E EXPERIENCE 28 - GF AgieCharmilles US

37
AGIE experience
No 28 January 2007
4. An optimum cutting technology
is selected from «Teccut»
or the technology is retrieved
from «Workmodel»,
a module for repeatedly recurring
jobs.
5. The PCD disk is clamped on
the Agiecut Progress 2.
6. Agiesetup 3D carries out
measurement cycles automatically
with the EDM wire
and the probe. In this way,
the 0-point is determined
exactly as the reference and
the location of the PCD disk
in the ED wire-cutting machine
is fixed
7. The contours are cut with a
full cut using a Berocut
0.25 mm wire.
8. The PCD cutting tips are taken
out as drop-out parts
and the PCD disk is unclamped.
9. The milling cutter shank
made of tungsten is then
clamped horizontally. «Agiesetup
3D» then determines
any possible twisting of C-
axis so that the cutting of
the shank to length will take
place 100 percent in right
angle.
10. The milling cutter shaft is
cut to exactly the required
length with one main cut.
11. In the meantime, the cutting
contour for the tip seats on
the shank is prepared with
Peps.
12. «Scriptfile» makes a direct
transfer of the geometries,
complete with the cutting
technologies, to Agiecut
Progress 2 possible.
13. The shank is clamped vertically
and also plotted with
«Agiesetup 3D», with the
probe in A, B and Z-axis direction
and with the wire in
X and Y-axis direction. In accordance
with the measurement
data determined, the
control system then organises
the machining program
around these values.
14. The symmetrical, tapering
tip seats of the shank are
ED wire cut.
15. The shank is unclamped and
the PCD cutting tips are
applied to the tip seats by
means of induction welding.
16. The now complete milling
cutter is clamped horizontally
on to the Agiecut Progress
2 once again in such a
way that the 2 PCD cutting
tips are aligned horizontally.
The measurement data on
the milling cutter head are
recorded with «Agiesetup
3D» so that the machining
program can align again.
17. The PCD cutting tips receive
their final cutting contour by
means of a taper cut by
Agiecut Progress 2, with
exactly the required angle.
In this connection, 0.05 mm
are left in place for the polishing.
18. As a final step, the PCD cutting
tips are polished with a
diamond lapping machine.
The machining steps can, it is
true, vary somewhat according to
the order, however, they do show
how rationally ED wire cutting
can be employed for the production
of PCD tipped milling cutters.
The absolute highlight in
this connection for Hamilton
Lichfield Ltd. is the «Setup 3D»
function which is employed for
each set-up procedure. Multiplied
over a year, a saving in time
amounting to days results.
The slot milling cutter is checked
once again for contour accuracy, symmetry
and precision on an optical measuring
system.
PCD inserts are inductionwelded into
the tip seats of the shaft.