FORM 200 Sp FORM 300 Sp · edM has a new standard in competitiveness a profitable choice This technological choice from GF AgieCharmilles, in comparison to linear motors, facilitates

FORM 200 SpFORM 300 Sp

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PROductivity at itS higheSt level

FORM 200 Sp FORM 300 Sp

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Productivity and performancehigh machining speedSpeed Finishingac FORM hMi

Systems eXPeRtMechanicscustomizationgF agiecharmilles

contents

transformation of axis speed and spark control into a productivity increase

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* FORM 200 Sp

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With the FORM X00 Sp range from GF AgieCharmilles, EDM has a new standard in competitiveness.

increase your usefulmachining time With the new « FORM X00 Sp » range, GF AgieCharmilles puts all its expertise into your hands, to help you to be outstanding in the most competitive capital equipment markets. The FORM 200 Sp and FORM 300 Sp machines break new ground, allowing you to gain valuable time in « blade » applications, pre-roughed 3D cavities and « surface » appearance. Aim : to gain in productivity while guaranteeing consistent polished surface finishes.

gF agiecharmilles accelerates  you to pole positionA veritable concentration of innovation and technology, the Speed Edition range indeed merits its name. By giving you the opportunity to greatly increase your useful machining time, the new FORM 200 Sp/300 Sp machines allow you to take pole position in your markets.

take pole positionProductivity and performance

• Z-axis motion speed up to 15 m/min * (49.2 ft/min)*

• Acceleration up to 10 m/s2 * (32.8 ft/s²)*• Faster, more economical

finishing settings• New management algorithm for

translation orbits (TRANS-EXPERT)• Autonomous cell management,

combining reliability and productivity (SCM : Self-Cell Management)

• New on-board documentation for accelerated operator training

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high machining speed

edM has a new standard in competitiveness

a profitable choiceThis technological choice from GF AgieCharmilles, in comparison to linear motors, facilitates evacuation of particles in cavities, thanks to the pulsation speed, without flushing and without deformation of the cavity.

This is a distinct plus for applications such as connector technology, ribs or micro machining. For machining deep ribs, high pulsation rates for better particle evacuation are required.

Without High Speed EDM 2

Improvement: 20%With High Speed EDM 2

Depth

Time

technical specificationsZ-axis speed up to 15 m/min (49.2 ft/min)acceleration up to 10.0 m/s2 (32.8 ft/s²)

comparative test with/without hS edM 2unprecedented performanceThe increase in Z-axis motion speed, and its extremely high acceleration, brings a performance increase of approximately 30 percent for medium to deep rib machining.

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Reduced or eliminate  costly hand polishingFor finishing settings, FORM 200 Sp/300 Sp machines score critical points. Detailed precision is observed, thanks to reduced wear rate, preserving electrode geometry. « Fast finishing » allows fine, even polished, surface finishes to be obtained (Ra < 0.3 μm), with unequalled consistency on large and small surfaces. In the majority of cases, costly and delicate manual polishing operations are reduced, or eliminated.

Ra µm

0.1

0.2

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0.4

0.5

0.6

0.7

0.8

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Without Speed Finishing

Cavity cm2

Technology: Surface

Technology: SurfaceWith Speed Finishing

10 20 30 40 50 60 70 80 90

comparative test with/without fast finishing module

Speed Finishing Supremely consistent fast surface finishing

Part express

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Throughput

ac FORM hMi Faster control, in complete security

Maximise productive timeDue to the necessity of maximizing productive time, the AC FORM HMI brings new solutions :• Part Express allows interruption of an operation

so that an urgent job can be inserted.• Job List organizes the order of jobs according

to manufacturing priorities.

dynamic manufacturing processThe development of AC FORM human-machine interface (HMI) is based on a study carried out with numerous mold makers in order to streamline the mold-making technique. The organization and layout of screens are a direct development of the information taken from this study. This user-friendliness, which has made GF AgieCharmilles interfaces so successful, has not only been maintained but has been developed even further to benefit the mold maker’s task.

electrodes designed under ac FORM hMi  offer ideal undersize and streamline the number of

electrodes necessary for machining.

Measurement cycles

Flexible work organizationWhether on a PC or on the FORM 200 Sp / FORM 300 Sp machines, AC FORM HMI offers you job organization

according to your priorities.

Measurement of essential offsets and positions  during work preparation : the measurements made

on a pre-measurement terminal can be used directly by AC FORM HMI.

DIAGSPHERESPHERE

HELIC

VECTVECT CYLINDRE

CONE

DOWN ORB ANGUL EXPAN

CONECONEISOGAP

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SMS notificationAll information related to machining can be

transmitted directly to the operator via SMS.

Machining under ac FORM hMi high surveillance,  with Systems EXPERT automated protection,

guarantees you results at the height of your requirements.

2d/3d machining cycles

control of work executed under ac FORM hMi  automatically creates a report after each machining session. The operator can access it via the network

or directly on the machine.

e-docThe FORM X00 Sp range incorporates new online help to allow the operator to find relevant information as quickly as possible. This occurs via simplified access to help menus, by having a clearly organized navigation interface, that is more user-friendly and easy to grasp, and including search by key words or user index. Machining examples are produced as hard copy, presented in a succinct manner.

They are called up by using the online help system, so that implementation of a machining process can be followed stage by stage. More than additional descriptive documentation, e-Doc allows a genuine knowledge transfer for the benefit of the operator, enabling him to improve his knowledge continuously, while reducing working days lost to training.

interactive graphical assistanceAll operations, such as measurement, machining or cavity-positioning cycles, are illustrated by graphics/icons, allowing the operator to understand intuitively and spontaneously.

automatic cad/caM link The different EDM machining sequences are automatically integrated into AC FORM HMI.

Platform : Windows• Integral PC • Touch screen• CD-ROM drive• USB port • Network connection

achieve more...

FORM 200 SpFORM 300 Sp

FORM 200 Sp  FORM 300 Sp

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Programming per application To facilitate the operator’s work, job programming has been optimized so as to orient it, as simply as possible, around a good choice of strategy, with no requirement for any in-depth knowledge of the EDM process.

Optimising all the parametersSystemseXPeRt

tRaNS-eXPeRt

SPac

PilOt-eXPeRt 4

POWeR cONtROl eXPeRt

Monitoring and optimization 24/7. Guarantees the best performance by continually taking account of machining conditions. This allows operation without operator intervention and assures full reproducibility of jobs.

Controls each spark to ensure perfect consistency of machined surfaces. It also allows real-time determination of machining discharges in accordance with the changing surface of the electrode.

The new algorithm for calculation of planetary translations allows substantial gains in machining speed, from roughing to finishing.

GF AgieCharmilles has exclusive rights to SPAC. It allows a possible short circuit (CC) to be broken instantaneously, by applying a specific discharge to it for a fraction of a second. Machining, which is no longer slowed down by CCs, continues at full speed, without interruption, thus improving productivity.

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Machining the injection channelGF AgieCharmilles technology, is specifically adapted for machining deep, small cavities and allows machining conditions to be maintained, whatever the depth of machining.

contouring benefitsContouring technology allows the use of cylindrical electrodes to implement complex geometries. The machining height/minimum radius ratio of the geometry can exceed 50. Contouring widens the possibilities for die-sinking EDM.

consistent surface finish Uniformity of texture in an injection-molded part is directly related to the quality of the surface finish in the mold. To obtain perfect surface finish, GF AgieCharmilles has developed a technology called «Surface». This technology allows the highest criteria for surface consistency to be met.

lowest wear: reducing wear to its minimum Observance of the smallest details is still a major asset of EDM machining. Thanks to the iQ (Innovative Quality) technology developed by GF AgieCharmilles, power adjustments are regulated so as to increase material removal while preserving the geometry of the electrode. Because the electrode shape remains unchanged as machining progresses, it allows minimum electrode use for maximum cavity erosion.

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Mechanics  Built-in endurance, fit for any test

Short “c” frame

Sturdy mechanical designShort C-axis construction and oversize cast iron frame guarantee mechanical stability and precision over the life of the machine. The weight of the part or volume of the dielectric has no effect. Further-more, the robustness of the machine absorbs all machining forces, to maintain a precise gap between part and electrode.

linear glass scales : Precision for lifeTo obtain lasting positional precision, only linear glass scales are effective. They eliminate the classical errors, such as play introduced by inversion, expansion and wear effects. The Dual Loop Positioning System (DLPS) perfected by GF AgieCharmilles is a closed-loop measuring system designed to give infallible precision, whatever the travel. It makes periodic maintenance and calibrating operations unnecessary.

Scale resolution : 50 nm

command cNc g0X10

axis movement (encoder motor)

Position reached?

yesStOP

no

Position verification (linear glass scale) 

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increased autonomy without manual interventionManufacture of a mold often requires a large number of electrodes whose spark-erosion time can vary noticeably from one cavity to another. The FORM 200 Sp/300 Sp machines have a new rotary changer which offers a large storage capacity for up to 160 electrodes. A double gripper-clamp, reduces unnecessary movements, notably speeding up the loading process.

Renishaw probeTo ensure positioning precision, an optical transmission probe can be managed by the FORM 200 Sp / FORM 300 Sp. Measurements allows dimensional inspection of machined cavities as well as the taking of references of the part, without having to remove it, thus saving a considerable amount of time. Furthermore, a measurement report is automatically generated by AC FORM HMI enabling rigorous checking and monitoring.

customization  choosing good options are a matter of strategy

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customization  choosing good options are a matter of strategy

Record productivityThis cell-management system expands and supplements the practicality of AC FORM HMI. Quasi-total autonomy of each cell radically optimizes machine time while simultaneously increasing operator comfort and eliminating risk of errors. Workshop productivity beats all records.

Machining flexibility and reliability of work resultsThanks to AC FORM HMI’s integral automation of machining sequences, as well as the design and functionality of Part Express, productive time is maximized, while still allowing urgent work to be slotted in easily. End-to-end reliability of the process is assured.

aim: 7,000 hours of edM/yearAutonomous cell-management maximizes machine time, which can now be increased from 2,500 hours on average, to close to 7,000 hours per year. Due to importing CAD/CAM data into the machine operator’s AC FORM HMI, taking references, as well as optimizing tool-changer cycles and flexible machining programming, results are backed up while allowing continuous production.

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thermostabilizationA global first, the double thermostabilization system of the FORM 200 Sp allows the impact of the workshop temperature variations on part machining precision to be cancelled out. This is a major innovation when working close to micron dimensions is being carried out. This solution eliminates the waiting time for thermostabilization of the machining zone and guarantees flawless precision in positioning and geometry. The finished product quality is flawless.

gamma technologiesThe result of numerous GF AgieCharmilles studies show that Gamma technology represents complete mastery of additives intended to increase the erosive performance of the EDM process. The additive GammaMIX 50 is a concentrate of conductive dielectric particles, in the correct proportions, to create consistent EDM. Thanks to effective circulation in the

work tank, the GammaMix 50 is perfectly distributed between the electrode and the part being machined. Depending on the conditions it is used under, a single dose of additive gives more than 400 machining hours, before complete filtration of the dielectric is necessary.

accura-c,  the best high-performance axis on the marketIt is not unusual to be confronted by machining where the electrodes are incorrectly located, even by such a distance that maintaining their position or stability during machining becomes problematic. Pulsation-induced movements in a liquid (dielectric) medium generate lateral forces (flexural or rotational) on the electrode, which must be resisted by the C-axis. Thanks to its very robust design, the Accura-C allows very high moments of inertia to be absorbed, up to 5000 kgcm2 (1708 lbsin2).

dielectric 1 Thermostat allowing dielectric

temperature regulation. 2 Water/dielectric heat exchanger.3 Dielectric circulation is an integral part

of the table.

air4 Double temperature-probe thermostat

allowing adjustment of air temperature to that of the dielectric.

5 Water/air heat exchanger.6 Coolant liquid electrovalve.

diagram showing the principleof double thermostabilization

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GF AgieCharmilles

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 fi nish 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 signifi cantly shortened. HSM has developed alongside EDM into one of the key technologies in mold and tool making.

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 texturing Laser texturing 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 texturing, compared to conventional surface treatment using manual etching processes, offers economic, ecological and design advantages.

Operations, Machine and Business SupportCustomer Services provides with three levels of support all kind of services for GF AgieCharmilles machines.Operations Support offers the complete range of original wear parts and certifi ed consumables including wires, fi lters, electrodes, resin and many other materials.Machine Support contains all services connected with spare parts, technical support and preventive services.Business Support offers business solutions tailored to the customer’s specifi c needs.

Tooling, Automation, SoftwareTooling for fi xing workpieces and tools; automation systems and system software for confi guring machine tools and recording and exchanging data with the various system components.

Milling

EDM

Laser

Customer Services

Automation

GF AgieCharmilles

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 fi nish 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 signifi cantly shortened. HSM has developed alongside EDM into one of the key technologies in mold and tool making.

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 texturing Laser texturing 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 texturing, compared to conventional surface treatment using manual etching processes, offers economic, ecological and design advantages.

Operations, Machine and Business SupportCustomer Services provides with three levels of support all kind of services for GF AgieCharmilles machines.Operations Support offers the complete range of original wear parts and certifi ed consumables including wires, fi lters, electrodes, resin and many other materials.Machine Support contains all services connected with spare parts, technical support and preventive services.Business Support offers business solutions tailored to the customer’s specifi c needs.

Tooling, Automation, SoftwareTooling for fi xing workpieces and tools; automation systems and system software for confi guring machine tools and recording and exchanging data with the various system components.

Milling

EDM

Laser

Customer Services

Automation

Achieve more...

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© Agie Charmilles SA, 2012The technical data and illustrations are not binding.They are not warranted characteristics and are subject to change.

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