GF Machining Solutions

AgieCharmilles

FORM P 350
FORM P 600
FORM P 900
GF Machining Solutions : all about you
When 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.

Passion for
Precision

2 AgieCharmilles FORM P 350 / 600 / 900

Contents Mechanical construction
AC FORM HMI
Generator
4
6
8
Autonomy and flexibility 10
GF Machining Solutions 18

Perfect results at your fingertips

The ergonomics of GF Machining Solutions’ new AC  FORM
human-machine interface (HMI) put customers in the driver’s
seat by making die-sinking EDM an intuitive, easy-to-learn
and easy-to-use process. That means greater autonomy over
your processes, higher efficiency, improved process reliabil-
ity and accelerated performance. The standardized working
environment created by the AC FORM HMI makes it easy to
achieve perfect machining results.
Mechanical construction

Compact and rigid

mechanical concept

linear glass scale encoder motor

(scale resolution : 50 nm)

CNC order

Checking the position

(linear glass scale) Movement of the axis
(encoder motor)

Robust mechanical concept Linear glass scales : lifetime accuracy

The construction as a short C frame and the oversized cast- To obtain reliable positioning accuracy, only linear glass
ing guarantee mechanical stability and precision throughout scales are effective. They eliminate all the classic errors,
the life of the machine. The weight of the part and the volume such as backlash, expansion and wear effects. The axis
of the dielectric have no effect. In addition, the robustness of servo control system developed by GF Machining Solutions
the machine absorbs all the machining forces to maintain a is a closed loop measurement solution designed to provide
precise gap between the part and the electrode. infallible accuracy, whatever the travel. It makes periodic
maintenance and calibration operations unnecessary.

4 AgieCharmilles FORM P 350 / 600 / 900

 Exceptional
efficiency
The FORM P 350, FORM P 600 and FORM P 900
combine productivity and flexibility

5 AgieCharmilles FORM P 350 / 600 / 900

AC FORM HMI

Faster control,
in complete security
Dynamic manufacturing process Maximize productive time
The development of AC FORM human-machine interface (HMI) Due to the necessity of maximizing productive time,
is based on a study carried out with numerous mold makers in the AC FORM HMI brings new solutions :
order to streamline the mold-making technique. The organi- • Part Express allows interruption of an operation
zation and layout of screens are a direct development of the so that an urgent job can be inserted.
information taken from this study. This user-friendliness, • Job List organizes the order of jobs according
which has made GF Machining Solutions interfaces so suc- to manufacturing priorities.
cessful, has not only been maintained but has been developed
even further to benefit the mold maker’s task.
4 | In

1 | Out

3 | Out

2 | In

6 AgieCharmilles FORM P 350 / 600 / 900

 e-Doc Automatic CAD/CAM link
The FORM P 350/600/900 range incorporates new online The different EDM machining sequences are
help to allow the operator to find relevant information as automatically integrated into AC FORM HMI.
quickly as possible. This occurs via simplified access to
help menus, by having a clearly organized navigation in- Platform : Windows
terface, that is more user-friendly and easy to grasp, and • Integral PC
including search by key words or user index. Machining • Touch screen
examples are produced as hard copy, presented in a suc- • CD-ROM drive
cinct manner. • USB port
• Network connection
They are called up by using the online help system, so
that implementation of a machining process can be fol-
lowed stage by stage. More than additional descriptive
documentation, e-Doc allows a genuine knowledge
transfer for the benefit of the operator, enabling him to
improve his knowledge continuously, while reducing
working days lost to training.

Flexible work Measurement of Electrodes designed Machining under Control of work SMS notification
organization essential offsets under AC FORM HMI AC FORM HMI high executed under All information related
AC FORM HMI offers you and positions during offer ideal undersize and surveillance, with AC FORM HMI to machining can be
job creation whether on work preparation : the streamline the number of Systems EXPERT automatically creates transmitted directly to
the FORM P 350/600/900 measurements made electrodes necessary for automated protection, a report after each the operator via SMS.
machine or on a PC and on a pre-measurement machining. guarantees you results machining session. The
allows you to organize terminal can be used at the height of your operator can access it via
them according to your directly by AC FORM HMI. requirements. the network or directly
priorities on the machine. on the machine.

Interactive graphical assistance 2D/3D machining cycles

All operations, such as measurement, machining or cavity-
positioning cycles, are illustrated by graphics/icons, allowing
the operator to understand intuitively and spontaneously.

DOWN ORB ANGUL EXPAN

Measurement cycles

VECT CYLINDRE DIAG SPHERE

SPHERE

ISOGAP CONE CONE HELIC

CONE

7 AgieCharmilles FORM P 350 / 600 / 900

Generator

Flexibility and power

guarantee reliable results
The FORM P 350, FORM P 600 and FORM P 900 sinker
spark erosion machines are fitted with an Intelligent
Speed Power Generator (ISPG) which, using patented
technologies, establishes new standards in surface
quality, material removal and accuracy of form.
Electrode wear is reduced in all machining operations,
from roughing to finishing, with copper or graphite
electrodes. Productivity shows an average increase of
30 percent, and can even reach 100 percent for pre-
milled forms. Even in the presence of deep, narrow
cavities, with poor flushing conditions, a 50 percent
increase in erosion speed can be obtained with no
increase in electrode wear.

Predictive planetary erosion Mastery of spark generators

With the Predictive Learning System (PLS), the erosion con- The ISPG generator yields distinctly higher removal rates on
ditions for orbital movements are continuously recorded and average than other products, whether it is machining blades,
analyzed. When there is a deviation, the planetary erosion conical shapes or pre-milled cavities, all of which are machining
process is thus optimized one step after the other. The cavi- challenges that can be resolved only with electro erosion. [3]
ties are then made quickly and accurately. [1]

Small, deep cavities Controlled process

The High Velocity Pulsation (HVP) unit allows efficient cavity Using perfected algorithms reacting more quickly, while or-
cleaning by rapid retraction with extreme reaction time and ganizing the electro erosion process safely even for Adap-
by smooth re-entry. The electrodes are moved rapidly during tive Current Control (ACC) and Adaptive Current Optimization
the return movement, with an extremely short reaction time, (ACO) high removal rates, productivity is increased. [4]
creating an action that yields good flushing conditions and,
for small deep cavities, guarantees that optimum erosion re-
sults are obtained. [2]

1 2
>>>

3 4

8 AgieCharmilles FORM P 350 / 600 / 900

The surface finish quality Large surfaces, no problem
The SF module allows excellent surface finish qualities to be Dynamic acceleration and adaptively controlled lift move-
obtained notably during finish machining and this can be ments allow optimum erosion results, even with large areas,
done with most conductive materials. whereas electrode return movements stop uniformly.

Lowest-wear EDM
The iQ (innovative Quality) technology developed by GF Machining Solutions is available for the FORM P 350,
FORM P 600 and FORM P 900. The iQ technology allows wear-free EDM with graphite and copper electrodes,
reducing the number of electrodes and corresponding costs and guaranteeing the highest accuracy of form.

Part material : Steel 1.2343 Part material : Steel 1.2343

Electrode material : Graphite R8710 Electrode material : Copper
Number of electrodes : 2 Under measure : 0.56 mm
Number of simple forms : 7 Machining depth : 20 mm
Machining depth : 9 mm Roughness : VDI 26, Ra 1.8 μm
Roughness : VDI 19, Ra 0.9 µm Result with iQ technology (total time) : 5 h 21 min.
Electric discharge machining time : 88 minutes Reduction in wear : from 20 % to 90 %
Average linear wear : 7 μm

9 AgieCharmilles FORM P 350 / 600 / 900

Autonomy and flexibility

Configurable
performance potential
High autonomy and reduction in dead time Integrated tool changer (option)
The FORM  P 350, FORM  P 600 and FORM  P 900 can be The FORM P 900 can be equipped with a tool changer inte-
equipped with integrated tool changers, allowing them to grated into the machining zone to keep machine dimensions
work for long periods without surveillance. These linear to a strict minimum. This changer is available with a capac-
changers allow satisfactory autonomy for work requiring a ity of 10 to 20 positions, installed on the left or right side of
smaller number of tools. the machining zone.

10 AgieCharmilles FORM P 350 / 600 / 900

Remote control menus adapted to operator tasks Get on the fast track to superior quality
To allow the operator to adapt the remote control to the GF Machining Solutions eTracking software platform, linked
manual task at hand, a menu is provided for configuring the with the computer numerical control (CNC) of EDM ma-
icons displayed on the remote control display. In addition of chines, help trim costs by reducing the number of rejected
standard icons, this menu allows the operator to define parts and focusing on post-machining control of suspect
semi-automatic movements or specific measuring cycles parts. Our eTracking software helps you establish standard
during the manual process. machining methodology from the start, lays a foundation for
machining quality, and creates a data record for certifica-
This is one of many AC FORM HMI features that put greater tion of quality production.
flexibility and efficiency at the operator’s fingertips.

Renishaw probe Accura-C, the best high-performance axis on the market

To ensure positioning precision, an optical transmission It is not unusual to be confronted by machining where the elec-
probe can be managed by the FORM P 350/600/900. Mea- trodes are incorrectly located, even by such a distance that
surement allows dimensional inspection of machined cavi- maintaining their position or stability during machining be-
ties as well as the taking of references of the part, without comes problematic. Pulsation-induced movements in a liquid
having to remove it, thus saving a considerable amount of (dielectric) medium generate lateral forces (flexural or rota-
time. Furthermore, a measurement report is automatically tional) on the electrode, which must be resisted by the C-axis.
generated by AC  FORM  HMI enabling rigorous checking Thanks to its very robust design, the Accura-C allows very high
and monitoring. moments of inertia to be absorbed, up to 5000 kgcm².

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Autonomy and flexibility

Configurable
performance potential
Increased autonomy without manual intervention
Manufacture of a mold often requires a large number of
electrodes whose spark erosion time can vary noticeably
from one cavity to another. The FORM P 350/600 machines
have a new rotary changer which offer a large storage
capacity for up to 160 electrodes. A double gripper clamp
reduces unnecessary movements, notably speeding up
the loading process.

Aim : 7,000 hours of EDM per year

Autonomous cell management maximizes machine time,
which can now be increased from 2,500 hours on average,
to close to 7,000 hours per year. Due to importing CAD/CAM
data into the machine operator’s AC FORM HMI, taking refer-
ences, as well as optimizing tool changer cycles and flexible
machining programming, results are backed up while allow-
ing continuous production.

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Record productivity Machining flexibility and reliability of work results
This cell-management system expands and supplements Thanks to AC FORM HMI’s integral automation of machining
the practicality of AC  FORM  HMI. Quasi-total autonomy of sequences, as well as the design and functionality of Part
each cell radically optimizes machine time while simulta- Express, productive time is maximized, while still allowing
neously increasing operator comfort and eliminating risk of urgent work to be inserted easily. End-to-end reliability of
errors. Workshop productivity beats all records. the process is assured.

13 AgieCharmilles FORM P 350 / 600 / 900

Technical Data

FORM P 350 FORM P 600 FORM P 900

FORM P 350 FORM P 600 FORM P 900

Machine
Architecture C-frame/Fixed table/Drop tank
Dimensions (*) mm (in) 1900 x 1690 x 2398 2265 x 2110 x 2780 2970 x 3100 x 3320
(74.80 x 66.53 x 94.4) (89.17 x 83.07 x 109.45) (116.93 x 122.05 x 130.71)
Total weight (without dielectric) kg (lbs) 2800 (6173) 4500 (9920) 7000 (15432)
Floor space (**) mm (in) 1900 x 1690 3040 x 2830 2970 x 3100
(74.80 x 66.53) (119.68 x 111.42) (116.93 x 122.05)
Complies with “Machines, 89/392/CEE 89/392/CEE 89/392/CEE
Safety and Health” directive
Complies with “Electromagnetic 89/336/CEE 89/336/CEE 89/336/CEE
Compatibility” directive

X, Y, Z axes
X, Y, Z travel (*) 350 x 250 x 300 600 x 400 x 450 900 x 700 x 500
mm (in) (13.78 x 9.84 x 11.81) (23.62 x 15.75 x 17.72) (35.43 x 27.56 x 19.68)
X, Y, axes speed m/min 6 (19.7) 6 (19.7) 6 (19.7)
(ft/min)
Z axis speed m/min 15 (49.2) 10 (32.8) 7.5 (24.6)
(ft/min)
Positioning resolution X, Y, Z µm (in) 0.05 (0.000002) 0.05 (0.000002) 0.05 (0.000002)

Work area
Worktank size (*) mm (in) 790 x 530 x 350 1220 x 870 x 470 1814 x 1215 x 700
(31.1 x 20.87 x 13.78) (48.03 x 34.25 x 18.50) (71.42 x 47.83 x 27.56)
Extendable in X
Worktable size (**) mm (in) 500 x 400 750 x 600 1100 x 900
(19.68 x 15.75) (29.53 x 23.62) (43.31 x 35.43)
Distance floor to clamping level mm (in) 1000 (39.37) 1000 (39.37) 1100 (43.31)
Min./Max. distance between table and chuck mm (in) 150/450 (5.91/17.72) 150/600 (5.91/23.62) 322/822 (12.68/32.36)

Workpiece and electrode

Max. electrode weight kg (lbs) 50 (110.23) 50 (110.23) 50 (110.23)
Max. workpiece weight kg (lbs) 500 (1102.31) 1600 (3527.40) 3000 (6613.86)
Max. workpiece dimensions (*) mm (in) 790 x 530 x 275 1220 x 870 x 470 1814 x 1215 x 600
(31.1 x 20.87 x 10.83) (48.03 x 34.25 x 18.50) (71.42 x 47.83 x 23.62)
Bath level (programmable) mm (in) 100 - 325 (3.94 - 12.8) 100 - 450 (3.94 - 17.72) 100 - 630 (3.94 - 24.80)
* Width x depth x height ** Width x depth

14 AgieCharmilles FORM P 350 / 600 / 900

 FORM P 350 FORM P 600 FORM P 900

Dielectric unit
Capacity l (gal) 410 (108.65) 700 (184.8) 2500 (662.5)
Number of filter elements and type 4 Paper filter 6 Paper filter 8 Paper filter

Generator
Generator type ISPG ISPG ISPG
Max. machining current (option) A 80 (140) 80 (140) 80 (140)
Best surface finish µm Ra 0.08 0.08 0.1

Electrical supply Standard

Standard voltage 3 x 380V/400V ± 10%. 50/60Hz (50Hz standard)

Cooling
Heat exchanger dielectricum/water Integrated Integrated Integrated
for the dielectricum

Control Unit
Operating system Windows
Data input 15” LCD screen, mouse or touch screen, keyboard and Remote control
User interface AC FORM HMI
Expert systems TECFORM
Console support Movable on cabinet or on foot

Modules
Z axis (15 m/min) Standard — Option
Linear tool changer (*) 4 (Std. tooling) 6 (Std. tooling) 10 (Std. tooling) Left
5 (Combi tooling) 6 (Combi tooling) 10 (Std. tooling) Right
Rotary tool changer (*) 16-80 pos. (Std. tooling) 16-80 pos. (Std. tooling) —
32-160 pos. 32-160 pos. —
(Combi tooling) (Combi tooling)
Flushing Injections 2 Laterals, 1 through the piece, 1 through the electrode, 1 suction
Heat exchanger air/water for the cabinet Option Option Option
Multicavity flushing 6 outputs Option Option Option
3D probe measuring system Option Option Option
for Erowa or System 3R
iQ graphite and copper module Standard Standard Standard
for reduction of electrodes’ wear

Standard C-Axis (*)

Max. electrode weight on automatic chuck kg (lbs) 50 (110.23) 50 (110.23) 50 (110.23)
Rotation speed rpm 0-100 0-100 0-100
Max. inertia kgcm2 2000 (683) 2000 (683) 2000 (683)
(lbsin2)

Accura C-Axis (*)

Max. electrode weight on automatic chuck kg (lbs) 50 (110.23) 50 (110.23) 50 (110.23)
Rotation speed rpm 0-100 0-100 0-100
Max. inertia kgcm2 5000 (1700) 5000 (1700) 5000 (1700)
(lbsin2)
* Option

15 AgieCharmilles FORM P 350 / 600 / 900

 FORM P 350

FORM P 600

16 AgieCharmilles FORM P 350 / 600 / 900

1605/63’’
1240/48.82’’
1900/74.80’’

2265/89.17’’
660/25.98’’ 605/23.82’’

660/25.98’’ 605/23.81’’
1020/40.16’’ 510/20.1’’
1690/66.53’’
1000/39.37’’
2110/83.07’’

600/23.62’’

125 125 125 125 400/15.75’’

75 125 125
500/19.68’’

750/29.53’’
1800/70.87’’
2100/82.68’’
3’’ 5’’ 5’’
2397.5/94.39’’
1800/70.87’’
2332/92’’
5’’ 5’’ 5’’ 5’’ 2780/109’’
 3318.5/130.65’’
2713.5/106.83’’
1905/75’’

1102/43.39’’
FORM P 900

2297/90.43’’
2100/82.68’’

727/28.62’’
1020/40.16’’
3102/122.13’’

47.83’’
3.5’’ 28.35’’
35.43’’
1215

720
900

180

7’’
90
1355/53.35’’

1300/51.18’’
1814/71.42’’

320/12.6’’
2204/86.77’’ 753/29.65’’
2968.5/116.87’’ 605/23.82’’
3573.5/140.69’’

17 AgieCharmilles FORM P 350 / 600 / 900

GF Machining Solutions

EDM (electrical discharge machining) Milling

AgieCharmilles wire-cutting, die-sinking Mikron high-speed (HSM), high-performance (HPM)
and hole-drilling machines and high-efficiency (HEM) Milling centers
For over 60 years we have been at the forefront of every EDM develop- Customers operating in the mold, tool and die and precision compo-
ment: designing and refining the EDM process and building machine nent manufacturing sectors stake their reputations on being able to
tools that deliver peerless part accuracies, surface finishes, cutting quickly and cost-competitively meet their customers’ demands.
speeds and process reliability. Today, our AgieCharmilles wire-cut- That’s why they invest in GF Mikron machines. Incorporating the lat-
ting, die-sinking and hole-drilling machines are recognized through- est and most advanced technologies and premium-performance
out the world as the best in the business. Our continuous research and components, Mikron HSM, HPM and HEM machines help you in-
development in digital generator technology, control systems and in- crease your production capabilities and improve your productivity.
tegrated Automation systems are evidence of our commitment to Designed and built for speed, accuracy and reliability, the machines,
keeping your EDM operations on the leading edge of technology. 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-
Laser chines, with their specific profile machining technology, specialized
AgieCharmilles Laser texturing machines CAD/CAM software and engineering competence for ultra-dynamic
Laser texturing is a fully-digitized surface engineering process that machining in titanium, Inconel, nimonic, titanium-aluminide and
has huge potential. The technology enables precise 2D and 3D tex- high-alloy steels, yield productivity gains as much as 30 percent,
tures or engravings to be machined accurately and directly onto thanks to reduced machining times. In the globally competitive aero-
complex parts or molds to improve and alter their aesthetic appeal, space and power generation manufacturing sector, that’s definitely
functionality and performance. The process is infinitely repeatable worth shouting about.
and offers many distinct environmental and economic advantages
over conventional texturing processes. Step-Tec Spindles
At the heart of every GF Mikron machining center is high-performance
Laser Additive Manufacturing (AM) Step-Tec Spindle. Step-Tec Spindles are essential core components of
GF Machining Solutions has partnered with EOS, the global leader our machining centers. Highly accurate and thermally stable Step-Tec
for high-end AM solutions, to integrate this innovative technology Spindles ensure that our machines can handle everything from
and further develop it into its current solutions to fully benefit the heavy-duty roughing to fine-finishing operations.
mold industry, by focusing on injection efficiency: optimized cooling
design to reduce cycle time, lower energy consumption, higher qual-
ity of plastic parts.

Customer Services
Operations Support, Machine Support and Business Support
To help you get the most and the best from your machine tools and
Tooling and Automation equipment, we offer three levels of support. Operations Support cov-
System 3R Tooling, Automation and software ers our range of original wear parts and certified consumables (EDM
Productivity is the key to manufacturing success, and automating a wires, filters, resins, electrodes etc.) to ensure that your machines
manufacturing process is a proven method of increasing its efficiency, are performing at the highest levels. Machine Support maximizes,
effectiveness, quality and reliability. System 3R’s integrated Tooling, through our best-in-class technical support, preventive services and
Automation and software solutions ranging from simple workpiece quality spare parts, your machine tool uptime. Business Support is
pallet and electrode changers through to flexible manufacturing and designed to help you make a real step-change in your productivity
robot handling systems are guaranteed to help you increase their and performance with solutions tailored to your specific needs.
competitive advantage.

18 AgieCharmilles FORM P 350 / 600 / 900

19 AgieCharmilles FORM P 350 / 600 / 900
 259.805.472–EN
GF Machining Solutions

At a glance
We 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

The technical data and illustrations are not binding.

© GF Machining Solutions Management SA, 2017

They are not warranted characteristics and are

subject to change.