Medical Machining Applications and More

GF Machining Solutions (Lincolnshire, IL) offers precision, performance and efficiency EDM systems for medical machining applications with the AgieCharmilles CUT 20 P wire and FORM 20iRTC sinker EDMs. On the wire EDM side, the AgieCharmilles CUT 20 P delivers speed and increased performance to medical applications such as cannula tube machining. Accommodating wire diameters from 0.006 in to 0.12 in, the machine comes standard with 0.10 in wire guides, while 0.006 in, 0.008 in and 0.012 in wire guides are also available. The machine’s low-maintenance, highly reliable wire threading system boasts autonomy and reduces operating costs.

Featuring X-, Y- and Z-axis travels of 13.77 in x 9.84 in x 10 in, respectively, the CUT 20 P can accommodate maximum workpiece dimensions of 35.4 in L x 26.7 in W x 9.8 in H. When considering the machine’s fluid bath, the CUT 20 P can hold submerged workpieces weighing up to 960 lb. The machine also achieves taper cuts of ±25 deg over 3.15 in tall. The machine’s Integrated Collision Protection on its X-, Y- and Z-axes prevents any breakage of sensitive parts and costly elements, allowing the operator to work with more confidence during job preparation and execution. Glass scales on the X- and Y-axes ensure exceptional positioning accuracy and highly repeatable results.

Adding to the smart design of the machine’s control is the inclusion of the “Speed” technology package that allows the CUT 20 P to achieve competitive results in terms of precision, time and surface roughness when machining jobs with two to four cuts. The CUT 20 P’s low energy consumption combined with the long working life of the wear parts reduces operating costs and helps to ensure profitability.

The company also offers the AgieCharmilles CUT 200 Sp speed edition wire EDM that provides fast spark-to-spark wire threading, energy efficiency and high productivity when cutting parts of variable heights and offers versatility through its ability to reliably hold tolerances measured in microns in both light and heavy parts. For ensuring high accuracy and speed as well as preventing wire breakage when machining parts with varying heights, the Power Expert smart module on the CUT 200 Sp continuously calculates part thickness, checking injection pressure and adjusting machine power accordingly. The CUT 200 Sp accommodates wire diameters ranging from 0.33 mm to 0.070 mm and can handle part tapers up to 45 deg, regardless of part thickness.

The machine’s digital CC generator enables surface finishes as fine as Ra 0.1 μm and an optional power module can boost cutting speed to 400 mm2/min with an adapted wire. The machine has a drop door to the work area for easy loading of workpieces. Moreover, its small footprint measures just 2,020 mm x 2,201 mm x 2,015 mm, yet has room for ample X-, Y-, Z-, U- and V-axis travels of 350 mm, 220 mm, 220 mm, 350 mm, 220 mm, respectively. To obtain high-positioning precision, the CUT 200 Sp’s axes are fitted with a linear glass scale with absolute coding at a resolution of 50 nm. An optional touch probe allows the user to inspect a finished part before its removal from the worktable, eliminating the need for part inspection with a CMM.

As one of the first sinker EDMs to sport the recently developed AC Form HMI (human machine interface), the AgieCharmilles FORM 20iRTC centers on user friendliness and intuitiveness to significantly shorten the learning curve for beginner EDM operators. The machine excels in burning deep-cavity ribs into mold cores and significantly reduces overall burn times by hours for such parts. The FORM 20iRTC provides the industry’s best price-to-performance ratio and also boasts outstanding connectivity capability, overall enhanced performance and a new modern compact design. The machine meets the cost-effective part production needs of the medical manufacturing industry. As a Windows-based platform, the FORM 20iRTC seamlessly integrates into workshop management systems. Other productivity enhancing features such as eConnect, eSupervision and eTracking further boost machine functionality for process control and outside system connectivity.

Designed with a shop’s valuable floor space in mind, the FORM 20iRTC is the industry’s most compact standard die-sinking EDM, yet provides ample axis travels of 13.78 in x 9.84 in x 9.84 in. Within its space-saving footprint, the machine even includes an integrated four-position linear tool changer. At the heart of the FORM 20 is the proprietary, high-end Intelligent Power Generator (IPG) with built-in quality-boosting and cost-saving intelligence. With every machine pulse, the 70 amp generator on the FORM 20 continuously optimizes the EDM process and dramatically reduces electrode wear as well as provides extremely uniform surface finishes. The machine reliably generates surface finishes of Ra 0.1 micron and radii down to 0.0007 in. Also embedded within the FORM 20 machine is the TECFORM module that eliminates the need for operators to adjust the machine generator parameters.

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As the industry’s most compact die-sinking EDM and one of the most cost efficient for general mold and die applications, the AgieCharmilles FORM 20 die-sinking EDM brings a uniform surface finish quality to part sizes up to 800 mm wide, 551 mm deep and 264 mm high. The machine provides exceptional performance using less power, requires just 3.7 kW/h at full power to continuously optimize the EDM process and dramatically reduce electrode wear.

With an optimum price/performance ratio, the AgieCharmilles DRILL 20 hole drilling EDM perfectly complements wire EDM systems by quickly and precisely processing starter holes in a variety of applications. Applying electrodes that range from 0.15 mm to 3 mm in diameter, the vertical hole-drilling EDM machine easily handles drilling depths up to 200 mm in workpiece materials that include steel, hard metal, aluminum and copper. The machine’s CNC-controlled X, Y and Z-axes with travel paths of 300 mm, 200 mm and 300 mm, respectively, allow for its broad application spectrum, while a variety of programmable touching cycles allow operators to achieve short setup times.

GF Machining Solutions, 560 Bond Street, Lincolnshire, IL 60069-4224, 800-282-1336, Fax: 847-913-5340, gisbert.ledvon@georgfischer.com, www.gfms.com/us.