Optimized Manufacturing Workflows

Contact Details

GF Machining Solutions
Address
560 Bond St.
Lincolnshire
60069
IL
United States
Phone
847-955-7177
Toll Free Phone
800-282-1336
Fax
847-913-5340

42.1859707, -87.9484143

June 28, 2020
Model Machining Cells Showcase Manufacturing Solutions

As part of its continued effort to provide customers with highly productive turnkey manufacturing systems, GF Machining Solutions has developed a number of model machining cells to showcase its comprehensive range of total manufacturing solutions. These models demonstrate everything from simple pairs of machines and robots to mixed- machine configurations for advanced hybridized additive/subtractive machining strategies.

Cell 1 – Additive and subtractive manufacturing workflow

As additive manufacturing (AM) and laser micromachining become increasingly common, manufacturers need a way to easily integrate these technologies with their conventional subtractive machining operations. GF Machining Solutions has an example of just this form of integration: a three-machine cell comprised of the DMP Flex 350, AgieCharmilles CUT AM 500 and Mikron MILL S 400 U for fast, optimized hybrid part-production operations.

The robust, flexible DMP Flex 350 enables the efficient 24/7 production of very dense, pure metal AM parts from tough-to-machine alloys, including Inconel, titanium, cobalt chrome, aluminum and steel. Short changeover times and streamlined 3DXpert® all-in-one parametric software allow shops to move quickly from 3D modeling to successful part printing, while the innovative CUT AM 500 uses an innovative tilting table and horizontal wire EDM to separate parts from build plates with lower running costs and higher part quality than conventional EDMs and band saws.

To complete parts produced with metal AM as quickly as possible, even when unattended, GF Machining Solutions has included the MILL S 400 U in the cell, a high-speed full simultaneous 5-axis milling machine with an integrated 18-pallet changer, automatic table and workpiece cleaning system and a range of smart machining modules for advanced in-process monitoring. Both the additive and subtractive processes utilize the same type of System 3R tooling to expedite moving parts between machines and ensure the highest repeatability.

Cell 2 – Lights-out automation

For the most demanding part-production applications, accuracy must be maintained over long periods of machining, even when left unattended overnight. In this second model cell, GF Machining Solutions highlights the long-term precision machining capabilities of three high-performance machine tools: the AgieCharmilles FORM S 350 die-sinking EDM, AgieCharmilles LASER S 1000 U laser texturing platform and Mikron MILL P 500 three-axis vertical machining center.

All three of these machines are capable of achieving micron-scale precision for the highest quality surfaces even during the longest machining cycles thanks to features such as integrated thermostabilization, rigid polymer concrete machine bases and software solutions such as Intelligent Spindle Monitoring (ISM), Smartpatch and Intelligent Speed Power Generator (ISPG). Even for exceptionally precise parts, these machines can deliver perfect repeatability all night long, every night, for lights-out automation that manufacturers can trust.

Cell 3 – Standalone robot

To make the most of advanced manufacturing technology, even a single machine’s productivity can be enhanced with the appropriate automation. In this model cell, the AgieCharmilles CUT P 550 Pro wire EDM solution is made even more productive with the addition of a System 3R WorkPartner 1+ (WPT1+), an automation solution that offers maximum magazine capacity in minimal floor space for unprecedented flexibility, making it easy for manufacturers to start with a single magazine and add one or two as required.

This is ideal for the high-speed productivity of the CUT P 550 Pro, which provides 20 percent faster cutting speeds with 25 percent less wire consumption thanks to its Intelligent Power Generator (IPG) technology. To maximize its productivity during unattended machining – and leverage the flexible capacity of the WPT1+ – the wire EDM solution also features new Spark Track technology with Intelligent Spark Protection System (ISPS) for the most secure processes available in the EDM sector today.

For even greater part-processing speeds, the CUT P 550 Pro will be compatible with the company’s new Uniqua control. First previewed at the grand opening of GF Machining Solutions’ new Biel, Switzerland-based milling machine factory in 2019, this innovative human-machine interface builds on the dynamic programming potential of the company’s VISION Controls with EIA/ISO code compatibility, as well as a range of features designed to improve wire cutting speeds from 14-28 percent on CUT P series machines.

Related Glossary Terms

  • alloys

    alloys

    Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.

  • bandsaw blade ( band)

    bandsaw blade ( band)

    Endless band, normally with serrated teeth, that serves as the cutting tool for cutoff or contour band machines.

  • electrical-discharge machining ( EDM)

    electrical-discharge machining ( EDM)

    Process that vaporizes conductive materials by controlled application of pulsed electrical current that flows between a workpiece and electrode (tool) in a dielectric fluid. Permits machining shapes to tight accuracies without the internal stresses conventional machining often generates. Useful in diemaking.

  • gang cutting ( milling)

    gang cutting ( milling)

    Machining with several cutters mounted on a single arbor, generally for simultaneous cutting.

  • machining center

    machining center

    CNC machine tool capable of drilling, reaming, tapping, milling and boring. Normally comes with an automatic toolchanger. See automatic toolchanger.

  • milling

    milling

    Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

  • milling machine ( mill)

    milling machine ( mill)

    Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.

  • milling machine ( mill)2

    milling machine ( mill)

    Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.

  • precision machining ( precision measurement)

    precision machining ( precision measurement)

    Machining and measuring to exacting standards. Four basic considerations are: dimensions, or geometrical characteristics such as lengths, angles and diameters of which the sizes are numerically specified; limits, or the maximum and minimum sizes permissible for a specified dimension; tolerances, or the total permissible variations in size; and allowances, or the prescribed differences in dimensions between mating parts.

  • wire EDM

    wire EDM

    Process similar to ram electrical-discharge machining except a small-diameter copper or brass wire is used as a traveling electrode. Usually used in conjunction with a CNC and only works when a part is to be cut completely through. A common analogy is wire electrical-discharge machining is like an ultraprecise, electrical, contour-sawing operation.