viser l‘excellence et le leadership grâce aux projets ...©sentation imagine...• die sinking...

GF AgieCharmillesRoberto Perez

Innovation, R&D dept.

11 Juin 2013

Viser l‘excellence et le leadership grâce

aux projets européens

GF AgieCharmilles Immagine FOF 2020 212/06/2013

Outline

Introduction, GF Agie Charmilles

Technology and challenges

R&D organisation and collaboration frameworks

Collaborative project example: Fofdation

Conclusion


Activities :

Electroerosion machines (EDM)

Laser texturing machines

High speed milling machines (HSM)

High speed spindles for milling machines

Tooling, Automation, Software

Services and consummables : Agie Charmilles SA

Sales : Agie Charmilles Sales

GF AgieCharmilles

2012 :

• Employees : 2800

• Sales : CHF 850 millions

• CEO : Pascal Boillat

• www.agiecharmilles.com

One Brand. One Promise. Achieve more


Technology: GF AgieCharmilles Laser Highlights

Mechanical concept with 4th et 5th axes as

option

Fiber Laser 20W ou 50W

Automation solution with pallet changer

Specific CNC for Laser machining

Pack Software


3D IGES or DXF files

Import Rhino

Design office

Tool Path + .ALL,.MCL

Example: laser innovations (Mapping + texture)

Maya or Rhino

Mesh file triangle (.STL)

Image Texture ( .TIF,.BMP )

Design office

Rhino

+

GFAC LASER DESIGN

+ Mapping

UV Layout or

Maya

Mesh quad (.OBJ from Maya, UV Layout)

Checker


• Die sinking EDM reproduces on a

metallic workpiece the shape of the tool-

electrode.

• No mechanical contact between the part

and the electrode

• Electrode (+), Pièce (-), dielectric oil :

This configuration minimizes the tool

wear and keeps the shape of the

elctrode throughout the whole process

Die sinking electroerosion


Innovative pieces and Technology….. for standard & micro applications

Main sector involve

Medical instruments, implants,

High precision mould

Watch making

Microelectronics

Micro drilling

Light-emitting diode (LED)

applications.

Micro application

Micro connectors

Micro stamping dies

Micro assembly

Injection moulding


SF Module standard on FORM 1000

• SF Module „Super Finish“

• Generator-extension module for Surface finishes down to Ra 0.05 µm

• The key for autonomous machining of small high accurate cavities with smallest inside radius and finest surface finish.

• Minimum radius

Surface finish Ra 0.05 µm

r = 5 μm


Micro-Mechanics for highest precision

Piece for watch industry

Make impossible, possible !


Micro application < 1mm³


Developed in 1960. The cutting is performed through micro-second

duration sparks from a wire electrode in water dielectric

Cutting process scheme

Wire sparks at work

Wire electroerosion


Precision aspects

• sharp angles

• taper cuts

• circularity

• distances

• parallelism


Typical applications - Carbide

Carbide machining

Micro connectors

Lead frames

Punches and dies

Electronic die

Wire 0.05mm

Geometrical precision +/-1 µm


Surface quality

High surface finish quality to meet today’s and tomorrow’s

manufacturing demands

2.5 1.58 1.26 0.5 0.32 0.2 0.1m Ra

Customer benefit: More flexibility in use.

• - Larger applications field.

- May eliminate the need for subsequent polishing.


Surface integrity

Inconel 718 Ti-6Al-4V

Customer benefits:

Cut 200 is the right machine for industries where safety is critical.

(medical, aerospace) Prevents unexpected fatigue failure.

Programming the right sparking energy = respect the surface integrity

After roughing,

recast layer < 6 µm

Affected layer after the main cut


After 4 finishing

cuts, recast layer

is not visible

Affected layer after 4 skim cuts

Courtesy of Birmingham university



Geometry

PCDThe use of anti-electrolysis generator settings from roughing to last finishing provides a perfect edge integrity while cutting sintered material:

•Tungsten carbide

•PCD

Customer benefits:

Maximize the service life of the

tools produced.

Magnification X1000


R&D EDM major functions and groups

R&D EDM: 120 engineers with key functions:

Innovation (11 engineers)

• New technologies, feasibilities and University research

• System Engineering, Architecture and Technical Portfolio

PMO (Project Management Office)

• Project Management

• Application champions

Automation systems and segmentation

• Automation tools – SW, customer automation projects

• Customised products and applications (complex solutions, automation)

Customer oriented functions and HMI

• HMI Software and SQA

• Application development and testing

Base Development linked with production

• Machine design including Mechanics and electrics

– Includes customer special mechanics and mechanical tests

• RT SW/HW – CNC design

• Generator design and technology base

• R&D development processes (SAP, BOM, PDM)

1

3

2

4

5


The two processes overlap against the axis of Technology Maturity Levels (TML)

EU collaborative research helps to reinforce Product Development Phase

through strong link with customers and adequate exploitation plans.

Technology

TXFR Period

Maturity

Product Development

(Engineering)

Technology Planning

PDP

TD

TML1

Technology Concept and/or

Application Formulated

TML2

R&D Proof of Concept

TML3

Individual System

Component Validated

TML4

Technology Prototyped in Operational Environment

TML5

Technology Qualified

through Client Operations

Technology and Product Development Processes are closely linked

UniversitiesTechnology Development

(Research)

Suppliers

Key customersPartner industries


Collaborations for Innovation

And more… long term relationship and preferred partnership with most recognized Swiss and European research institutes for materials and production technologies, thanks to EU networking projects.

http://www.bham.ac.uk/

http://www.unige.ch/

http://hepia.hesge.ch/fr/nc/accueil/


Example : Towards the smart-machine – The Fofdation project ultimate goal

Industrial concerns• Global demand fluctuation • Greater product variability & quality (customer centric)• Productivity & time-to-market pressures• Growing complexity of machines & processes • Triple bottom-line responsibility

(economic, social, environmental)NC Program GenerationSimulationValidation

Optimisation

Our visionimagine...• All the factories sharing data seamlessly to design and produce

anywhere• All the people building a green planet• No pollution, no waste to clean, no smoke to destroy• The factory of the Future enabling a sustainable world and fair

trade


Progress beyond the state of the art in the new concept around smart-machines

Top-down approach, disparate andincompatibles IT islands, lack ofinteroperability, point solution…

Holistic & bi-directional approach, end-to-end digitization,convergent and science-based process, interoperable ITmodules, plug-and-produce IT environment, lifecyclemanagement, sustainability monitoring,… all integrated !

Today, Tomorrow, powered by FOFdation …


GFAC application: simplified smart CNC

Smart CNC: Introduction of complete geometries so to be able to

optimise the machining process following changing conditions


Smart Management System: eTracking concept & architecture

Concept A new e-communication and control platform :

• Connected to the machine: smart execution activities

• Placed in the office: supervision and management activities

Functionalities to cover:

• Activities Before, during, and after machining

Architecture

Track & Trace level

Mode execution

Workshop supervision level

Mode management

eSupervisioneSupervision

m/c 1 m/c 2

Data Base

Global customer network level

Top level management


Defining a model and communication channel to

close the loop with CADCAM

Machining Histograms, Energy cons.

Compare

Part #1

Check if part is correct

Detect where problems occur

Identify critical factors in part design

Assess energy consumption

Part signature

Reference

DataBase

(History

& Traceability)

Machine level smartness

3D CAD

model

ClassCad

Step-NC

model


eTracking aero – Part monitoring

Monitoring of process signals correlated to axes position: quality

assurance

Préparation d’une piècePréparation d’une pièce

Machining process

KPI

Machining path


eTracking – Shop monitoring

Dashboard of machine of the workshop



Associate users to each machine of workshop



Define periods when user can receive email



Define machine states (per user) that trigger sending email and states

contained in email


Conclusion

GF Agie Charmilles works in a highly dynamic context requiring

multiple competencies and reduced time to market and

productivity

Collaborative projects are crucial to maintain level of excellence

through networking, access to leading edge resources, active

partnership with suppliers and customers: from sequential to

parallel development process

Fofdation project has helped to orient, develop and industrialise

our R&D efforts in the perspective of future manufacturing

systems

Open Innovation : Not all smart people work for us

(Henry Chesbrough)

viser l‘excellence et le leadership grâce aux projets ...©sentation imagine...• die sinking...

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