important

in machining parts, such as this aluminum

alloy support bracket.

Flight Controls and AvionicsMany of the housings and components found in flight controls and avionics feature complex geometries with tight tolerances. GF AgieCharmilles high-speed and high-performance machining centers boost productivity by allowing these components to be machined in just one or two setups. Additionally, reliable unmanned operation can be achieved through our ‘Smart Machining’ features and automation capabilities, such as large tool towers and pallet magazines.

1 Extra fine surface can be produced at high

feed rates through Mikron’s direct driven

rotary and swivel axes.

2 Automation can easily be implemented to

boost productivity on parts, such as this

aluminum frame component.

3 With a demand for high tolerances and a

perfect visual impression, this component

requires many tools and the utmost in 5-axis

positioning precision.

4 5-axis simultaneous machining is a must

for production of this structural wing

component.

5 The ability to produce thin support walls is

vital in many aerospace applications.

Structural PartsWhen producing the structural parts for an airplane, uncompromised quality is a requirement, not an option. The reliability and support received from GF AgieCharmilles ensures that every part is a perfect part.

1 Tight tolerances are a necessity for parts related to airflow applications,

such as this thin-walled component made of 718 Inconel.

2 The Mikron HPM line of machining centers offers the performance needed

to produce parts like this complex combustor machined in 718 Inconel.

3 The ‘fir tree’ section of this component requires uncompromising accuracy.

Engine ComponentsAerospace engine components require long cycle times in heavy cutting conditions. GF AgieCharmilles machines maximize productivity and minimize costs, while providing the high performance you need, even during extended cutting processes.

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CUT 1000 AWCCUT 300

Wire EDM

GeneralMax. Workpiece Dimensions

X, Y, Z Axis Travels

U, V Axis Travels Max. Workpiece Weight Machine Dimensions Rapid Traverse Taper Angle Standard Taper Angle Optional Surface Integrity Surface FinishGeneratorGenerator TypeMaximum Cutting Rate

WireStandard Wire Size

Optional Wire Sizes

Maximum Wire Spool

Wire Guide Types

WireProcessorDisplayHard Disk Drive CapacityRAMUSB Port instead of Floppy Drive Ethernet Port

CUT 300

1200 x 700 x 400 mm47.2 x 27.6 x 15.75 in550 x 350 x 400 mm21.65 x 13.8 x 15.75 in550 x 350 mm (21.7 x 13.8 in)1,500 kg (3,307 lbs)2600 x 2540 x 2240 mm102.4 x 100 x 88.2 in3 m/min(9.8 ft/min)30° at maximum height 45° at maximum height< 2 µm (< 0.0001 in)recast after 4 passesRa 0.1 µm (4 µin)

AC Clean Cut340 mm2/min(32 in2/min)

0.33 to 0.15 mm (0.013 to 0.006 in)0.33 to 0.070 mm(0.013 to 0.003 in)8 kg (17.6 lbs) ISO standards5 kg (11 lbs) JIS standardsClosed diamond type without clearance

CeleronLCD 12" TFT (Touch Screen)40 GB–2

RJ45 standard

CUT 1000/OilTech

300 x 200 x 80 mm11.81 x 7.87 x 3.14 in220 x 160 x 100 mm8.66 x 6.29 x 3.93 in± 40 x 40 mm (1.57 x 1.57 in)35 kg (77 lbs)1500 x 2000 x 1970 mm59 x 78.7 x 77.55 in1-3000 m/min (3.3-9842 ft/min)± 3° at maximum height

< 2 µm (< 0.0001 in) recast after 4 passesRa 0.05 µm (2 µin)

IPG-V–

0.2 to 0.1 mm (0.008 to 0.004 in)0.06 to 0.02 mm(0.0027 to 0.0008 in)8 kg (160 lbs)

1 set for all diameters 0.20 to 0.07 mm (0.0078 to 0.0027 in)

PENTIUMLCD 15" TFT (Touch Screen)80 GB1024 MB2

RJ45 standard

With a trend towards parts with more complex geometries, today’s EDM innovations offer an ideal solution for many aerospace applications. GF AgieCharmilles’ EDM technology allows for high productivity and accuracy when machining intricate and complex components.

Cutting Complex Geometries

CUT 300The benchmark in EDM speedThe CUT 300 submerged wire EDM offers unbeatable speed and accuracy in the automatic rough and finish machining of heavy aerospace components. While featuring a compact and space-saving design, the machine easily supports heavy workpieces without losing accuracy. Additionally, features such as in-process inspection and track & trace ensure the quality of every part.

CUT 1000/OilTechThe world’s most accurate wire EDMThe CUT 1000 utilizes the finest possible wires to provide the world’s most accurate wire EDM process. Automatic threading of wires down to 0.02 mm (0.0008 in) in diameter allows for high levels of autonomy to boost productivity and efficiency. The CUT 1000 OilTech offers a dielectric oil option.

Turn While BurnEDM the impossibleTurn While Burn technology allows for the machining of highly complex 3D aerospace part shapes and eliminates performing secondary operations on separate machines. The system uses a high precision, servo-controlled programmable B-axis indexer that rotates parts in sync with a machine’s X- and Y-axis movement.

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FO 350 SP FO 550 SP

GeneralMax. Workpiece Dimensions

X, Y, Z Axis Travels

Max. Workpiece Weight Machine Dimensions Max. Electrode Weight Rapid Traverse Max. C-Axis Speed Measurement Resolution Positioning Resolution Control/Servo ResolutionTableClamping Area T Slots T Slot SizeT Slot SpacingWorktankDielectric CapacityMax. Dielectric Volume

GeneratorAmps

TypeControlCNC ProcessorDisplayHard Disk Drive CapacityRAM USB ports Ethernet Port

FO 350 SP

780 x 530 x 300 mm30.7 x 20.9 x 11.8 in350 x 250 x 300 mm13.8 x 9.8 x 11.8 in500 kg (1,100 lbs)1900 x 1690 x 2522 mm74.8 x 66.5 x 99.3 in50 kg (110 lbs)3 m/min (9.8 ft/min)100 rpm0.005 mm (0.000002 in)0.005 mm (0.000002 in)0.0001 mm (0.0000039 in)

500 x 400 mm (19.7 x 15.75 in)312 mm (0.47 in)125 mm (4.92 in)

410 l (108 gallons)410 l (108 gallons)

64 amps standard128 amps optionalISO pulse

PENTIUMLCD 12.1 TFT (Touch Screen)40 GB512 MB2RJ45 standard

FO 550 SP

1200 x 850 x 400 mm47.2 x 33.5 x 15.75 in600 x 400 x 450 mm23.6 x 15.7 x 17.7 in1600 kg (3530 lbs)3040 x 2830 x 2960 mm119.7 x 111.4 x 116.5 in100 kg (220 lbs)60 mm/s (2.36 in/s)100 rpm0.001 mm (0.00004 in)0.0005 mm (0.00002 in)0.0001 mm (0.0000039 in)

750 x 600 mm (29.5 x 23.6 in)512 mm (0.47 in)125 mm (4.92 in)

498 l (133 gallons)820 l (219 gallons)

64 amps standard128 amps optionalISO pulse

PENTIUM12.1 TFT Color (Touch Screen)20 GB minimum40 GB2RJ45 standard

Die-Sinking EDM

FO 350 SPHigh performance in a compact designSpeed and performance come together in the compact FO 350 SP fixed-table die-sinking EDM. The high-speed Z-axis pulse rates, together with high acceleration speeds provide aerospace manufacturers with faster part processing, longer electrode life and superior surface finishes.

FO 550 SPUser-friendly die sinking EDMDie-sinking EDM has never been easier than with the FO 550 SP. Through an incredibly intuitive Windows-based control, the FO 550 SP allows operators with minimal training to efficiently produce high-quality parts with extreme tolerances.

iQ TECHNOLOGYNear zero electrode weariQ Technology builds a protective layer onto graphite electrodes to practically eliminate wear. iQ Technology allows aerospace manufacturers to use very thin vane-type electrodes to produce extremely fine, stepped narrow slots without fear of electrode deterioration.

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DRiLL 300

GeneralMax. Workpiece Dimensions

X, Y, Z-Axis Travels

Z-Axis Travel W-Axis Travel Max. Workpiece Weight Machine Dimensions

ElectrodeElectrode diameterOptional small holes

DRiLL 300

1000 x 700 x 400 mm(39.37 x 27.56 x 15.7 in)600 x 400 mm(23.62 x 15.7 in)450 mm (17.72 in)Optional 650 mm (25.59 in)450 mm (17.72 in)1000 kg (2,205 lbs)1400 x 2320 x 2180 mm55.12 x 91.34 x 85.83 in

0.3 to 3 mm (0.012 to 0.12 in)0.1 to 6.0 mm (0.0039 to 0.24 in)

High-Speed EDM Drilling

DRiLL 300 Quick, simple and precise holemakingThe small footprint and up to a 50 electrode / 8 guide changing capability makes the Drill 300 a powerhouse for production cooling hole applications. The Agie Charmilles ISPG proven generator technology provides intelligent technology settings for entry/exit machining and cylindrical control. The result is superior surface and profile quality while maintaining high speeds and minimum electrode wear. Electrode Wear Management is included as a smart feature within the intuitive CNC control, and will change electrodes automatically without any additional programming. The operator friendly HMI (Human Machine Interface) is designed to minimize set-up time and reduce the learning curve – a must for multi-shift operations.

Lean, green and blueSave energy – an economic and ecological necessityIn order to control production costs, saving energy has become a priority in many workshops. The Econowatt modules manage the electrical power of the machine so as to never waste energy while the machine is running unattended. When machining is finished or interrupted, the power supply is reduced to the minimum, lower than 1kW, or completely disconnected depending on the parameters of the machine. Automatic restart is programmed according to a daily schedule corresponding to the operating hours of the workshop. The machine is switched on in sufficient time to be thermostabilized when the workshop opens. The power consumed is continuously displayed on a screen page.

Controlled operational costsThe excellence of GF AgieCharmilles wire EDM technology also resides in the control of operational costs. The potential for using less expensive wires and reduced filtration cost, added to a lower consumption of electricity, make machines such as CUT 200, 300 and 400 particularly economical to run.

Econotec technology - high speed, lower costProduction requirements mean thatsavings must be made at all levels,especially on consumables. Thanks to complete control of the EDM wire process, Econotec technology allows 30 % faster machining times with a 0.3 mm diameter wire, while reducing cost by 20 %.

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Continuous ImprovementPeter LaFond, President of Steel Tool Engineering, challenges his employees to be problem solvers when it comes to manufacturing jet engine components. As an innovative partner to customers, their problems are Steel Tool Engineering’s problems, and the solutions often originate from advanced technology and support from GF AgieCharmilles.

GF AgieCharmilles automation systems and electric discharge and high-speed milling machines (EDM and HSM) give Steel Tool Engineering the means to incorporate innovative techniques. With a varied toolbox of cutting edge technologies, Steel Tool Engineering routinely overcomes manufacturing challenges, reduces part costs for its customers, and adds to the company’s competitive advantage. Through this, Steel Tool Engineering maintains a highly regarded reputation as a leading supplier

of flight-critical engine components for commercial and military aircraft.

“We maintain a healthy fear of our competitors and keep up with who is out there and if they are out-manufacturing us. Whether they accomplish that by producing in low-cost labor regions or by way of advanced technology, our strategy is one of continuous improvement, and we are going to always strive to implement it before the competition does,” declared LaFond.

Continuous improvement at Steel Tool Engineering isn’t based on stand-alone machines, but on highly complex, automated manufacturing systems. The company acquires many of these turnkey systems from GF AgieCharmilles because, like Steel Tool Engineering, the world’s technology leader in EDM and HSM partners with customers to provide value through innovative products and services and is relentless in its drive toward continuous improvement.

Automation Solutions

GF AgieCharmilles automation solutionsModest demands, maximum benefitsEasy to use pallet changers for EDM and milling machines require minimal floor space, supervision and operating cost while delivering:

+ Increased machine capacity+ Increased productivity and flexibility+ Simple access to pallets or tools+ Lower production costs+ Lower unit cost+ Shorter depreciation time+ Minimum footprint

Automation for every configuration level An array of tailor-made optionsWhether your application requires 10 pallets or 240, modular magazines can be combined to offer an unprecedented flexibility that can be adapted to each user’s needs. Light magazine capacity 25-80 palletsHeavy magazine capacity 10-20 pallets

Milling High-Speed and High-Performance Milling CentersIn terms of cutting speed, HSM centers are 10 times faster than conventional milling machines. Greater accuracy and a better surface finish are also achieved. This means that even tempered materials can be machined to a condition where they are largely ready to use. One essential advantage of HSM is that with systematic integration, the process chain can be significantly shortened. HSM has developedalongside EDM into one of the key technologies in mold and tool making.

EDM Electric Discharge MachinesEDM can be used to machine conductive materials of any hardness (for example steel or titanium) to an accuracy of up to one-thousandth of a millimeter with no mechanical action. By virtue of these properties, EDM is one of the key technologies in mold and tool making. There are two distinct processes – wire-cutting EDM and die-sinking EDM.

Laser Laser AblationLaser ablation supplements and extends the technologies offered by GF AgieCharmilles. With our laser technology, we enable you to produce texturizing, engraving, microstructuring, marking and labeling of 2D geometries right through to complex 3D geometries. Laser ablation, compared to conventional surface treatment using manual etching processes, offers economic, ecological and design advantages.

Uptime+ Program Everything SupportUptime+ provides comprehensive services for GF AgieCharmilles machines. The program offers the complete range of original wear parts and certified consumables including wires, filters, electrodes, resin and many other materials. Uptime+ machine support covers all services connected with spare parts, technical support and preventive services, while helping develop manufacturing solutions tailored to the customer’s specific needs.

Automation Tooling, Automation, SoftwareTooling for fixing workpieces and tools, automation systems and system software for configuring machine tools and recording and exchanging data with the various system components.

GF AgieCharmilles

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BostonUSA

CharlotteUSA

Global Support and Services

A world-wide network of support and customer services ensure maximum uptime of your GF AgieCharmilles machine tool

ApplicationsGF AgieCharmilles customers gain access to dozens of local Application Engineers providing training, programming and troubleshooting.

ConsumablesA complete range of original wear parts and certified consumables at your fingertips; all in-stock orders received by 4 p.m. ship the same-day.

ServicePreventative maintenance and repair services to minimize downtime and maximize productivity.

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804.

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us.gfac.com

© Agie Charmilles SA, 2011 The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change.

560 Bond St.Lincolnshire, IL 60069

Tel. (800) 282-1336

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