Experience: Issue 21 (PDF | 2.3 MB)

Experience in a new Look

Agiecut Classic 3S

Present at trade fairs

Vertex-Design award

New consoles

Reducing operating costs

HTM - Tyrolia Technology

Ehrhardt Tool & Machine Co.

Braun Formenbau GmbH

Royal Die & Stamping Co.

Alhorn GmbH & Co.

Chelar Tool & Die, Inc.

PARTNER TO THE BEST

T H E A G I E E D M M A G A Z I N E

NO. 21SEPTEMBER

2002

Precision taken to the edge

GFGEORG FISCHER Manufacturing TechnologyAGIE CHARMILLES Group

AGIE SACH-6616 LOSONETELEFON +41 91 806 91 11TELEFAX +41 91 806 92 [email protected]

of the smallest diameter▲ Two wire spools for differenttypes of wire● The complete operation of thewires takes place fully automatical-ly ■ New, highly efficient generatorIPG (Intelligent Power Generator)▲ Control system Agievision 3000with new functions.

026.

648

The Agiecut Vertex ED wire-cut-ting system opens up new possi-bilities in the production of partsfor the electronics, medical andwatch branches as well as in themanufacture of micromechanicalparts and punched films:■ The most accurate ED wire-cut-ting machine in the world thanksto its innovative mechanical struc-ture with its patented monoblockand optimum thermal behaviour▲ Best surface roughness up to Ra = 0.05 µm

● Automatic thread-ing of wires with0.2 to 0.02 mm di-ameter■ The wire diameterplus 50 µm give the size ofthe smallest possible threadinghole in the workpiece■ High autonomy even with wires

AGIECUTVERT X

No. 21of September 2002Appears in GermanEnglish, French andItalian

Editor:M. KatzGraphics: R. GrizziPrinted:Tipografia Poncioni SALosone - Switzerland

© AGIEA company in the AGIECHARMILLES Group.No responsibility is takenfor the technical data orcontent of articles.

AGIE SACH-6616 LOSONETEL. +41 91 806 91 11FAX +41 91 806 92 [email protected]

Cover picture:New inhalation systemof Braun FormenbauGmbH produced on a16+16 fold injectiontool.

Dear Readers,

After 20 issues of Experience ofthe Best we have given the Agiecompany’s customer magazine anew appearance. With colour anda new layout, we are taking ac-count of our customers’ requeststo present modern applicationsfrom the world of ED machining.The new title "experience TheEDM magazine of Agie" empha-sises the international nature ofour clientele and the appearanceof Agie as a "Global Player" in theEDM world market. A marketwhich is subject to constantchanges. Whether with increasedrequirement for automation or thetrend towards miniaturisation.Challenges which Agie is facingwith innovative products.

ED wire-cutting for high workpiecesThe most recent example is the ED wire-cutting system Agiecut Classic3S. The latest model in the Agiecut series is specially designed for ma-chining high workpieces of up to 420 mm submerged. By way of illus-tration we have reproduced a scale 1:1 with this height on this page.Numerous functions of the well-tried, open-system Agievision control al-low carefully targeted, rapid planning, set-up and ED machining.

0 mm

420 mm

UBMERGED

Global Player in theEDM world market‘‘ ’’

3

2AGIE experienceNo 21 September 2002

04.09. – 11.09. IMTS Chicago USA

10.09. – 14.09. AMB Stuttgart Germany

12.09. – 15.09. METALL WORKING TOOL Manila Philippines

16.09. – 20.09. MSV Brno Czech Republic

24.09. – 27.09. MACHINE TOOLS Oslo Norway

25.09. – 29.09. TATEF Istanbul Turkey

25.09. – 30.09. INT. TECHNICAL FAIR Plovdiv Bulgaria

01.10. – 01.10. TBA MANUFACTURING Jakarta Indonesia

03.10. – 08.10. BIMU Milan Italy

08.10. – 11.10. MACHINE TOOLS Stockholm Sweden

15.10. – 19.10. MAQUITEC Barcelona Spain

28.10. – 04.11. JIMTOF Tokyo Japan

21.11. – 24.11. THAI METALLEX Bangkok Thailand

04.12. – 07.12. EUROMOLD Frankfurt Germany

New consoles withlarge screensThe new Classic 3S, just like theAgiecut series Classic, Challenge,Evolution and Excellence, as wellas the ED die-sinking series Im-pact, Innovation and Exact, arebeing supplied with new consoleswith immediate effect. The oper-ating convenience is even furtherimproved by a new 15’’ screenand the integrated mouse pad.The PC, diskette and CD drivesare also integrated into the con-sole, emphasising the functionalcharacter of the striking design.

Present at all important trade fairsAgie exhibits at all important ma-chine tool trade fairs. You see thelatest Agie EDM systems, soft-ware and peripherals, as well asour customers’ EDM applications.Here below is a survey of the sec-ond half of 2002.

Agie design winsaward once againAfter 1998, Agie is once againamong the winners of the DesignAward from the renowned Indus-trie Forum in Hanover. TheAgiecut Vertex ED wire-cuttingsystem was honoured, receivingthe much sought-after awardfrom among over 1000 entrants.

Reducing operating costsYou have decided on one of themost reliable and durable ma-chine tools on the market: AnEDM system from Agie. If you ob-serve the maintenance and ser-vice intervals, you will ensure thecreation of value by your invest-ment in the long term. In addition,Agie now offers wearing part kits3000 and 8000 for all Agiecut EDwire-cutting systems which guar-antee 3000 or 8000 hours of op-eration respectively. It has neverbeen so favourable to reduce op-erating costs.

We hope that we have found yourinterest with the choice of articlesin this issue of experience andwish you stimulating reading. Sin-cerely yours

Michael Katz

Technical Editor

3AGIE experience

No 21 September 2002

HTM Sport- und Freizeitgeräte AG

4

Country Austria

Production - Ski bindings- Complete supplier of components

Target market International

Employees 280

Founded 1848, 1948 Tyrolia, 1996 HTM

Edm systems 2 Agietron Innovation 2 with 28 compartment electrode changer1 Agietron EMS 2.202 Agietron EMT 1.101 Agietron EMT 1.20

HSC 1 Bostomatic 12G

Programming - ProEngineer CAD- CAM, PowerMill

Clamping systems Erowa

Measuring, checking - Zeiss

- Tesa Leitz in production network with Agievision PC


Tyroliaplatz 1

Schwechat

A-2320

Tel +43 (01) 701 79-262

Fax +43 (01) 701 79-202

[email protected]

www.tyrolia-technology.com

Contact person René Harrer, Business Development

Helmut Brandt, Technical Development


Tyrolia Technology Engineering & Production was founded in1996 as a profit centre of HTM Sport- und Freizeitgeräte AG.The company has 280 employees on its payroll and is basednear Vienna’s Schwechat Airport. Through the complete pro-duction of ski and snowboard bindings, the company is able tofall back on much and diverse production know-how whichflows profitably into all the orders from various industries.

checking devices as well as, last,but not least, two ED die-sinkingsystems which operate in a pro-duction network with the high-speed cutter Bostomatic 12 G.The production example “fanwheel” is representative for the ef-ficient continuity in tool making byTyrolia Technology.

ED die-sinking in an economic production network with HSCThe profit centre as a complete provider of production solutionsIn 1999, Tyrolia Technology Engi-neering & Production was posi-tioned in the market as a profitcentre of HTM Sport- undFreizeitgeräte AG. The youngcompany’s strong points are:- Outstanding, innovative tech-nologies- greatest production depth- complete process cycle. Cus-tomers national and internationalappreciate these services, espe-cially in the case of requirements,such as:- development of mechanical sys-tems for heaviest duties- replacement of metal by plastic- electrostatic powder coating ofnon-conductive plastics- zinc-cobalt coatings in massproduction.For this, HTM Sport- undFreizeitgeräte AG has the mostmodern means of productionand planning at its disposal:Workstations with 3D Pro-Engineer, injection mould-ing machines, differentialscanning calorimeters,milling machines andlathes, punching ma-chines, profile and sur-face grinding machines, measuring stations, gal-vanising lines, power-coat-ing equipment, 10-colourprinting machines, testing and

5

5AGIE experience


Combine complex moulds on one electrodeGraphite as electrode material hasdecisive advantages:- High removal rates are achievedwith it.- Complete mould inserts can beED machined with one electrodeas even the finest ribbs combinedwith complex moulds or large ar-eas can be milled at high speedin graphite.- Graphite can be machined easi-ly and quickly with HSC.

Production time was halved Anyone who can react quickly tocustomers’ requirements nowa-days has a lead over the competi-tors in tool and mould making. Ty-rolia Technology has worked stepby step towards this competitiveadvantage:1. The conversion from copper tographite brought 58% time savingin electrode production withmilling. Twenty hours alone for de-burring and cleaning the copperelectrodes were no longer neces-sary.2. Compared with conventionalmilling, it was possible to cut thetime by 78% with high-speedmilling of graphite electrodes.3. ED die sinking with graphitereduced the time compared withcopper by 43%. Applied to thefan wheel, production time wasmore than halved. Or, in otherwords: Tyrolia Technology wasable to save 286 hours.

The same operating surfaceon the PC as on the machineThese are the most importantsteps in the stage of preparingthe work for the fan wheel:- Load the CD data from the cus-tomer.- Improvements to suit the toolwith Pro-Engineer.- Generate the 3D electrodegeometries.- Prepare the milling program withCAM Pro-Engineer for the pro-duction of roughing and finishingelectrodes made of graphite.- Fix the turned graphite blankson the electrode holders.- Plot the electrodes on the Tesa-Leitz measuring instrument whichis in a data network with theBostomatic 12 G and the twoAgietron Innovations.- Transfer the values measured tothe Bostomatic 12 C and the Agi-etron Innovations.- Prepare the ED die-sinking pro-gram with Agievision PC. WhatTyrolia Technology particularly ap-preciates here is that, thanks toAgievision PC, ED die-sinkingprograms no longer have to beprepared on the machine, but thisis carried out on the PC with theabsolutely identical operating sur-face. The utilisation of the ED die-sinking system can thus be strik-ingly increased.

From the data from the Swiss company Aluwag, theclient for the complete production of a mould in-sert for a die-casting tool, HTM generates the CADprogram for the fan wheel for a truck engine. Whenpreparing the work, the individual productionsteps, such as high-speed cutting of graphite elec-trodes and ED die sinking, are fixed.

show the individual steps in the production of themould insert:Workshop drawing with finished graphite elec-trode.High-speed cutting machine Bostomatic 12G formanufacturing the graphite electrodes.The graphite blank fixed to the chuck is preset andplotted on the measuring instrument. The valuesserve as reference data for further machiningsteps.

The finished graphite electrode after 25 hourshigh-speed cutting. The mould insert is completedwith roughing and finishing on the ED die-sinkingsystem Agietron Innovation 2.

The fan wheel above as a die-cast blank with thecasting sprues and stays. The die-casting processis extremely accurate in reproduction and requiresthe finest surfaces on the mould insert in order toensure a good flow behaviour so that no air bub-bles or cavities become trapped inside during die-casting.



As internal actual cost calculation of the

fan wheel showed, thanks to the combi-

nation of high-speed cutting of the

graphite electrodes with bostomatic

and ed die-sinking of the mould

insert with agietron innovation,

we were able to cut the produc-

tion time of the die-casting tool

by more than half.

Helmut Brandt,

Technical manager of

HTM Sport- und

Freizeitgeräte AG

We would like to thank TyroliaTechnology Engineering & Pro-duction, in particular their Techni-cal Manager, Ing. Helmut Brandt,the Head of Toolmaking, RaimundPremauer, as well as the BuyingManager, Stefan Wollner, for theirkind support and helpful-co-oper-ation on this report.

Responsible

sales engineer:

Friedrich Scharinger,

Agie Sales Ltd

Tool name Mould insert for die-cast tool

Finished part name Fan wheel for truck engine

Mould insert material Steel 1.2344 hardened to 50 HRC

Finished part material Aluminium alloy

Tool service life 80,000 to 120,000 units

Electrode material Graphite 0.3 mm undersize in diameter and max. 0.5 mm radius

Electrode production 15 hours high-speed milling each for roughing, semi-finishing and

finishing electrodes

Milling time 2.5 hours premilling of the insert with 0.5 mm oversize

Ed die-sinking time 35 hours roughing, 62 hours semi-finishing and finishing with an

EDM depth of 44 mm

Surface roughness VDI 22

Finishing Micro blasting VDI 20 (3 hours polishing and compacting)

The tool data

“ ”

7AGIE experience



The Ehrhardt Tool & Machine Co., Inc. isbased in the state of Illinois, a few mileseast of St. Louis. The company specializesin stamping dies and automated assemblyequipment for the heating, air conditioningand consumer appliance industries basedon its efficient toolmaking, stamping andassembly operations.

Country USA

Products Toolmaking and production of- Heating and ventilation elements- Shower and whirlpool components- Equipment for civilian nuclear energy plants


Employees 80

Founded 1937

Edm systems 2 Agiecut Challenge 31 Agiecut 200 D1 Agie Mondo Star 401 Agie Mondo Star 50

Programming UnigraphicsPeps von Camtek

Clamping systems Mecatool for ED wire cuttingCustom design for R & D die sinking

Measuring, checking - Brown & Sharpe CMM

- Sheffield CMM- Optical checking systems

Ehrhardt Tool and Machine Co., Inc.

25 Central Industrial Drive

Granite City

62040 Illinois

Tel +1 (314) 436 6900

Fax +1 (314) 436 6905

[email protected]

Contact person Patrick Walsh,

Vice President of Operations


Toolmaking as the key to economic productionThe Ehrhardt Tool & MachineCo., Inc., founded in 1937, is lo-cated a few miles to the east ofSt. Louis in an industrial park inGranite City. In the 82,000square feet large, fully air-condi-tioned factory building, toolmak-ing, the stamping shop for pilotruns, the welding shop, the spe-cial machine construction andCNC production take up an areaof some 52,000 square feet. Thecompany, with 80 employees onits payroll, has its own designand construction department thatutilizes Unigraphics CAD/CAM,Auto Cad and Mastercam sta-tions geometry and solid model-ling creation as well as convertingcustomer DXF/IGES files. An ex-tremely efficient quality controlsystem with 3 optical testing de-vices and 3 coordinate measur-ing machines reflect the compa-ny’s dedication to maintain highquality standards. Production iscarried out in two shifts with over3,200 man-hours being expend-ed weekly. Productivity and prof-itability is achievedwith a flexible staffand a high measureof autonomy withautomation of itsmachine tools.

The perfect exampleof this at Ehrhardt

Tool & Machine Co., Inc. are thetwo Agiecut Challenge 3 ED wire-cutting systems which are em-ployed mainly for the manufactureof tool inserts and can be super-vised from the operator’s homewith Agie Contact Manager duringweekend and night shifts.

ED wire cutting both for tool inserts and batch production

Starting with a detail drawing, the pro-gressive die is designed by means ofCAD programs. The toolmaker createsgeometry programs for electrodes andfor ED wire cut system. The operatorlinks them with the technologies andfixes the machining strategy, measuresand locates the workpieces withAgiesetup 3D. Ersosion can be startedon the Agiecut Challenge 3.

9AGIE experience


In addition to progressive dies,the toolmaking department atEhrhardt Tool & Machine Co.,Inc. manufactures products inseries. What is not necessarilycommonplace here is the ma-chining process and the productbeing machined: Cavities withhigh positioned accuracy areeroded in a component used infuel elements for the civilian nu-clear industry using an Agie EloxMondo 50 ED die-sinker.

Ehrhardt’s rationaland precise batch production with EDdie sinking

Thanks to the Agie Elox Mondo50’s large open height between thetable and quill, is extremely well-suited for this machining.

ED wire-cut die and workshopdrawing for a progressive die forthe production of ventilation com-ponents.

The advantages of Agiecut Challenge when ED wire cutting Economic ED wire cutting of highprecision and complex tool insertsproduced from tool steel and ex-pensive carbides requires a largespectrum of machining technolo-gies and generator capability,both for a high removal rate andfor the finest surfaces. Featureswhich are applied convincingly atEhrhardt Tool & Machine Co., Inc:- Reliable threading of wires of alldiameters with Agiejet.- Exact taper angles, create free-form surfaces and ED machineequal collar heights with Agiecon-ic.- fast cutting speeds of up to 300mm2/min. with the universal highperformance generator AgieHSSC.- Cut radii in full cut at maximumspeed with Dynamic Corner Con-trol.- ED machine stepped work-pieces or workpieces with open-ings in the cutting direction in aconsiderably shorter time withVariocut.- Generate non-oxidizing surfaceswith Purecut so that tool insertsare ready for use without furthertreatment.- Arrange cutting sequences forseveral workpieces with differinggeometries with Usersequenceand define timing criteria usingthe Early/Late function.These are brief, but decisive, fea-tures which make ED wire cuttingsuccessful for Ehrhardt Tool &Machine Co., Inc.

The advantages of Agievision when planningand setting upIn order to efficiently manufacturea large number of tool insertsfrom a wide range of materialtypes in varying heights and incomplex forms with ED wire cut-ting, rational planning and settingup are essential. At Ehrhardt Tool& Machine Co., Inc, the followingprocedures have proven to besuccessful:- Part geometry creation withPeps, the CAD/CAM program-ming system from Camtek.- Online transfer of the CAD/CAM data via Ethernet to the ex-ternal Agievision PC station. TheCAM-Link software module of theAgievision control system auto-matically retrieves the geometrydata and converts the machiningtargets and requirements.- Clamping of the workpieces on aMecatool pallet.- Plot the workpieces on the pre-setting position and determine thereference points.- Setup of the workpiece palletwith Agiesetup 3D, which auto-matically determines the work-piece position. Agievision then al-locates the new reference valuesto the geometry program.- Based on the operator definingonly the desired surface rough-ness, contour tolerance, work-piece material and height, as wellas the EDM wire, Easywork auto-matically generates machiningtechnologies, the working se-quence and operation.- Transfer of the complete EDMprogram from Agievision PC toAgiecut Challenge 3.- Check of the data for complete-ness with Formalcheck and as asafety measure simulate the ma-chining with Graficheck.In this phase of planning and set-up, Agievision provides the secu-rity of allowing the operator topreview the entire machiningprocess.



11AGIE experience


ships beginning with the design,material selection, going throughtoolmaking and ending with theproduction of the finished part.Quality runs like a thread throughall stages of production atEhrhardt Tool & Machine Co.,Inc.

Name Mold die

Material Cold-work steel D 2

Number of cuts 1 main cut, 2 trim cuts

Surface roughness 12 RMS

EDM time 12 hours die16 hours punch

State-of-the-art equipmentfor uncompromising precision Confidence is good, a successfulresult is better. This piece of wis-dom applies, of course, toEhrhardt Tool & Machine Co., Inc.the practice of daily using state-of-the-art measuring and testingdevices. However precisely a toolmay be manufactured, the deci-sive fact ultimately is the quality ofthe finished part produced by it.

A chain of dependent relation-

A die is being cut on the Agiecut Challenge3. Thanks to the Agievision module Userse-quence, the machining strategy can bescheduled to meet operator time require-ments.

The palletized tool inserts are measured ata presetting position. The measurement da-ta are then automatically transferred to theED wire-cutting system and Agievision allo-cates the reference values to the geometryprogram. A glance suffices: Every-thing’srunning to utmost satisfaction.

We would like to thank EhrhardtTool & Machine Co., Inc., in par-ticular their President Keith Cotterand their Vice President of Opera-tions Patrick Walsh, as well asour sales representative GaryFrick, of Hartwig Inc., for theirkind support and helpful coopera-tion on this article.

Responsible

Sales Manager:

Don McMillan,

Agie Ltd, USA

The tool insert data

High autonomy as a prerequisite for

automated machining sequences was

the deciding factor for purchasing our two

Agiecut Challenge 3S. The time-saving

functions of the Agievision Control provide

an additional productive and economic

Flexibility which would have been unattain-

able in ED wire cutting.

Pat Walsh,

Vice president of operations

of Ehrhardt Tool & Machine Co.

“

”

The spectrum from Braun FormenbauGmbH ranges from simple to multiple andfrom single to multicomponent injectionmoulding tools. A maximum of quality andprecision is common to them all.

Country Germany

Products Multicomponent tools and rotary tables for- Sanitary and consumer goods industry- Automotive, electronics and electrical industry- Hygiene and medical industry


Employees 141

Founded 1977

Edm systems 2 Agietron Innovation 2 with handling device1 Agietron Innovation 35 Agietron Integral 21 Agiecut Evolution 33 Agiecut 250 HSS1 Agiecut 150 HSS

Clamping systems - Erowa- Mecatool

Software - 2D CAD ME 10 from Hewlett Packard- 3D CAD Catia 4.1.8 Solid Designer from HP- 2D CAM Mecanic and Surf Cam- 3D CAM Power Mill

Measuring - CNC measuring instrument from Zeiss- Measuring instrument from Numerex - 5D-measuring instrument from Vision- CNC coordinate measuring instrument from Mitutoyo- 3D measuring instrument 400 CNC- Measuring instrument from Smart Scope



Unter Gereuth 14

Bahlingen

DE-79353

Tel +49 (0) 76 63-93 20-0

Fax +49 (0) 76 63-93 20-42

[email protected]

www.braunform.com

Contact person Erich Braun, Managing Director

Verena Bohnhorst, Marketing ManagementHenry Breisacher, Management ED Machining


Exact with the moulds –Exact in ED die-sinkingThe company’s 25th anniversary marks successful mould makingover a quarter of a centuryThe Braun Formenbau GmbHcompany, based in the small townof Bahlingen in Baden in south-western Germany, was founded in1977 and today earns a turnoverof over 15 million Euros with 141employees. In 1997, the companydecided to create a second leg tostand on with the series produc-tion of complex plastic parts andclean room production under thename Braun GmbH. Both compa-nies are certified in accordancewith international quality stan-dards. With developments of itsown from rack tools, hot runnertechnology, 2 and 3 componenttools, rotary table systems as wellas fully automatic 2 componentlathe tools, Braun FormenbauGmbH is among Germany’s mostinnovative mould makers. Withthe example of a 16+16-fold in-jection tool for a novel inhalationsystem, we show how creativelyBraun Formenbau GmbH usesEDM as a production process.

From the geometry da-ta sent by the customer,

the mould for the lower partof the casing for an inhalation system isgenerated as a 3D model using the CADprogram Catia.

Simplified cross section through the injec-tion moulding tool. 3D presentation of thelower part of the casing for a powder in-halation system. With the mould-flow analy-sis, the flow behaviour inside the mouldduring the injection moulding process issimulated.

Functional design thanks toconstruction to suit the tool Function and design today playan ever more important role inthe development of new plasticarticles. The best example is anovel powder inhalation systemconsisting of the upper and lowerpart of the casing made of thematerial ABS with an averagewall thickness of 1.8 mm and thefunctional elements inside, alllinked together by a hinge andsnap connection. In addition,there are two observation aper-tures made of the material MABSlet into the lower part of the cas-ing offering excellent transparen-cy with a good surface quality.The mass production of thishigh-quality multicomponentplastic article made great de-mands on the tool technologyused by Braun FormenbauGmbH with respect to processreliability and output quantity. Af-ter completion of the pilot phase,it was clear that the lower part ofthe casing with the integratedapertures could only be econom-ically realised using the two-com-ponent injection mouldingprocess. For this, the tool wasmodified in such a manner thatno injection points to the aper-tures are to be seen from out-side. Construction to suit the toolat the service of function and de-sign.

13AGIE experience


The two mould inserts for the inside andoutside of the lower part of the casing withthe accompanying graphite and copperelectrodes.

The data input on the ED die-sinking sys-tem Agietron Innovation takes place pur-posefully according to the quality and ma-chining targets. The handling device dockedonto an Agietron Innovation is completelyloaded with electrodes and palletisedclamped workpieces and ready for ED diesinking. A 2-part mould insert with ED diesinking.

Quality is standard - everything else individualThe injection cycle show how in-dividual the injection mouldingtool for the casing is:1. Close mould2. Simultaneous injection of

the preliminary and finished injection moulding3. Air to pneumatic pistons

of the lifting plate on the nozzle side

4. Open mould5. Ejection by means

of machine ejector6. Machine ejector return7. Tool ejector return by

means of pneumatic piston8. Open the holding device

for the rotary table9. Open the end-of-travel lock

for the rotary table10. Turn 180°11. Run in the end-of-travel lock for the rotary table12. Clamp the holding device

for the rotary table13. Cycle endAnd the optimum interplay of allthe tool elements shows whatstandard quality is. Braun For-menbau GmbH has given impres-sive proof of “Molding your vi-sions” with this example.

Continuity of the data at all stages of productionFrom the receipt of the cus-tomer’s CAD data until the fin-ished part, data continuity is en-sured at all stages of productionat Braun Formenbau GmbH:- Construction of the tool with thevarious mould inserts in the basisof the CAD data for the finishedpart.- Deciding on the productionprocess in accordance with thetool data.- Generation of the electrodemoulds from the CAD data.- Generation of the milling and EDwire-cutting programs.- Transfer of the CAM data to theED wire-cutting system and thehigh-speed milling machine. Thistakes place with Agie Scriptfile, asoftware module containing all thespecific production requirements,such as roughness, precision andproduction sequences.- Presetting of the electrodes andthe palletised clamped work-pieces on the measuring ma-chine.

This presupposes two conditions:1. A uniform clamping system forall machining processes makingpresetting and measurement pos-sible outside of the machine, and2. a data network from theCAD/CAM workplaces to all quali-ty testing and checking machinesand devices for an efficient vari-ance comparison of the data.

The set-up and EDM phase aredetermined for the Agietron Inno-

vation 2 operator by the followingsequences:- Loading the handling devicewith electrodes and palletisedclamped workpieces.- Completing the CAD electrodedata with material type, undersizeand grade of difficulty.- Data input by describing theworkpiece in accordance withthe placing, quality and prioritytarget of the machining.- On the basis of the machiningassignment, combining the elec-trodes into a family which canthen be shifted to any coordinatepoint without any further data in-put.The system then fixes the gradeof difficulty automatically, gener-ates the technology from this andprepares the machining se-quence according to the numberof electrodes available. Depend-ing on the machining assign-ment, various planetary strate-gies take care of the concave orconvex widening, as well assharp inside or outside edges.Machining strategies can be con-trolled according to priority withthe Usersequence and Piecein-sert modules.



Tool name 16+16-fold injection moulding tool

Finished part name 2-component lower part of the casing of a powder inhalation system

Mould insert material 1.2344

Finished part material MABS and ABS

Tool weight ca. 2500 kg

Electrode material 95% graphite, 5% copper

Electrode production High-speed milling

Edm time 25.2% of the total production time

Surface roughness Mould inserts VDI 18 – 22

We would like to thank BraunFormenbau GmbH, in particulartheir Managing Director ErichBraun, the Head of Marketing,Verena Bohnhorst, as well as thehead of ED Machining, HenryBreisacher, for their kind supportand helpful-co-operation on thisreport.

Responsible

sales engineer:

Frieder Nothacker,

Agie GmbH

The complete inhalation systemmanufactured using the two-compo-nent injection moulding process.

We see the greatest potential for increasing the economic viability of our

mould-making in the networked production system with complete data

continuity. Only in this way the capacity of our cnc machine tools can be

further increased. All the networking necessary up to the fully automated

edm cell can be implemented at various configuration levels with the

ed wire-cutting and die-sinking systems from agie, which have been

prepared for automation, and the open-system agievision control

system. That is why agie is still the first choice for ed machining for us.

Erich Braun

Managing director of


15AGIE experience


The tool data

”

“

ROYAL DIE & STAMPING CO.Custom Manufacturer of Quality Components

Royal Die & Stamping, based to thenorthwest of Chicago, produceselectrical contacts, connectors,terminals and other components onits 60+ presses, for the automotive,telecommunications, electronicsand other industries. The companyhas an efficient toolmaking depart-ment at its disposal, the heart ofwhich is the extremely modernEDM department.

Country USA

Products Electrical contacts, terminals, metal stampings, insert/injection moldings and components for the automotive, power distributor, telecommunications and other industries


Employees 100

Founded 1938

Edm systems 2 Agiecut Evolution 31 Agiecut Evolution 21 Agiecut 150 HSS1 Agiecut 1702 Agiecut 100D1 Agie Mondo Star 20

Programming Mecanic, CAM, Auto CAD 2000

Clamping system Mecatool

Measuring, checking - MicroVu

- optical measuring system- On-line-CMM

Royal Die & Stamping Co., Inc.

949 E. Green Street

Bensenville

60106 Illinois

Tel +1 (630) 766 2685

Fax +1 (630) 766 0401

www.royaldie.com

[email protected]

Contact person Henrik Freitag, CEO

Erik Freitag, President


7

With ED wire cutting the future has only just begunToolmaking and punching inthe third generationAfter just a few minutes by carfrom O’Hare International Airportin Chicago you stand in front ofthe modern building of Royal Die& Stamping Co. The businesswas founded in 1938 and is runby the third generation of thefounding family. The companyowner and CEO is Henrik Freitag.Today the company has over 100employees and exports its manu-factured components to all partsof the world. With its own design,toolmaking, stamping, moldingand assembly lines, Royal Die &Stamping Co. offers a completerange of custom components.Royal Die & Stamping works withan extensive array of materials likebrass, copper, beryllium, steel,phosphor-bronze and nickel-silverin order to be able to deal withcustomers’ orders “Just in time”.The EDM department is also simi-

larly organized, for the majority ofpunches, dies or mold inserts thatmust be manufactured on shortnotice so that the toolmaker canassemble the tool on scheduleand deliver it to the stampingshop exactly on time for the be-ginning of production. This pre-supposes a great deal of flexibilityamong the operating staff of theED wire-cutting systems. Thewire-cuts themselves must beequipped to provide the perfor-mance and functions for these re-quirements. This is one of the rea-sons why investment was madein Agie EDM systems.

Hundred percent repeatabilityin form and precisionA multistage die for the produc-tion of cable clamps, requirepunches and dies as well asforming inserts to be manufac-tured using ED wire cutting. Therelevant data for the ED wire-cut-ting program, such as workpieceheight and material, surfaceroughness and contour tolerance,can be taken from the detaileddrawings and entered using Easy-work. Agievision then automati-

cally generates machining tech-nologies, the job sequence andprocedure. The further workingsteps are:- Clamping the workpieces.- Determine the workpiece positionin the work area automatically withthe measuring probe and EDMwire. Agiesetup 3D takes accountof any possible offset in tilt andskew of the workpiece and allotsthe new reference values to thegeometry program to produce per-fect parts.- ED wire cutting of the insertswith a contour tolerance of ±0.002" Tkm and a surface qualityof 10 – 20 RMS.- Rush orders can also be insert-ed at any time. Pieceinsert makesit possible to interrupt a job inprogress, machine the rush orderand resume the interrupted ma-chining without reprogramming.

A workshop drawing of the com-plete multistage die for the pro-duction of cable clamps for batter-ies. All tool inserts are displayed indetail. They serve as the model formachining programs. The operatorcan then take all the relevant datafor ED wire cutting from thesedrawings: workpiece height andmaterial, surface roughness, con-tour tolerance and radii accuracy.From this the ED wire-cutting sys-tem generates the machining tech-nology independently.

17AGIE experience


The tool data

Precision which still showsafter 50 million parts The quality management at RoyalDie & Stamping Co., a QS-9000certified company, involves a con-tinuous chain of measures begin-ning with the PPAP Product PartApproval Process in accordancewith QS-9000 standards, thecheck of tool inserts using stateof the art video inspection devicessuch as Micro Vu through onlinemeasurements on the presses tothe final check of the finishedparts with measurement and testrecords. This comprehensivequality system is appreciatedworldwide by customers such asBMW, Marconi, Ford (Tier 1 and2), Chrysler, Andrew and manymore.Quality Management at Royal Dieand Stamping Co. begins withaccurate prototyping using Agiewire EDM machines that expe-dites the process. The PPAPteam is then involved in the prod-uct development along with thecustomer providing for reducedcosts and lead times.For Royal Die & Stamping Co. it isboth a confirmation and challengethat they satisfy the high qualityrequirements of their demandingclientele and have to place themeasuring bar ever higher: Cus-tom Manufacturer of Quality Com-ponents

Look into the tool assembly department atRoyal Die & Stamping. The 15 different na-tional flags show the international nature ofthe employees.

The multistage operation die with thestamped strips of cable clamps whichshows the various cutting, punching andbending stations.

Look into the EDM department at Royal Die& Stamping Co. The inserts for the multi-stage operation die are ED wire cut readyfor fitting here, such as these mold dies.

With its own toolmaking and punching de-partment under one roof, Royal Die &Stamping Co. has the advantage of beingable to manufacture tools on its own press-es and to react quickly in the event of dam-age to an active part. The display of a pressshows the current pressing pressure withwhich the cable clamps for batteries arepunched.

Tool Name Progressive press tool

Tool Lenght 72 inch

Tool working life 50 million parts

Finished part name Cable clamp for batteries made of a copper alloy, tin coated

and encased in plastic

Materiale active parts Power metallurgy manufactured steel CPM 10 V

EDM wire CCA 0.006” - 0.008” Ø

Number of cuts 1 main and 3 trim cuts

Surface quality 10 - 20 RMS


18experienceNo 21 September 2002

We would like to thank Royal Die& Stamping Co., in particular theirCEO Henrik Freitag and PresidentErik Freitag, as well as our salesrepresentative Joe Talarczyk fortheir kind support and friendly co-operation on this article.

Responsible

Sales Manager:

Don McMillan,

Agie Ltd, USA

One “evergreen” of the Royal Die & Stamping Co. are modular ca-ble hangers made of stainless steel. Hardly noticed by the public,they do their duty in telecommunication towers, in tunnels, onbridges and buildings worldwide, resisting wind velocities of up220 km/h. Royal Die & Stamping Co. constructs the over 1 meterlong multistage tools in modular construction with which quantitiesof up to 50 million are produced. All the tool inserts giving preci-sion are made of powder metallurgy manufactured steel and areED wire cut with CCA wires of 0.006-0.008” diameter. The surfaceachieved is 10 – 20 RMS and contour tolerance is ± 0.002 inchTkm.

Produce modular cable hangers with a modular multistage operation tool

Almost 90% of our tool inserts are manu-

factured by wire EDM. This shows the

high importance of this departure within

our enterprise. Reflected also in the in-

vestments in the past years. 3 wire EDM

systems of the newest generation and 4

additional wire EDM machines. No doubt,

that Agie was for us first choice.

Henrik Freitag,

Owner and CEO of


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19AGIE experience


The Alhorn company offers complete solutions for its international clientelefrom construction, through tool and mouldmaking to the first matching of injectionmoulded parts.

Country Germany

Target market Europe

Founded 1977

Employees 65

Products Construction Injection moulding tools for- Connectors- Automotive technology and electronics- Technical casings- Mobile phone casings- Sanitary technology- Lamp casings

Edm systems Agietron Innovation 3Agiecut Challenge 3Agiecut 150 HSSAgiecut 100 DAgiecut 200 DAgiecut 220 D

Programming Version Mecanic 99 (ED wire cutting)CAD SolidWorks 2001 Plus, CAD/CAM Works 2001, completely integrated in SolidWorks andTeksoft CAD/CAM system 5 (milling)

Measuring, checking 2 MicroHite 1, MicroHite 350, 2 MicroHite 600

Measuring instrument Werth Video Check IP 250Measuring microscope Leitz WM DigitalCoordinate measuring centre Vista with PC control C99as presetting place for ED die sinkingSetting and measuring instrument Zoller Bravo 2as presetting place for milling

Clamping system System 3R and Erowa (ED die sinking)Mecatool (ED wire cutting)

Alhorn GmbH & Co.

Alhorn GmbH & Co. KG

Daimlerstrasse 10

Lübbecke

DE 32312

Tel +49 (0)5741 30 19-0

Fax +49 (0)5741 30 19 60

[email protected]

Contact person Willi Alhorn, Managing Director


High-tech tools for demanding customersThe company Alhorn GmbH &Co. KG was founded in 1977 anduntil 1986 manufactured exclu-sively injection moulding tools.The company’s strength lays al-ready at that time in the realisa-tion of technically difficult, com-plex contours with the highestprecision. In 1987, it began withinjection moulding which hassince been continuously expand-ed. The objective of the Alherncompany, right from the outset,was to cope with the ever in-creasing demands with the mostprogressive technologies andthus achieve a highest degree offlexibility and customer satisfac-tion. This also included the large-scale expansion of productionand construction which was initi-ated with comprehensive buildingmeasures at the end of 2001.

Nearly the complete range of precision mould makingThe clientele of the Alhorn com-pany includes world-market lead-ers in the plug connector andcontact industry, such as TycoElectronics AMP, Weidmüller In-terface, Phoenix Contact, DelphiAutomotive Deutschland, Grote &Hartmann and Hartnig Electric. Inaddition, components are sup-plied for the mobile phone, auto-mobile, sanitary and lightingequipment industries. The Alhorncompany’s range of services isrounded off by its own injectionmoulding plant with 18 machinesfrom 25 to 300 t mould clampingforce, as well as its own measur-ing and testing centre.

From the processing of the customer’sCAD data through the preparation of 3Drenderings to the first matching, the toolsand finished parts manufactured by theAlhorn company are optimised andchecked to suit the tool in all phases.

High-precision EDMensures precisly fitting finished parts

21AGIE experience


the edm systems agietron innovation 3 and agiecut challenge 3 were for us

an investment in the future, because with them we have the possibility of au-

tomating our ed machining at any time. In addition, there is agievision which

gives us all the freedom of networking and data transmission.

Willi Akhorn

Managing director of

Alhorn GmbH & Co. KG

Exact positioning and high removalWhen ED machining at the Al-horn company, the exact posi-tioning of changed electrodes ismuch appreciated. This allowsunsupervised EDM operationwhich can be structured in ac-cordance with the company’sown time criteria with theUsersequence function. The

With a few inputs safety to the machining targetWhen buying the Agietron Innova-tion ED die-sinking system, theadvantages of Agievision onceagain became apparent to the Al-horn company. The only controlsystem that has been speciallydeveloped for the requirements ofED machining and offering acommon operating surface bothfor cutting and sinking. On ac-count of the process control re-quirements, the data input whendie-sinking is structured with thepages Easywork, Easygeo andEasymachining in accordancewith the grade of difficulty of themachining target:- Minimal details on the work-piece and electrode suffice togenerate an ED machining.- By simply clicking on the plane-tary strategy selected, the ma-chining technology is automatical-ly activated and allotted to the re-quired geometry.- By simply clicking on them,complex machinings can be se-lected: calibrate drilling with orbit,drilling or screw, thread, castingsprue, punch with undercut,punch, lateral undercuts or lateralED machining.Agievision automatically generatesthe optimum technology in eachcase which is executed with max-imum reliability.

The precision tool for manufacturing socketcasings is used on an Arburg automatic in-jection moulding machine.

The data input on the Agietron Innovation 3ED die-sinking system is carried out pur-posefully in a few steps with the Agievisioncontrol system.

The 39-pin socket casing is subjected to athorough check on the Werth Video CheckIP 250 measuring instrument.

With the Agievision Easymachining module,the machining "EDM sprue" can be select-ed by simply clicking on it.

The mould nest makes the complexity ofthe injection moulding tool for the 39-pinsocket casing clear. High precision andquality guarantee a burr-free removal fromthe mould.

Alhorn GmbH & Co.

process is monitored continuouslyby the fuzzy-adaptive servo systemACC and ACO, with the perfor-mance being automatically adjust-ed to the active EDM surface. Theresult is a high removal rate withlow electrode wear. A factor whichreduces the number of electrodesto a minimum.

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We would like to thank AlhornGmbH & Co. KG, in particulartheir Managing Director, Willi Al-horn, for their kind support andhelpful-co-operation on this re-port.

Responsible

sales engineer:

Klaus Schmidt,

AGIE GmbH

Name 8-fold injection-moulding tool with 4 hot gate nozzles on subdistributors

Finished part name 29-pin socket casing MQS,MPQ, PQ LWL

Finished part material PBT GF 20 Ultradur B 4300 G4

Tool material 2312 mould plates2363 mould inserts2767 mould cores and slides

Electrode material Copper

Electrode production Milling, ED wire cutting, grinding

Edm time 306 hours ED wire cutting315 hours ED die cutting

Surface quality Ra = 0,35 µm

Two mould nests of the 8-fold injection-moulding tool for the production of 39-pin socket casings.

Thanks to Agievision, the common con-trol system for ED die sinking and wirecutting, the data input on the AgiecutChallenge 3 ED wire-cutting system canalso be carried out without problem byan Agietron Challenge operator.

On the Zeiss-Vista coordinates measuringcentre, the geometry data for the elec-trodes are recorded, transmitted to theAgietron Innovation 3, allotted to the ap-propriate machining task there and pro-vided with the accompanying machiningtechnology.

Tested quality and reproducible precisionCustomer satisfaction has firstpriority at the Alhorn company.All measures are aimed at this.Whether in construction withcost-saving tool optimisation, intool and mould making withshorter throughput times or wheninjection moulding with automat-ed sequences. In this connection,the Alhorn company’s measuringand checking centre is interdisci-plinary. For the modern measur-ing instruments, microscopes anddevices are used by all depart-ments. Solely with the objectiveof supplying the customer withdocumented quality and preci-sion. A claim which is expressedwith an above average qualityawareness among all Alhorn em-ployees and is proved by injectionmoulded parts produced by thethousand.

23AGIE experience


The tool data

Country USA

Products Large progressive dies for stampingof metal components and bending sheet steel

Target market 90% USA, 10% international

Employees 48

Founded 1962

Edm systems 1 Agiecut Evolution 3 with an Astrodisc robot1 Agiecut 270 HSS

Programming Esprit

Clamping system Mecatool

Measuring, checking Brown & Sharpe CMM

Chelar Tool & Die, Inc. enjoys an outstand-ing reputation with customers across NorthAmerica as a manufacturer of large-dimen-sion progressive dies for the stamping ofsheet steel and metal components. Thecompany has 48 employees and is based inBelleville, Illinois, just a few miles east ofSt. Louis.


11 North Florida Avenue

Belleville

62221 Illinois

Tel +1 (618) 234 6550

Fax +1 (618) 234 7551

www.chelar.com

[email protected]

Contact person Malcolm J. Katt, President

Chelar Tool & Die


The specialist for large-dimension progressive dies in the USAChelar Tool & Die, Inc. wasfounded in 1962 by the threebusiness partners Elmer A. Katt,Arthur Engel and Charles Flynt.The company started with 7 em-ployees. Already in 1964, Chelarinvested in an ED die-sinkingmachine – known only to a fewtoolmakers at that time and con-sidered an exotic machiningprocess. Malcolm J. Katt, theson of one of company’sfounders, is the President andCEO of Chelar Tool & Die, Inc.Thanks to continuous invest-ments in state-of-the-art machin-ing and software technologies,the company increased its salesstrikingly. The heart of tool manu-facturing here are an Agiecut 270HSS ED wire-cutting system andan Agiecut Evolution 3 ED wire-cutting system automated bymeans of an Astrodisc robot.During the first year after com-missioning, EDM production wasincreased by 53% and full pay-back of the investment tookplace after 18 months in thecase of the Agiecut Evolutionplus robot. All workpieces to bemachined with wire-cutting areclamped on pallets and preseton a measuring machine. In viewof the large volume of punchesand dies needed for progressivedies, their manufacture is a con-siderable factor for cutting costsand machining times.

Great in dimensions and great in precision

Chelar Tool & Die, Inc. got the order tobuilt a progressive die for the manufac-ture of casing components for air-condi-tioning units. The tool construction andthe use of various machining techniquesare discussed on the basis of the cus-tomer’s drawing.

25AGIE experience


When we upgraded and expanded with agie’s new evolution 3,

we chose it for three reasons. first, because of the great success

we had with the original agiecut 270 hss purchased in 1994; second,

because the evolution 3 took us to a higher level of automation; and third,

because we needed to hold more and larger workpieces to keep pace with

our customers’ needs.

Malcolm Katt,

President of


EDM output increased to6,800 hours a year A progressive die, such as for theproduction of casing componentsfor air-conditioning units, quicklytakes on enormous dimensionswith all its punching, cutting, em-bossing and bending stations.The number of precise and activeparts required are enormous. Soit becomes clear why Chelar Tool& Die, Inc. invested in automatedED wire cutting:- The Astrodisc ShopmasterSD10 handling device can ac-commodate up to 10 workpiecepallets.- The workpieces are clamped onpallets and preset on the Brown & Sharpe CMM that theAgiecut Evolution 3 does not haveto be occupied with setup func-tions.- The robot changes the pallets

The contours of 6 punches are cut on theAgiecut Evolution 3. The various screw tap-pings were made before ED wire cutting.

The Agiecut Evolution 3 ED wire-cuttingsystem with the Astrodisc robot. Up to 10different workpieces can be loaded and un-loaded for autonomous machining.

A look into the magazine of the AstrodiscRobot from which the gripper takes theworkpiece to be machined and in which it isdeposited again after EDM. Thanks to theirfitting accuracy, wire-cut punches can beused immediately and do not require anysecondary treatment of the surfaces.

Wire-cut die made of tool steel D 2 whichwill serves as a station for bending steelsheets in a large-dimension progressive die.

Precision does not fall by the waysideProgressive dies from Chelar Tool &Die, Inc. are manufactured in modu-lar construction so that worn ordamaged moving parts can be re-placed quickly and without prob-lem. The prerequisite for this is thatthese parts must be 100% identicalin form and precision. Productiontime and quality are inextricablylinked:- With control of ambient condi-tion in the EDM department.- With surface roughness down to Ra = 0.2 µm.- With cutting rates up to 300 mm2/min.- With workpiece dimensions upto 1050 x 650 x 250 mm.- With an automatic wire threadingsystem which is 99% reliable andless than 28 seconds for a com-plete thread.- With a chip identification systemfor the safe loading and unloadingof workpiece pallets without oper-ator attendance.


Chelar Tool & Die.

on the ED wire-cutting systemwith a positioning accuracy of 5 µm.- The ED wire-cutting system au-tomatically generates the correctmachining technology for the re-spective workpiece.- Weekends and nights can beutilized profitably and unattended!

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We would like to thank ChelarTool & Die, Inc., in particular thecompany’s President Malcolm J.Katt, as well as our sales repre-sentative Rick Survant, of HartwigInc., for their kind support andfriendly collaboration on this arti-cle.

Responsible

Sales Manager:

Don McMillan,

Agie Ltd, USA

The Tool insert data

Name Punch and die for a progressive die

Finished part Casing components for an air-conditioning plant.

Punched from cold rolled, color coated,

1 mm (0.04 inch) thick and 914 mm (36 inch)

wide steel sheet.

Insert material Cold work steel D 2

EDM time 9 hours for 6 preset punches

Number of cuts 1 main and 1 trim cut each

Surface roughness Ra = 1,8 µm

With the Brown & Sharpe CMM measuringdevice, all the parts comprising precisionin the progressive die are plotted andrecorded. Chelar must achieve quality inthe µm range to manufacture a large di-mension tool of 2 m length or more.

27AGIE experience


The targets set for the automatedED wire cutting were achievedand even surpassed expecta-tions. Chelar Tool & Die, Inc. isnow aiming for an increase up to8,000 EDM hours annually.

Great in dimensions and great in precision All moving and active parts in thedie, such as punches, die plates,strippers or forming inserts are EDwire cut at Chelar Tool & Die, Inc.on the two Agiecut systems. ForMalcolm J. Katt, ED wire cutting isthe ideal manufacturing processfor achieving repeatable precisionon workpieces. In addition, thehigh degree of autonomy of theAgiecut Evolution allows machin-ing to be automated, thus utilizingnights and weekends without at-tendance – a real “lights-out” op-eration!. The Agievision moduleUsersequence with the Early/Latefunction is helpful for this. Opera-tor attended machining se-quences can be scheduled exact-ly by using these functions. ChelarTool & Die, Inc. uses Ethernet asLAN network, to link all machinetools, the Esprit programming sta-tion, Agievision PC and the mea-suring machine. As a result, CAMdata is transmitted online. Data onany tool or measurement recordscan be accessed at any time.Quality of profitability or profitablequality. Both apply for Chelar Too& Dies, Inc.

Documents

Experience: Issue 21 (PDF | 2.3 MB)