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New Wire EDMs Designed to Machine Complex Molds

GF Machining Solutions has introduced the AgieCharmilles CUT 200/300 MoldTech series of wire EDMs that meets the specific needs of moldmakers. The machines are equipped with a special bundle of dedicated technical features and capabilities for accurate and efficient machining of highly complex parts with variable surface heights or taper cuts. Such challenging components include those for aluminum extrusion dies and for the aerospace and medical industries.

At the heart of the MoldTech package is the TAPER-EXPERT smart module for cutting highly precise large taper angles with perfect surface finishes. TAPER-EXPERT allows the use of large radius wire guides and soft brass wire, and it compensates in real time for the pivoting point drift in the Z direction when the angle changes. The results are surface finishes of (Ra) 0.2 µm and better angle cuts up to 30 degrees.

With the dedicated onboard AgieCharmilles AC CUT HMI (human-machine interface), the MoldTech machines reduce setup time and improve productivity. The interface is easy to use and provides TAPER-EXPERT ADVANCE, a new taper adjustment function that lets operators fine-tune the CNC parameters and control taper accuracy. Also through the AC CUT HMI, a powerful onboard CAM system called AC OPTICAM 3D seamlessly imports 3D CAD files, including Parasolid and IGES. Users can then bring solid model files into the control, quickly extract all ruled shapes and automatically generate the ISO code for each profile.

Other features in the MoldTech package include a smart threading system called the MULTIJET, a wire-breakage prevention module called POWER-EXPERT and a smart system called SURFACE-EXPERT. The MULTIJET system uses nozzles that can automatically thread start holes as small as 1.5 mm in diameter, even while the machine is in a position to cut tapers of up to 30 degrees.

The POWER-EXPERT smart module continuously calculates part thickness, checks injection pressure and adjusts machine power accordingly to prevent wire breakage and improve accuracy and cutting speed. SURFACE-EXPERT constantly tweaks sparking parameters when cutting parts with abrupt variations in height, which also helps prevent wire breakage.

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GF Machining Solutions

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