agiecharmilles am s 290 tooling - gf machining … agiecharmilles am s 290 tooling gf machining ......

GF Machining Solutions

AM S 290 ToolingAgieCharmilles

DedicatedSolutions

2 AgieCharmilles AM S 290 Tooling

GF Machining Solutions : all about youWhen all you need is everything, it’s good to know that there is one company that you can count on

to deliver complete solutions and services. From world-class electrical discharge machines (EDM),

Laser texturing and Additive Manufacturing through to first-class Milling and Spindles, Tooling,

Automation and software systems — all backed by unrivalled customer service and support — we,

through our AgieCharmilles, Microlution, Mikron Mill, Liechti, Step-Tec and System 3R technologies,

help you raise your game and increase your competitive edge.

Conformaldesign

Industry trends

Additive Manufacturing

Conformal channels

Additional benefits

AgieCharmilles AM S 290 Tooling

GF Machining Solutions’ approach

Post-processing

Technical specifications


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Contents

Beat the competition with Additive ManufacturingGF Machining Solutions has long been a major actor in plastic

injection and die casting by providing market players with

high-performance machine tools. Customers trust our solu-

tions to manufacture the most complex molds and inserts.

GF Machining Solutions goes further by incorporating

Additive Manufacturing (AM) technology to its portfolio with

the AgieCharmilles AM S 290 Tooling, based on quality proven

EOS technology. Push existing limits with previously unachiev-

able thermal regulation.


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Seize opportunities in growing industries

Industry trends

Such growth gives rise to increased competition and ever-

greater research and innovation efforts. Industry players are

facing serious challenges with strategic processes with in-

creasing complexity: deliver new products and new materi-

als on the market while improving product quality, limiting

costs, reducing cycle time and improving time to market.

GF Machining Solutions understands these challenges and

its experts and partners can support companies from plastic

industry during the whole process, from the original idea to

the final product.

Plastics industry growth is linked to trends such as the investigation of lighter and more efficient products for transportation; the increasing aging population and growing income as drivers for medtech; and rising need for packaging to meet consumer needs.

3D printing represents a great

progress for the plastics industry.

CAGR+5.5 %

Medical

Electronics

Automotive

Agriculture

Construction

Furniture

Housewares

Packaging

Worldwideplastics production in million tons(Source: PlasticsEurope)


Beat the competition

The quality of these parts is linked to the quality of the

tools used. Temperature control within these dies is of

chief of importance. Efficient thermal regulation in dies is

essential for stress-relieved cooling of the workpiece and

positively impacts final part quality by eliminating hotspots

for example.

As a bonus, improved temperature homogeneity can increase

tools lifespan, therefore limiting the high cost of replacing

production tools.

For small to medium die-casting parts, AM is ready to be-

come a great solution for market players.

Industry trends

There is increasing pressure to more quickly deliver higher quality die-casting parts. AM works for all kinds of products and is a very efficientoption for dies characterized by thick walls.


A fully integrable path to the future

Additive Manufacturing

A performant and reliable technologyAs an AM technology, DMLS uses an ytterbium fiber Laser fired

into a bed of powdered metal, aiming the Laser automatically at

points in space defined by a 3D model, melting—or, rather,

welding—the material together to create a solid structure.

Beyond conventional machine toolsThe AM S 290 Tooling, based on EOS’ direct metal Laser sin-

tering (DMLS) technology, is GF Machining Solutions’ first 3D

printing solution. The “configured for you” system can pro-

duce mold inserts as never before, allowing you to transcend

conventional to conformal cooling and experience the ther-

mal management benefits of conformal heating/cooling

channels for plastic injection and die casting.

AM is a hot industrial topic as applications are numerous and promising—and initiatives are multiplying all over the world. GF Machining Solutions has embraced AM as a leading technology providing new opportunities for its customers, and understands how it complements traditional technologies, particularly in mold and die manufacturing. Today, GF Machining Solutions meets customers’ needs with both an AM solution and support in integrating this technology into their machining processes.

Global No. 1 in metal Additive Manufacturing

Global No. 1 in mold and die segment

A dedicated AM machine to mold and die


Increase mold performance

Conformal channels

Thanks to 3D printing, you can build inserts with conformal channels, meaning that they are placed closer to the final molded part and that they respect the part’s geometry. This breakthrough then aligns the exchange of temperature inside the mold and therefore optimizes production in terms of time, cost and quality.

Mold flow simulationSimulation is essential to creating these conformal chan-

nels, and very effective and easy-to-use software solutions

are available. GF Machining Solutions’ AM team supports you

both in learning channel design and in the simulation work

before production.

Structural analysisAs a leading manufacturer of machine tools and a partner to

mold and die makers for decades, GF Machining Solutions

knows that the presence of conforming channels must not im-

pact the quality of the tools. Correctly designed, it can be guar-

anteed that 3D printed inserts have the same mechanical

strength as conventional molds and their lifetime can even

increase due to more uniform internal temperature exchange.

Conventional channels Heating/cooling channels inside an insert are of capital importance in the plastic injection and die-casting processes. AM technology complements traditional machining methods’ which cannot produce high-quality conformal channels at low prices. With AM, you can design better conformal channels for less money with better quality.

© images: Pôle Européen de Plasturgie

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Shorter cycle time

Less scrap and warpage

Shorter lead time

Greater design flexibility

Injection cycle

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Heating phase:Fine detail reproductionSurface quality

Optimized temperature homogeneity• Higher surface quality• Better texture details

Cooling phase:Plastic solidification phase

Optimized solidification time• Higher part quality: less deformation• Shorter cooling time: for same quality

Filling and melt packing

Ejection

Solidification

AM can do more than you think

Additional benefits

Smaller replacement costs

Faster ROI

Higher revenue

PrototypingThe mold design process requires expensive iterative steps

to eliminate defects through a trial-and-error approach. This

has an impact on the time you need but, more importantly,

on the money you spend.

Thanks to conformal cooling and simulation software, you

can dramatically improve the iterative design process and

turnaround times. You improve your lead time by getting the

final production mold quicker. Users of this technology can

get a faster return on investment—even before the injection

process has started. In this increasingly competitive market,

this can be crucial to beat the competition.

FlexibilityThanks to a new freedom of design, you can produce less

expensively with higher performance tools. The absence of

restriction on the mold geometry permits greater feasibility

in general.

Mold replacementReplacement of the molds is very expensive and their life-

span is critical. Better thermal control can extend the effi-

ciency and life time—an attractive benefit for all players,

especially those in the die casting.

Mold repairWhen a part of a mold is damaged, it is sometimes possible

with AM to preserve the insert. You can cut out the damaged

section and reprint the geometry directly on the top. This can

represent big advantages in terms of time and money savings.


DedicatedSolutions

A dedicated solutionAgieCharmilles AM S 290 Tooling

The EOS technology is recognized as the best on the market.

With the AM S 290 Tooling, you achieve incomparable quality

on your final printed inserts. Work with confidence that

you’re using the same EOS technology relied upon and trust-

ed by well-known companies in such critical industries as

aerospace and medtech for parts production.

With a System 3R MacroMagnum chuck integrated into its

build platform, the AM S 290 Tooling leverages the Refer-

ence Point License Calibration software to permit location of

parts relative to the build platform. That’s a big benefit when

you’re manufacturing hybrid workpieces. This significantly

improves the ability for upstream and downstream integra-

tion of the AM process in the whole production process.*

GF Machining Solutions recommends today two performant materials for the manufacture of molds and inserts for plastic injection and die-casting processes.

EOS Maraging Steel MS1

Available layer thicknesses µm 20 / 40 / 50Yield strength MPA 1990Tensile strength MPA 2050Hardness HRC 50-56Corrosion resistance Good

EOS Stainless steel CX

Available layer thicknesses µm 30Yield strength MPA 1670Tensile strength MPA 1760Hardness HRC 51Corrosion resistance Excellent

GF Machining Solutions uses the proven quality of EOS and offers the market a configured-for-you system for the production of inserts and molds with conformal channels.

* Other chuck manufacturers are available


An easy-to-use system

Intuitive software for fast learning

400-watt ytterbium fiber Laser for unrivaled printed parts

Optimized process gas management for reduced maintenance costs

Monitoring options for controlled production

Quality proven EOS technology

Various accessories for powder management

Hybrid mold insertThe hybrid mold insert is the most economical solution

for parts characterized by geometrically simple and

complex sections. Such hybrid parts can be created by

directly generating the additively manufactured part

on top of the conventionally manufactured base or by

separately finishing and assembling both parts. This

cross-technological approach is perfectly delivered by

one single solutions provider. Our AM team can advise

you to determine what is the most efficient and cost-

effective approach to your application.

Multiple parameter options for adapted prior knowledge

Integrated chuck for seamless integration


From 3D printing to injection


3D printed core and cavity after post-processing for production of plastic valves


Strong support for better lead time

GF Machining Solutions’ approach

It is important to understand that AM cannot function without conventional technologies and many post-processes. That’s why GF Machining Solutions offers you a complete solution: a dedicated machine with an integrated chuck as well as the team and the approach to support you in your decision to invest in AM.

5. Additive Manufacturing simulation

8. Post-processes

1. 3D CAD Mold design 3. Thermal simulation and structural analysis

4. Additive Manufacturing preparation

7. Heat treatment

6. Additive Manufacturing of both cavities and cores

Re-engineering for better partsAM: complete process

2. 3D conformal channel design


With our solutions, the process is accessible to everyone and

is economically advantageous. Complexity is not anymore a

cost driver!

The AgieCharmilles AM S 290 Tooling provides solutions by

facilitating the integration of AM into your production pro-

cess chain to produce inserts and hybrid parts; facilitate in-

sert post-processing; and rework build platforms.

Our great strengths are our unique multi-technology portfo-

lio and our expertise in industrialized processes, especially

in mold and die. Our research collaborations with renowned

industrial and academic partners around the world directly

benefit our customers.

Customer Services and trainingAs your business evolves, so does its needs, you can

count on GF Machining Solutions for the individually tai-

lored solutions to enhance your operational excellence.

We help you keep pace with the continuously changing

business and market environments and outperform your

competitors. Optimize your uptime with original spare

parts, expert technical support and preventive and ad-

vanced services. Increase your productivity, motivate

your employees, make true experts of your machine op-

erators, and achieve better machining results with our

training programs.

One single solutions provider

Knowledge of the industry Software integration developmentAn AM team to advise you

throughout the production chain

Milling Customer Services

Laser Additive Manufacturing

Tooling AutomationSpindles Wire cutting Die sinking Hole drilling


Master AM with the best partner

Post-processing

With GF Machining Solutions, you have the opportunity to

partner with a manufacturer of multiple technologies that

manages to make them compatible with each other.

Combining the AM S 290 Tooling and—for example—

a Mikron MILL S 400 U Milling machine is the most efficient

option if you want to build parts with a perfect surface finish.

The future is in complete solutions combining performant

technologies in an efficient way, and GF Machining Solutions

is your partner on the path to the future. And—just as we

have pioneered the Automation of traditional machining

technologies—we are blazing a path for AM Automation.

Don’t compromise; choose the AM S 290 Tooling.

Industry 4.0AM is completely integrated into the concept of Industry 4.0 and the need to optimize

production processes with intelligent use of information. 3D printing and the ma-

chines that enable it are part of a larger puzzle consisting of creation, simulation and

post-processing stages. GF Machining Solutions collaborates with EOS and other

partners to both connect all the stages and make them complementary. With excellent

transfer and intelligent use of information, we optimize the entire process and the

whole “software chain”.

Milling Laser texturing

In mold and die as well as other applications in various segments, GF Machining Solutions is at the forefront of efficiently blending traditional and new manufacturing technologies by optimizing parts and process flow and improving data flow and systems connectivity.

Wire-cutting EDM


Technical specifications

AM S 290 Tooling

MachineBuilding volume mm (in) 250 x 250 x 269 (9.85 x 9.85 x 10.59)Laser type Yb-fibre laser; 400 WPrecision optics F-theta lens; high-speed scannerScan speed Up to 7.0 m/s (23 ft./sec)Focus diameter µm 100Power supply A 32Power consumption kW Max. 8.5 / typical 3.2Nitrogen generator IntegratedCompressed air supply 7000 hPa; 20 m3/h (102 psi; 706 ft3/h)Argon supply 4000 hPa; 100 l/minMinimum Argon purity: 99.996% Argon 4.6Integrated chuck ** System 3R MacroMagnum

Dimensions *System mm (in) 2500 x 1300 x 2190 (98.4 x 51.2 x 86.2)Recommanded installation space mm (in) Min. 4800 x 3600 x 2900 (189 x 142 x 114)Weight kg (lbs) Approx. 1250 (2756)

Data preparationSoftware EOS RP-Tools; EOSTATE; EOSPRINT; Materialise Magics RP with SG+

and further modulesCAD interface STL Optional: converter for all standards formatsNetwork Ethernet

* Width x depth x height ** Optional: Erowa PowerChuck P

1565 / 61.61’’

670/ 26.38’’

2185

/ 8

6.02

’’

1665

/ 6

5.55

’’

2010

/ 7

9.13

’’

1725 / 67.91’’

1310 / 51.57’’

300

11.8

1’’

670

/ 26

.38’

’

800

/ 31

.5’’

670 / 26.38’’

50019.68’’

50019.68’’



EDM (electrical discharge machining)AgieCharmilles wire-cutting, die-sinking

and hole-drilling machines

For over 60 years we have been at the forefront of every EDM develop-

ment: designing and refining the EDM process and building machine

tools that deliver peerless part accuracies, surface finishes, cutting

speeds and process reliability. Today, our AgieCharmilles wire-cut-

ting, die-sinking and hole-drilling machines are recognized through-

out the world as the best in the business. Our continuous research and

development in digital generator technology, control systems and in-

tegrated Automation systems are evidence of our commitment to

keeping your EDM operations on the leading edge of technology.

MillingMikron MILL S (high-speed Milling), Mikron MILL P (high-

performance Milling) and Mikron MILL E (high-efficiency Milling)

Customers operating in the mold, tool and die and precision compo-

nent manufacturing sectors stake their reputations on being able to

quickly and cost-competitively meet their customers’ demands.

That’s why they invest in GF Mikron machines. Incorporating the lat-

est and most advanced technologies and premium-performance

components, Mikron MILL S, Mikron MILL P and Mikron MILL E ma-

chines help you increase your production capabilities and improve

your productivity. Designed and built for speed, accuracy and reli-

ability, the machines, like you, are proven performers.

Liechti dedicated aerospace and energy machining centers

Aerospace and power generation turbine manufacturers increas-

ingly turn to Liechti dedicated five- and six-axis machining centers

to machine complex, high-precision airfoils on blades, disks, blings,

blisks/IBRs and impellers. It’s easy to see why because these ma-

chines, with their specific profile machining technology, specialized

CAD/CAM software and engineering competence for ultra-dynamic

machining in titanium, Inconel, nimonic, titanium-aluminide and

high-alloy steels, yield productivity gains as much as 30 percent,

thanks to reduced machining times. In the globally competitive aero-

space and power generation manufacturing sector, that’s definitely

worth shouting about.

Step-Tec Spindles

At the heart of every GF Mikron machining center is high-performance

Step-Tec Spindle. Step-Tec Spindles are essential core components of

our machining centers. Highly accurate and thermally stable Step-Tec

Spindles ensure that our machines can handle everything from

heavy-duty roughing to fine-finishing operations.

Tooling and AutomationSystem 3R Tooling, Automation and software

Productivity is the key to manufacturing success, and automating a

manufacturing process is a proven method of increasing its efficiency,

effectiveness, quality and reliability. System 3R’s integrated Tooling,

Automation and software solutions ranging from simple workpiece

pallet and electrode changers through to flexible manufacturing and

robot handling systems are guaranteed to help you increase their

competitive advantage.

LaserAgieCharmilles Laser texturing machines

Laser texturing is a fully-digitized surface engineering process that

has huge potential. The technology enables precise 2D and 3D tex-

tures or engravings to be machined accurately and directly onto

complex parts or molds to improve and alter their aesthetic appeal,

functionality and performance. The process is infinitely repeatable

and offers many distinct environmental and economic advantages

over conventional texturing processes.

Laser Additive Manufacturing (AM)

GF Machining Solutions has partnered with EOS, the global leader

for high-end AM solutions, to integrate this innovative technology

and further develop it into its current solutions to fully benefit the

mold industry, by focusing on injection efficiency: optimized cooling

design to reduce cycle time, lower energy consumption, higher qual-

ity of plastic parts.

Customer ServicesOperations Support, Machine Support and Business Support

To help you get the most and the best from your machine tools and

equipment, we offer three levels of support. Operations Support cov-

ers our range of original wear parts and certified consumables (EDM

wires, filters, resins, electrodes etc.) to ensure that your machines

are performing at the highest levels. Machine Support maximizes,

through our best-in-class technical support, preventive services and

quality spare parts, your machine tool uptime. Business Support is

designed to help you make a real step-change in your productivity

and performance with solutions tailored to your specific needs.


At a glanceWe enable our customers to run their businesses efficiently and effectively by offering innovative Milling, EDM, Laser, Additive Manufacturing, Spindle, Tooling and Automation solutions. A comprehensive package of Customer Services completes our proposition.

www.gfms.com

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agiecharmilles am s 290 tooling - gf machining … agiecharmilles am s 290 tooling gf machining ......

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