Aerospace Manufacturing Solutions

Aerospace Manufacturing Solutions

Message from the President GF AgieCharmilles Your partner in constant innovation Aerospace and aeronautic manufacturing has long been a core expertise of GF AgieCharmilles. Therefore, we understand that high precision machining and stringent manufacturing requirements are extremely critical components of this quickly evolving industry. Aerospace manufacturing encompasses a wide variety of parts, diverse in shape, size, design and material. To meet the complex needs of the industry, GF AgieCharmilles offers complete turnkey manufacturing solutions built around the world s most advanced high-speed and high-performance machines. From turbine blade repair to heavy milling of titanium alloys to production of very large components, our array of machine and automation technologies offers unmatched precision and productivity. As a result, we remain committed to understanding your manufacturing processes, and working closely with your team to ensure you receive the highest level of accuracy and productivity when using our milling machines and EDM solutions to produce intricate, complex parts. In fact, you ll find our diverse portfolio of standard-setting, high-speed and highperformance solutions can take on difficult-to-machine materials in a wide variety of applications, from turbine blade repair to heavy milling of titanium. And if you re not sure what machine is right for you, we have application engineers that can help select, implement and optimize your equipment. Furthermore, our source of strength doesn t end with our machines. Through our Uptime+ program, we provide customers with the world-class service, support and training needed to ensure your manufacturing processes run smoothly well into the future. All GF AgieCharmilles machines are backed by Uptime+, the industry s strongest, all-encompassing customer service and support program. Our highly qualified and experienced engineers provide training, technical information and expert application advice on the selection, implementation and optimization of equipment. Whatever aerospace manufacturing challenges you face, our team of experts works ceaselessly to overcome them. Complex aerospace parts require flexible, reliable machines with impeccable precision and backed by the best service and support program in the industry. With uncompromised machine performance, turnkey solution productivity and unmatched Uptime+ service and support, GF AgieCharmilles can meet all of your aerospace manufacturing needs. We appreciate your support of GF AgieCharmilles and look forward to doing business with you. Sincerely, Glynn Fletcher, President Agie Charmilles LLC 3

HPM 450U HPM 800U HPM 1350U HPM 1850U Work Area Milling Tough Materials Aerospace components are often made of hard-tomachine materials that necessitate a unique approach to manufacturing. GF AgieCharmilles excels in meeting this challenge. Our robust spindles provide the power and speed needed to maintain high productivity while milling difficult materials. HPM Series High-performance 5-axis machining for complex aerospace parts of all sizes. The HPM (High-Performance Milling) Series offers reliable accuracy with high removal rates, even in difficult-to-machine materials. Perfect for aerospace production, these machines feature state-of-the-art motor spindles, glass scales for precision machine positioning, direct drive swiveling and tilting axes for full 5-axis simultaneous machining and uncompromised, rigid and ergonomic machine body designs. Whether machining airframe components, landing gear parts or turbine blades, HPM Series machines offer turnkey automated system capability for every aerospace part application. Through pallet changers and tool magazine options, this series of machines allows for considerable customization to meet specific production needs and lights-out operations. Work Area Swiveling Axis Tilting Axis Spindle Options Feed Rate X/Y/Z Feed Rate X/Y/Z Rapid Traverse Rate Axis Feed Rate Axis Rapid Traverse Rate Work Table Clamping Surface Max Table Load Pallet Changer Tool Changer Options CNC Control Options Smart Machine Features 600 x 450 x 450 mm 3.6 x 17.7 x 17.7 in +45 /-10 1,000 RPM, 0.1 hp ISO-B40 0,000 RPM, 40.3 hp HSK-A63 15m/min (590 ipm) m/min (866 ipm) 50 rpm (Rotary) 140 rpm (Rotary) Ø 450 mm (17.7 in) 150 kg (330 lbs) 7, 8 pallets up to 350 x 350 mm (13.8 x 13.8 in) 30-tool ISO-B40 60-tool ISO-B40 30-tool HSK-A63 60-tool HSK-A63 10-tool HSK-A63 170-tool HSK-A63 0-tool HSK-A63 APS, APS Extended, ITC, ITC 5X, RNS CAMplete Post Processor and Machine Simulation 800 x 800 x 550 mm 31.5 x 31.5 x 1.65 in +91 /-11 0000 RPM, 5.3 hp HSK-A63 60 m/min (36 ipm) 60 m/min (36 ipm) 60 rpm (Rotary) 50 rpm (Tilting) 60 rpm (Rotary) 50 rpm (Tilting) Ø 630 mm (4.8 in) 500 kg (1100 lbs) 7, 9, 1 pallets up to 610 x 508 mm (4 x 0 in) 30-tool HSK-A63 60-tool HSK-A63 115-tool HSK-A63 165-tool HSK-A63 10-tool HSK-A63 Siemens 840D -APS, APS Extended, ITC, ITC 5X, RNS CAMplete Post Processor and Machine Simulation 1350 x 1150 x 895 mm 53.15 x 45.8 x 35.4 in +16 /-10 15000 RPM, 50.96 hp HSK-A63 15 000 RPM, 50.96 hp ISO 40 4000 RPM, 40.3 hp HSK-A63 15 m/min (590 ipm) 3 m/min (160 ipm) 40 rpm (Rotary) 11 rpm (Swiveling) 40 rpm (Rotary) 0 rpm (Swiveling) Ø 1100 mm (43.31 in) 1600 kg (350 lbs) 3 pallets up to 1016 x 838 mm (40 x 33 in) 30-tool HSK-A63 46-tool HSK-A63 9-tool HSK-A63 30-tool ISO 40 46-tool ISO 40 9-tool ISO 40 Siemens 840D APS, APS Extended, ITC, ITC 5X, RNS CAMplete Post Processor and Machine Simulation 1850 x 1400 x 905 mm 7.83 x 55.1 x 35.63 in +0 /-10 10000 RPM, 45.59 hp HSK-A100 15000 RPM, 50.96 hp HSK-A63 4000 RPM, 40.3 hp HSK-A63 15 m/min (590 ipm) 40 m/min (1575 ipm) 30 rpm (Rotary) 11 rpm (Swiveling) 30 rpm (Rotary) 0 rpm (Swiveling) Ø 1600 mm (63 in) 4000 kg (8800 lbs) 3 pallets up to 145 x 1016 mm (49 x 40 in) 30-tool HSK-A100 175-tool HSK-A100 46-tool HSK-A63 10-tool HSK-A63 10-tool HSK-A63 Siemens 840D APS, APS Extended, ITC, ITC 5X, RNS CAMplete Post Processor and Machine Simulation Milling HPM 450U HPM 800U HPM 1350U HPM 1850U 4 5

HSM 400U LP HSM 600U LP Work Area Work Area Swiveling Axis Tilting Axis Spindle Options 500 x 40 x 360 mm 19.69 x 9.45 x 14.17 in +110 /-110 54,000 RPM, 11.4 hp HSK-E3 4,000 RPM, 18.1 hp HSK-E40 30,000 RPM, 18.1 hp HSK-E40 800 x 600 x 500 mm 31.5 x 3.6 x 19.7 in +30 /-110 4,000 RPM, 18.1 hp HSK-E40 30,000 RPM, 18.1 hp HSK-E40 36,000 RPM, 46.9 hp HSK-E50 Feed Rate X/Y/Z Rapid Traverse Rate Axis Rapid Traverse Rate 60m/min (,36 ipm) 165 rpm (Swiveling) 50 rpm (Turning) 60m/min (,36 ipm) 60 rpm (Swiveling) 150 rpm (Turning) HSM Series High-speed 5-axis machining for unmatched productivity. Every aspect of an HSM (High-Speed Milling) Series machine is designed around high-speed machining to maximize productivity of aerospace part processing operations. Rigid structural machine designs, high-speed spindles, advanced control systems, powerful feed drives and axis mechanisms, together with integrated automation features, all combine to deliver unparalleled HSM Series machine performance. Work Table Clamping Surface Max Table Load Pallet Changer Tool Changer Options CNC Control Options in accordance with pallet size 5 kg (55 lbs) M.M. 156/18X ITS 148/0X 0-tool HSK-E3 40-tool HSK-E3 18-tool HSK-E40 36-tool HSK-E40 68-tool HSK-E40 168-tool HSK-E40 308-tool HSK-E40 in accordance with pallet size 10 kg (65 lbs) UPC/Dynafix/7X GPS 40/10X 18-tool HSK-E40 36-tool HSK-E40 68-tool HSK-E40 168-tool HSK-E40 308-tool HSK-E40 15-tool HSK-E50 30-tool HSK-E50 60-tool HSK-E50 10-tool HSK-E50 170-tool HSK-E50 0-tool HSK-E50 For high-speed, full, simultaneous 5-axis machining to achieve superior contoured part surface finishes, the HSM Series machine features spindle speeds up to 54,000 RPM and feed rates on linear motor machine axes. Milling HSM 400U LP HSM 600U LP 6 7

1 Extra fine surface can be produced at high feed rates through Mikron s direct driven 1 3 rotary and swivel axes. Automation can easily be implemented to boost productivity on parts, such as this aluminum frame component. 3 With a demand for high tolerances and a perfect visual impression, this component requires many tools and the utmost in 5-axis positioning precision. 4 5-axis simultaneous machining is a must 4 for production of this structural wing 5 component. 5 The ability to produce thin support walls is vital in many aerospace applications. Structural Parts 1 When producing the structural parts for an airplane, uncompromised quality is a requirement, not an option. The reliability and support received from GF AgieCharmilles ensures that every part is a perfect part. 3 1 3 1 Between machined and molded components, an airplane cockpit contains a host of components that benefit from the efficient and accurate performance on GF AgieCharmilles EDMs, HSMs and HPMs. This electronic component housing demonstrates the performance of Mikron Flight Controls and Avionics machining centers. 3 Productivity and efficiency are important Many of the housings and components found in flight controls and avionics feature complex geometries with tight tolerances. GF AgieCharmilles high-speed and high-performance machining centers boost productivity by allowing these components to be machined in just one or two setups. Additionally, reliable unmanned operation can be achieved through our Smart Machining features and automation capabilities, such as large tool towers and pallet magazines. in machining parts, such as this aluminum alloy support bracket. Engine Components Aerospace engine components require long cycle times in heavy cutting conditions. GF AgieCharmilles machines maximize productivity and minimize costs, while providing the high performance you need, even during extended cutting processes. 1 Tight tolerances are a necessity for parts related to airflow applications, such as this thin-walled component made of 718 Inconel. The Mikron HPM line of machining centers offers the performance needed to produce parts like this complex combustor machined in 718 Inconel. 3 The fir tree section of this component requires uncompromising accuracy. 8 9

cut 300 CUT 1000/OilTech Cutting Complex Geometries With a trend towards parts with more complex geometries, today s EDM innovations offer an ideal solution for many aerospace applications. GF AgieCharmilles EDM technology allows for high productivity and accuracy when machining intricate and complex components. CUT 300 The benchmark in EDM speed The CUT 300 submerged wire EDM offers unbeatable speed and accuracy in the automatic rough and finish machining of heavy aerospace components. While featuring a compact and space-saving design, the machine easily supports heavy workpieces without losing accuracy. Additionally, features such as in-process inspection and track & trace ensure the quality of every part. CUT 1000/OilTech The world s most accurate wire EDM The CUT 1000 utilizes the finest possible wires to provide the world s most accurate wire EDM process. Automatic threading of wires down to 0.0 mm (0.0008 in) in diameter allows for high levels of autonomy to boost productivity and efficiency. The CUT 1000 OilTech offers a dielectric oil option. Turn While Burn EDM the impossible Turn While Burn technology allows for the machining of highly complex 3D aerospace part shapes and eliminates performing secondary operations on separate machines. The system uses a high precision, servo-controlled programmable B-axis indexer that rotates parts in sync with a machine s X- and Y-axis movement. Wire EDM General Max. Workpiece Dimensions 100 x 700 x 400 mm 47. x 7.6 x 15.75 in X, Y, Z Axis Travels 550 x 350 x 400 mm 1.65 x 13.8 x 15.75 in U, V Axis Travels 550 x 350 mm (1.7 x 13.8 in) Max. Workpiece Weight 1,500 kg (3,307 lbs) Machine Dimensions 600 x 540 x 40 mm 10.4 x 100 x 88. in Rapid Traverse 3 m/min (9.8 ft/min) Taper Angle Standard 30 at maximum height Taper Angle Optional 45 at maximum height Surface Integrity < µm (< 0.0001 in) recast after 4 passes Surface Finish Ra 0.1 μm (4 μin) Generator Generator Type AC Clean Cut Maximum Cutting Rate 340 mm /min (3 in /min) Wire Standard Wire Size 0.33 to 0.15 mm (0.013 to 0.006 in) Optional Wire Sizes 0.33 to 0.070 mm (0.013 to 0.003 in) Maximum Wire Spool 8 kg (17.6 lbs) ISO standards 5 kg (11 lbs) JIS standards Wire Guide Types Closed diamond type without clearance Wire Processor Celeron Display LCD 1" TFT (Touch Screen) Hard Disk Drive Capacity 40 GB RAM USB Port instead of Floppy Drive Ethernet Port RJ45 standard 300 x 00 x 80 mm 11.81 x 7.87 x 3.14 in 0 x 160 x 100 mm 8.66 x 6.9 x 3.93 in ± 40 x 40 mm (1.57 x 1.57 in) 35 kg (77 lbs) 1500 x 000 x 1970 mm 59 x 78.7 x 77.55 in 1-3000 m/min (3.3-984 ft/min) ± 3 at maximum height < µm (< 0.0001 in) recast after 4 passes Ra 0.05 µm ( µin) IPG-V 0. to 0.1 mm (0.008 to 0.004 in) 0.06 to 0.0 mm (0.007 to 0.0008 in) 8 kg (160 lbs) 1 set for all diameters 0.0 to 0.07 mm (0.0078 to 0.007 in) Pentium LCD 15" TFT (Touch Screen) 80 GB 104 MB RJ45 standard 10 cut 300 11 CUT 1000 AWC

FO 350 SP FO 550 SP General FO 350 SP High performance in a compact design Speed and performance come together in the compact FO 350 SP fixed-table diesinking EDM. The high-speed Z-axis pulse rates, together with high acceleration speeds provide aerospace manufacturers with faster part processing, longer electrode life and superior surface finishes. Max. Workpiece Dimensions X, Y, Z Axis Travels Max. Workpiece Weight Machine Dimensions Max. Electrode Weight Rapid Traverse Max. C-Axis Speed Measurement Resolution Positioning Resolution Control/Servo Resolution Table Clamping Area T Slots T Slot Size T Slot Spacing Worktank Dielectric Capacity Max. Dielectric Volume 780 x 530 x 300 mm 30.7 x 0.9 x 11.8 in 350 x 50 x 300 mm 13.8 x 9.8 x 11.8 in 500 kg (1,100 lbs) 1900 x 1690 x 5 mm 74.8 x 66.5 x 99.3 in 50 kg (110 lbs) 3 m/min (9.8 ft/min) 100 rpm 0.005 mm (0.00000 in) 0.005 mm (0.00000 in) 0.0001 mm (0.0000039 in) 500 x 400 mm (19.7 x 15.75 in) 3 1 mm (0.47 in) 15 mm (4.9 in) 410 l (108 gallons) 410 l (108 gallons) 100 x 850 x 400 mm 47. x 33.5 x 15.75 in 600 x 400 x 450 mm 3.6 x 15.7 x 17.7 in 1600 kg (3530 lbs) 3040 x 830 x 960 mm 119.7 x 111.4 x 116.5 in 100 kg (0 lbs) 60 mm/s (.36 in/s) 100 rpm 0.001 mm (0.00004 in) 0.0005 mm (0.0000 in) 0.0001 mm (0.0000039 in) 750 x 600 mm (9.5 x 3.6 in) 5 1 mm (0.47 in) 15 mm (4.9 in) 498 l (133 gallons) 80 l (19 gallons) FO 550 SP User-friendly die sinking EDM Die-sinking EDM has never been easier than with the FO 550 SP. Through an incredibly intuitive Windows-based control, the FO 550 SP allows operators with minimal training to efficiently produce high-quality parts with extreme tolerances. iq TECHNOLOGY Near zero electrode wear Generator Amps Type Control CNC Processor Display Hard Disk Drive Capacity RAM USB ports Ethernet Port 64 amps standard 18 amps optional ISO pulse PENTIUM LCD 1.1 TFT (Touch Screen) 40 GB 51 MB RJ45 standard 64 amps standard 18 amps optional ISO pulse PENTIUM 1.1 TFT Color (Touch Screen) 0 GB minimum 40 GB RJ45 standard iq Technology builds a protective layer onto graphite electrodes to practically eliminate wear. iq Technology allows aerospace manufacturers to use very thin vane-type electrodes to produce extremely fine, stepped narrow slots without fear of electrode deterioration. Die-Sinking EDM FO 350 SP FO 550 SP 1 13

Lean, green and blue Save energy an economic and ecological necessity In order to control production costs, saving energy has become a priority in many workshops. The Econowatt modules manage the electrical power of the machine so as to never waste energy while the machine is running unattended. When machining is finished or interrupted, the power supply is reduced to the minimum, lower than 1kW, or completely disconnected depending on the parameters of the machine. Automatic restart is programmed according to a daily schedule corresponding to the operating hours of the workshop. The machine is switched on in sufficient time to be thermostabilized when the workshop opens. The power consumed is continuously displayed on a screen page. DRILL 300 Quick, simple and precise holemaking The small footprint and up to a 50 electrode / 8 guide changing capability makes the Drill 300 a powerhouse for production cooling hole applications. The Agie Charmilles ISPG proven generator technology provides intelligent technology settings for entry/exit machining and cylindrical control. The result is superior surface and profile quality while maintaining high speeds and minimum electrode wear. Electrode Wear Management is included as a smart feature within the intuitive CNC control, and will change electrodes automatically without any additional programming. The operator friendly HMI (Human Machine Interface) is designed to minimize set-up time and reduce the learning curve a must for multi-shift operations. High-Speed EDM Drilling drill 300 General Max. Workpiece Dimensions 1000 x 700 x 400 mm (39.37 x 7.56 x 15.7 in) X, Y, Z-Axis Travels 600 x 400 mm (3.6 x 15.7 in) Z-Axis Travel 450 mm (17.7 in) Optional 650 mm (5.59 in) W-Axis Travel 450 mm (17.7 in) Max. Workpiece Weight 1000 kg (,05 lbs) Machine Dimensions 1400 x 30 x 180 mm 55.1 x 91.34 x 85.83 in Electrode Electrode diameter 0.3 to 3 mm (0.01 to 0.1 in) Optional small holes 0.1 to 6.0 mm (0.0039 to 0.4 in) Controlled operational costs The excellence of GF AgieCharmilles wire EDM technology also resides in the control of operational costs. The potential for using less expensive wires and reduced filtration cost, added to a lower consumption of electricity, make machines such as CUT 00, 300 and 400 particularly economical to run. Econotec technology - high speed, lower cost Production requirements mean that savings must be made at all levels, especially on consumables. Thanks to complete control of the EDM wire process, Econotec technology allows 30 % faster machining times with a 0.3 mm diameter wire, while reducing cost by 0 %. drill 300 14 15

GF AgieCharmilles automation solutions Modest demands, maximum benefits Easy to use pallet changers for EDM and milling machines require minimal floor space, supervision and operating cost while delivering: + Increased machine capacity + Increased productivity and flexibility + Simple access to pallets or tools + Lower production costs + Lower unit cost + Shorter depreciation time + Minimum footprint Continuous Improvement Peter LaFond, President of Steel Tool Engineering, challenges his employees to be problem solvers when it comes to manufacturing jet engine components. As an innovative partner to customers, their problems are Steel Tool Engineering s problems, and the solutions often originate from advanced technology and support from GF AgieCharmilles. GF AgieCharmilles automation systems and electric discharge and high-speed milling machines (EDM and HSM) give Steel Tool Engineering the means to incorporate innovative techniques. With a varied toolbox of cutting edge technologies, Steel Tool Engineering routinely overcomes manufacturing challenges, reduces part costs for its customers, and adds to the company s competitive advantage. Through this, Steel Tool Engineering maintains a highly regarded reputation as a leading supplier of flight-critical engine components for commercial and military aircraft. We maintain a healthy fear of our competitors and keep up with who is out there and if they are out-manufacturing us. Whether they accomplish that by producing in low-cost labor regions or by way of advanced technology, our strategy is one of continuous improvement, and we are going to always strive to implement it before the competition does, declared LaFond. Continuous improvement at Steel Tool Engineering isn t based on stand-alone machines, but on highly complex, automated manufacturing systems. The company acquires many of these turnkey systems from GF AgieCharmilles because, like Steel Tool Engineering, the world s technology leader in EDM and HSM partners with customers to provide value through innovative products and services and is relentless in its drive toward continuous improvement. Automation for every configuration level An array of tailor-made options Whether your application requires 10 pallets or 40, modular magazines can be combined to offer an unprecedented flexibility that can be adapted to each user s needs. Light magazine capacity 5-80 pallets Heavy magazine capacity 10-0 pallets Automation Solutions 16 17

Global Support and Services GF AgieCharmilles A world-wide network of support and customer services ensure maximum uptime of your GF AgieCharmilles machine tool Applications GF AgieCharmilles customers gain access to dozens of local Application Engineers providing training, programming and troubleshooting. Consumables A complete range of original wear parts and certified consumables at your fingertips; all in-stock orders received by 4 p.m. ship the same-day. Service Preventative maintenance and repair services to minimize downtime and maximize productivity. Boston USA Charlotte USA Milling EDM Laser Uptime + Program 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. Laser Ablation Laser ablation 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 D geometries right through to complex 3D geometries. Laser ablation, compared to conventional surface treatment using manual etching processes, offers economic, ecological and design advantages. Everything Support Uptime+ provides comprehensive services for GF AgieCharmilles machines. The program offers the complete range of original wear parts and certified consumables including wires, filters, electrodes, resin and many other materials. Uptime+ machine support covers all services connected with spare parts, technical support and preventive services, while helping develop manufacturing solutions tailored to the customer s specific needs. Automation 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. 18 19

59.804.98 us.gfac.com Agie Charmilles SA, 011 The technical data and illustrations are not binding. They are not warranted characteristics and are subject to change. 560 Bond St. Lincolnshire, IL 60069 Tel. (800) 8-1336 Achieve more...