AC Progress V

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AC Progress V2

<The series for fast, precise ED wire cutting

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AC Progress V3 AC Progress V4

Contents Highlights 4Mechanics 6The generator 10The control 14

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to Ra 0.1 µm

Highlights For progressive ED wire cutting

Optimal technologies The best possible technology is gen-erated individually for each machin-ing job and workpiece height and only a few data inputs.

Continuous positional accuracyA precision concept is realized by the interaction of a mechanical design for high static rigidity of the machine, dual measuring systems and control unit, meeting all special requirements to achieve highest positioning accu-racy for the realization of fine blanking tools or multiple clamping.

Perfect shape accuracy over the whole workpiece heightBest linearity, precise inside radii atevery workpiece height, on stepped-workpieces, taper cuts, even with complex transitions. Wire Bending Control and Advanced Wire Offset, a standard feature on all the AC Progress V.

Thin wireTo extend the application range of the AC Progress V systems, an optional kit for using wires with diameters of down to 0.07 mm can be fitted. With this option, shapes requiring an internal radii of just 0.05 mm can be achieved.

High quality surface finishA surface finish of Ra 0.2 µm is reached as standard on all AC Progress V. Roughness Ra down to 0.1 µm can be reached with the SF module option.

from ø 0.07 mm to ø 0.33 mm

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Simple choice of technology favoring precision, speed or quality The absolute minimal data input from the operator is required to generate bespoke machine settings for each workpiece. As well as minimizing operator interface time, each setting is optimized to ensure the maximum performance. What is more, by offer-ing alternative proposals the control system allows the operator the option to refine his choice, favoring either precision, speed or the quality of the finished item.

The advantage of using 2 different wires on a single-wire system The AC Progress V’s unique wire drives system allows a very special function in which two wires can be used. Duotec in itself can massively reduce the time taken and running cost’s normally attributed to finer wire jobs. After carrying out the main cut on a larger diameter of wire a finer di-

ameter wire is used to detail corners and provide the final trim cuts. Other benefits of Duotec includes a more robust process as the majority of the material removal is completed on a larger diameter wire.

Drastic reduction in non-productive time Non-productive time is an important aspect of any total machining cycle. This is especially important when car-rying out repetitive machinings with short erosion times for single shapes. High speed positioning lowers move-ment time between jobs, and with Agiejet P a high-speed threading cycle enables threading times to be consid-erably reduced - less than 7 seconds. In addition to the super fast threading the “spark to spark” time between the end of one machining sequence and the beginning of the next has also been considerably shortened. When considering these refinements sub-stantial gains in profit can be made.

Technology for highest productivity Prodtech is a new technology pack-age for high cutting speed, specially developed to reach good quality and accuracy in steel. The new perform-ances are achieved through new type of pulses, optimization of the number of cuts and through the introduction of new cutting strategies. With Prodtech quality and erosion performances can be obtained, which meets in an opti-mal way the requirements of single part and stamping tools production.

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According to sizeMechanics

The pioneering production is manu-facturing all the accuracy relevant mechanical and electronic compo-nents in house. During assembly a unique system stores measure-ment values and test results in the control system of the AC Progress V. Machine-resident measurement data, proof the high production qual-ity and can be called up by specialists at any time.

Mechanical concept sizes 2 and 3High static and dynamic rigidity with the C-frame construction in cast iron. The entire work area can be used for small detail machinings on large workpieces or for multiple clampings.

Mechanical concept size 4Predestinated for highest workpiece weights on a fixed table. X, Y, U and V axes as slides and arms with the wire guides. Taking in account of their long travel paths, the axes are arranged in accordance with the principle of best positioning accuracy achievable. The entire work area can be used for small detail machinings on large workpieces or for multiple clampings.

Continuous positional accuracyA precision concept is realised by the interaction of dual measurement sys-tems, control and mechanical design, meeting all special requirements for high and large workpieces.

Long-lasting mechanical componentsThe largest-dimensioned, high precision recirculating ball screws, as well as pre-tensioned, closed and also large-dimensioned guides on all axes, a long working life and high precision on the workpiece are ensured.

Optimal temperature stability All the heat generated in the system is dissipated by cooling water. The cooling of the generator, control sys-tem and dielectric unit is regulated by heat exchangers.

Certified quality Every AC Progress V is laser meas-ured, followed by cutting a pallet with practice-oriented inspection pieces. The AC Progress V is supplied with an integrated quality certificate. The time taken for the complete test is almost double as much as that for the actual assembly.

Trendsetting compact constructionThe machine, control system, gener-ator and dielectric unit are integrated in a space saving arrangement in the fully encased system. AC Progress V machines are delivered as one unit on a frame with rollers. The machine can thus be manoeuvred with mini-mum effort and, thanks to its small footprint, it also fits in narrow places. Putting into service is extremely sim-ple with a total of just 4 connections.

Increased wire tension Improved form accuracy and sur-face quality on tapered surfaces. A changed geometry of the toroids, allows an increased wire tension during taper cutting and the wire is optimally guided.

Reliable wire chopperSimple and reliable wire disposal with the integrated wire chopper, important to avoid electromagnetic radiation.

Electromagnetic shieldingWith their fully encased architecture, AC Progress V machines comply with all safety regulations of International and EU standards.

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For high operating convenienceMechanics

AC Progress V ED wire-cutting ma-chines can be easily operated, both through their software and through their mechanical design. The inter-action of mechanism, electronics, pneumatics, kinetics and software make the machine an easily to handle design element when wire changing, when setting up, when threading, in accessibility and production.

Autonomy All components, like standard wire spools up to 25 kg as well as un-matched running time for wear parts, real long term machining (machining hours) is achieved.

Simple wire changeNo expensive wire guides are needed for different wire diameters. Wire changing can be carried out with-out the need of mechanical adjust-ments. The combined wire-guide and threading system works with all wire diameters.

Reliable wire threading The machine can be used to full capacity in reliable night and weekend operation. Agiejet threads reliably in all cases such as multiple clampings, of multiple openings in one workpiece or in the rare case of a wire break

(even wires of 0.07 mm diameter). A prerequisite for real autonomous, automated ED wire-cutting operation.

Good accessibility With a well studied layout, all the modules relevant for maintenance and wear are easily reached. Filters, deionising resin, wire cutting blades, power supplies, nozzles, etc. can be maintained simply and with shortest downtime.

Convenient setting upAll important control functions are available and grouped in Agiejogger, the handbox with its electronic hand-wheel and LCD display. All phases of setting up can be carried out conven-iently.

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Flexible clampingWith the standard clamping frame, no expensive clamping devices are re-quired. Multiple machining jobs can be carried out without problem, the work area can be optimally utilised.

Space-saving doors The machine doors can be swivelled out and pushed back on rollers, paral-lel to the machine, the work tank door is lowered vertically, both not interfer-ing with the surrounding workspace of the machine.

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With avant-garde digital technology

Intelligent generatorIncreased EDM output, more power-ful electronics, efficiently controlled EDM process. With IPG-V (Intelligent Power Generation Vertex) an im-provement in the form factor of the pulses and a reduction in the pulse duration are achieved.

Fully digitised pulse control. The generator and in particular analogue electronics have been combined into one single digital element. This contains a multitude of individual components and is programmable. Changes can thus be carried out by means of the software, without having to change the PC boards. Innovations can be imported immediately.

The generator

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Individualised technologies The best possible cutting technology from a database of pulses instead of a technology database. Alterna-tive proposals for the quality targets are given. Whether brass or coated, whether thick or thin, with every wire type both, maximum cutting rates in full cut and finest surfaces and best precision in trim cut are achieved. ED wire cutting that allows to reliably achieve the desired result without the need of test cuts. Teccut technologies are generated individually in accord-ance with workpiece features. For

this, the workpiece is described with its height, form, material, surface quality and accuracy. According to the material and quality target, Tec-cut selects the pulses for the full cut. Building up on this technology, the pulses for the trim cuts are called up through algorithms and are then adapted individually to the actual working conditions and the required precision. A machining made to measure, without compromises in respect to workpiece height, preci-sion or cutting rate.

Controlled process Continuously optimised servo with state-of-the-art FPGA (Field Pro-grammable Gate Arrays) technology and completely digital data record-ing. At the same time, the current state of the process is measured as close to the spark as possible and, thanks to the enormous computer throughput, kept continuously at an optimal level.

Precision full cut Reduced number or even completely eliminated trim cuts. Individually generated technologies allow single precision full cuts, depending on the accuracy and surface quality required.

Less power consumption Significant less power consumption at higher cutting rates with the IPG-V generator.

Best operating efficiency Fast cutting speeds can be achieved with eCut technologies and wires from 0.1 to 0.15 mm diameter. eCut technologies cut down strikingly on the consumption of filters and resin, as well as of both, coated and brass wire. Less deposits of wire material on the workpiece reduce the trim cuts. Cut surfaces on workpieces have a homogeneous surface according to the roughness value. eCut technolo-gies reduce the spark gap in the case of fine wire machining jobs so that ab-solute accuracy is realised in the case of complex contours and the smallest inside radii.

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AWO Perfect contour accuracy and cylindricity

WBC

Highest form accuracy Best accuracy and linearity are achieved on the whole contour. Wire Bending Control determines the lateral wire deviation, caused by the process, in real time and is corrected with the process control, even at high cutting rates. At every point of the contour cut, WBC reliably imple-ments the precision and roughness target entered in the control system – both in the case of cylindrical and ta-pered and also stepped workpieces.

Physical and process-determined influences are continuously regulated and optimised by the control system. The efficiency of the pulses is convert-ed specifically into precision-leading results. In combination with the IPG-V heavy duty generator, these exclusive functions increase the accuracy on the workpiece.

Accurate linearity Perfect contour accuracy and cylin-dricity. With AWO (Advanced Wire Offset), the influences of wire wear and flushing are technologically compensated.

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Automatic power adjustment Power is automatically adjusted to changing conditions. With Variocut, stepped workpieces or workpieces provided with openings can be cut at optimal speed as the cutting cross section is continuously monitored.

Fast machining High speeds and fine roughness are achieved with the IPG modules of the reliable, fully digitised genera-tor. Roughing pulses are perfectly adapted to the wire diameter and workpiece.

Constant speed in all contoursPrecise full cuts at maximum speed. Dynamic Corner Control continu-ously corrects physically determined contouring errors. The wire path is dynamically optimised. As a result, the quality of the geometry in full cuts improves so that trim cuts can be carried out faster, reduced or even avoided.

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User friendly and powerful for reliable results

Efficient hardwareHigh memory capacity and low energy consumption. A high capacity hard disk, a 1.1 GHz Pentium Proc-essor, up to 1 GB RAM, two USB 2.0 connections and a DVD/CD drive are available for data exchange. An easy adjustable console with a large LCD-screen, keyboard and mouse allow fatigue-free data input.

Newly structured user interface Direct access to main activities and clear overall view of the current situ-ation. With Agievision 5, the proven 3-window structure has been re-tained giving complete control at all times. A new taskbar simplifies the preparation of the EDM program. All the important activities are present-ed on it with large, intuitive icons. Colour icons display the passive or active state dynamically.

Agievision is a control system devel-oped specially for ED machining and shopfloor requirements. The oper-ating convenience has been further in-creased with Version 5. A few data in-puts are sufficient in order to generate the EDM programme target-oriented – using the Microsoft® Windows® operating system, just like on your PC at home.

Target-oriented data inputAutomatic generating of machining technologies and sequences with Easywork. It only requires surface quality, geometry, contour tolerance, workpiece material and height, as well as the wire type.

Machining templates User-specific templates. Continu-ously growing database of machining jobs when stored as templates and simply modified for similar jobs.

Visualized production safetyContinuous verification of job completeness. No risk of forgotten machining relevant data. Formal-check displays missing data inputs in clear text. Graficheck visualises the machining job as a 2D and 3D-simulation, together with the proc-ess state in one window. Functions, assuring full confidence for the whole machining job.

The control

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No manual alignment Automatic three-dimensional workpiece location with Agiesetup 3D in the work area, using the EDM wire and a touch probe. The control system takes account of any possible offset in space and independently as-signs the new reference values to the geometry program.

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PC AC Progress V

Management System for flexible planning

EDM-specific Job Management SystemOptimally manageable machining without reprogramming by a CAM-station. The batch function combines several Jobs in one. With Agievision, priorities and sequences can be set flexibly and changed at any time.

Data input adapted to organizational conditionsFlexible data input in accordance with the infrastructure of the work-shop. With Agievision, the data input can be carried out flexibly: - All data input entered directly on the machine.- Import geometries and complete with the target data on the machine.- Import geometries and target data, completed with measuring and position data on the machine .- Import entire job data, including measuring and position data.

ED wire sinking is intended to be used flexibly for the most varied machining jobs in accordance with the work-shop’s day-to-day requirements. The Agievision control guides by time-saving and productivity-enhancing modules.

Reduced non-productive timeFree selectable threading mode: Agiejet P for highest speed (7 sec-onds), best reliability in critical conditions or a combination of both. Situation adaptable positioning mode. Any combination of these functions are possible.

Easy and flexible problem-free job insertionNo loss of data or need of reprogram-ming when interrupting and inserting a job with Pieceinsert. The inter-rupted job is resumed exactly there where it was stopped, without the need of modifying existing data.

The control

Flexible prioritiesArrange and select individually the cutting sequences for workpieces. Directly on the machine and without the need of an external CAM system. Even during ED machining, the Early/Late function, allows to alter cutting sequences in accordance with time criteria (e.g. EDM start in the evening and removal of drop-out parts in the morning) or any combination think-able.

Remotely monitored ED wire cuttingYour PC is online with the ED wire-cutting machine, at home or in your office, any time. With Agievision, the ED machining in progress can be monitored at every machining phase. The current performance efficiency can be checked and even parameters optimised.

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Preplanning of jobsAgieplanning, the ideal module for planning without complicated calcu-lation of contour lengths or cutting rates. Handled by means of a simple job description directly on the ma-chine or on a PC, the machining time, the wire consumption are at hand for cost/planning calculations.

AgiegeoImporting and exporting files in DXF and IGES. With this software, 2D-ge-ometries can be modified directly on the machine.

Identical data input on the PCAgievision PC, the job management system in your office or at home. All the input and function pages are identical with the AC Progress V.

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About GF AgieCharmilles

High-Speed and High-Performance Milling Centers

In 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 developed alongside EDM into one of the key technologies in mold and tool making.

Electric Discharge Machines

EDM 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.

Tooling, Automation, Software

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

HSM Spindle Technology

Development, production and sale of the motor spindles that form the core components of modern HSM centers. The spindles rotate at speeds between 10 000 and 60 000 rpm.

Services and Consumables

Service, maintenance, spare parts and consumables for EDM, milling and HSM systems as well as for other machine tools; consumables include filters, wire, graphite, copper electrodes and special resin.

Milling

EDM

Automation

Spindle

Service

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Technical DataAC Progress V

TravelsX/Y/Z axes mm in 350x250x256 13.77x9.84x10 500x350x426 19.7x13.77x16.8 800x550x52531.5x21.65x20.67

max. speed X/Y m/min. ft/min. 3 9.84 3 9.84 3 9.84

U/V axes mm in ±70 ± 2.7 ±70 ± 2.7 800/550 31.5/21.65

Max. taper angle <°/height mm in 30°/100 30°/3.93 30°/100 30°/3.93 30°/500 30°/19.68

Dual measuring System for X/Y axes standard standard standard

Workpiece Max. workpiece dimensions L x W x H mm in 750x550x250 29.5x21.6x9.8 1050x650x420 41.3x25.6x16.5 1300x1000x510 51.9x39.3x20

Max. workpiece weight, with bath (without bath) kg lb 200/450 440/992.08 400/800 880/1763.70 3000 6613.86

Max. cutting rate with CCS Ø 0.33 mm wire Cylindrical cut mm2/min. in/h > 500 47 > 500 47 > 500 47

Finishing quality, best roughness Ra µm µin 0.2 8 0.2 8 0.2 8Best Ra with SF modul, finishing power module Ra µm µin 0.1 4 0.1 4 0.1 4

Wire threading system AGIEJET Threadable height mm in Up to 250 9.84 Up to 420 16.5 Up to 525 20.67

Threading nozzle ø mm in 2 0.07 2 0.07 2 0.07

1 0.039 option 1 0.039 option 1 0.039 option 0.6 0.0234 option 0.6 0.0234 option 0.6 0.0234 optionWire guides, Standard equipment ø mm in 0.15-0.33 0.0059-0.0129 0.15-0.33 0.0059-0.0129 0.15-0.33 0.0059-0.0129

Wire guides, Extension kit ø mm in 0.07-0.10 0.0027-0.0039 0.07-0.10 0.0027-0.0039 0.07-0.10 0.0027-0.0039

Combination wire guide system “V” guide cylindrical up to 2° cylindrical up to 2° cylindrical up to 2° Toroid guide 2° up to 30° 2° up to 30° 2° up to 30°Increased accuracy in tapered cut AGIECONIC PLUS option option optionWire drive, wire spool kg up to 25 up to 25 up to 25Wire disposal chopper chopper chopper

Work area Accessibility front front/top front/topFrontal drop door manual manual manualUniversal clamping frame for best utilisation of the work zone standard standard standardMachining in bath mm in 250 9.84 420 16.5354 525 20.669

High power generator IPG-VP integrated ~ A 60 60 60Wide range of tested tech. for common users work piece materials standard standard standardCorrection of the cylindrical residual error, AWO (Advanced Wire Offset) standard standard standardDynamic path optimisation and process adaptation in the radii DCC standard standard standardReal time detection and correction of the wire bending WBC standard standard standardReal time detection of the workpiece cross section and automatic power optimisation VARIOCUT standard standard standardMachine

AC Progress V2 AC Progress V3 AC Progress V4

Dielectric conditioning unitDielectric conditioning unit integrated l us gal 750 200 1000 264 1600 423

Filter cartridges 4 canisters with 8 cartridge filters standard standard standardFiltrate quality µm µin 5 197 5 197 5 197

Deionizing Deionizing bottle charge volume l us gal 10 2.64 10 2.64 10 2.64

option 30 7.92 option 30 7.92 option 30 7.92

Cooling Generator and control unit with air/ water, and dielectric with water/ water heat exchanger standard standard standard

System System dimensions L x W x H mm in 1640x2040x2220 64.5x80.3x87.4 1940x2300x2600 76.4x90.5x87.4 2900x3050x2850 114.2x20.1x112.2

Net weight kg lb 2580 5688 3460 7628 6000 13228

Weight ready-to-run kg lb ca. 3350 7385 ca. 4200 9260 ca. 11000 24250

Control unit integrated, modules and functionsRemote control with all setup functions AGIEJOGGER with electronic handwheel and LCD displayOperator interface system 15”-LCD-display, Keyboard and mouseControl unit integrated AGIEVISION object oriented man-machine interfaceOperating system Multitasking Windows XPOperating mode MultiprocessorCPU’s Pentium for CNC and operator interfaceServocontrolled axes X/Y/Z/U/VSupplementary servocontrolled axis A axisSmallest programmable step 0.0001 mm (0.000004 in)Easy preparation of machining programs EASYWORKAutomatic pickup cycles AGIESETUP 3D, for automatic determination of workpiece plane and positionAutomatic technology selection based on machining objectives TECCUTImport of job-specific data from CAD/CAM systems CAMLINKPredefined machining strategies AUTOSEQUENCEPredefined and user defined machining strategies USERSEQUENCESimple 2D on-board geometry programming IGES files AGIEGEO with import of DXF and IGES filesImport in Agiegeo of third party ISO codes AGIEGEO ISOCONVERTERQuickly insert rush orders without effort PIECEINSERTDNC port with Xon/Xoff and LSV2 protocols DNCHelp functions, explanations with text and graphics HELP and online manualMachining simulation 2D and 3D view GRAFICHECKAutomatic instructions and commands execution EASYRUNAutomatic machining sequence definition LOTTO for multiple workpieces clampingRethreading on wire break/on «no- thread» detection restart after power failure Rescue strategiesLanguages English, CN, CZ, DE, DK, ES, FR, HU, IT, JP, NL, PL, RU, US, SEStorage capacity > 40 GB HD, 1 GB RamInterfaces 2 x RS232C, 1 x parallel, 1 LAN (Local Area Network), 1 USBData storage media CD/DVD Rom for updates and on line manual, floppy-disk, USB

Interface for automation (only Progress V2)Basic equipment for handling devices AUTOMATIONCommunication interface for handling devices ROBOTCOMMANDCommunication interface for cell computer connection HOSTCONTROL

ConnectionsLine power 12.1 kWLine voltage 3 x 400 VCompressed air 6 bar, 5 m3/h (85 psi, 6.54 yd3/h)Cooling capacity required 9-11 kW

AC Progress V2 AC Progress V3 AC Progress V4

AC Progress V2

AC Progress V3

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AC Progress V4

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