New Tech, New Talent at GF Machining

The open house event marked the North American debut of the company’s AgieCharmilles Cut P series wire EDMs. In addition to features detailed in the text below, these machines feature new Intelligent Power Generator (IPG) technology that is said to deliver surface finishes as smooth as Ra 0.08 µm while also boosting cutting speeds. This is possible, in part, through various functions that dynamically adjust power levels, spark parameters, cutting paths and more during machining. Other notable capabilities include cutting at angles ranging to 30 degrees throughout the entirety of Z-axis travel (45 degrees optional); positioning and contour accuracies of ±2 µm; collision protection at maximum axis travel speeds of 3 m/min.; and temperature regulation within ±0.2°C to ensure repeatability.

Examples of medical components produced on Cut P series machines, which are also said to be well-suited for aerospace, automotive, mold/die and electronics industry applications.

Milling machines aren’t just for milling these days. With a Hirth coupling locking the spindle rigidly in place, the company’s Mill P 800 U ST (for “simultaneous turning”) can consolidate setups and eliminate secondary operations. Four-axis, simultaneous-turning capability is said to be particularly useful when avoiding tool-shape errors requires positioning the cutting tool at a 90-degree angle to the workpiece surface.

EDMs and milling machines alike are increasingly paired with automation. GF Machining Solutions offers a source for that, too: technology from System 3R, a division of the company that celebrated its 50th anniversary at this year’s open house. In addition to carousel-style robots, System 3R specializes in standardized tooling systems that that enable transferring parts from workstation to workstation without losing references.

As demonstrated by conversations at both ends the machine, compact automation in the form of an 18-position pallet changer was a significant draw for this Mill X 400 U five-axis machining center. Featuring a 42,000-rpm spindle, the machine is designed for the kind of speed, precision and quality surface finishes demanded by modern medical applications in particular.

Crowds were large enough that patience proved to be a virtue when navigating aisles and getting questions answered. This area housed the company’s laser technology, including an expanded line of three- and five-axis laser-texturing machines like the ones in the background. Capable of texturing, micro-structuring, engraving, marking and labeling of 2D and 3D geometries, machines like this potentially have a big future in replacing labor-intensive chemical etching processes common to automotive interior tooling applications.

The AM 290 S additive manufacturing (AM) machine was made possible through a collaboration between the Switzerland-based GF Division and EOS, a German supplier of AM technology. It is designed primarily to enable mold and die manufacturers to build inserts with conformal cooling channels that snake closely along the contours of the insert’s geometry. A stark contrast to the typical network of straight bores, these curving channels provide more efficient, consistent cooling that speeds production, improves part quality and reduces costs.