E EXPERIENCE 28 - GF AgieCharmilles US

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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.
38 AGIE experience No 28 January 2007 Hamilton Lichfield Ltd. The tool data Name Tool material Tool working life EDM time Number of cuts EDM wire type PCD tipped slot milling cutter Shank made of tungsten carbide Cutting tips made of PCD (polycrystalline diamonds) 100 times longer than conventional groove milling cutters 5 minutes for cutting the shaft to length 20 minutes for the two symmetrical, tapering tip seats 5 minutes for PCD cutting tips 1 main cut in each case Berocut 0.25 mm diameter “ The Agiecut Progress 2 is the most versatilely employable machine tool for our application requirement. The Agiesetup 3D function especially has strikingly reduced the set-up times. We would like to thank Hamilton Lichfield Ltd., in particular their Managing Director, Kelvin Bushnell, and Workshop Manager, Kevin Baines, for their kind support and helpful collaboration with this report. ” Kevin Baines, Workshop Manager of Hamilton Lichfield Ltd. Agie Specialist: Max Swinbourne, +GF+ AgieCharmilles Ltd.
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E EXPERIENCE 28 - GF AgieCharmilles US

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