At EMO Milano 2021, GF Machining Solutions highlighted EDM technologies designed to help manufacturers increase productivity and accuracy. These die-sinking and wirecutting EDM machines – along with robust solutions that target the mold and die industry – provide operating precision, superb part quality and automated options.

The show marked the unveiling of the new AgieCharmilles CUT P Pro series of wire-cutting EDM machines designed for increased productivity, always available and ideal for every application with the largest technology database. The series includes the CUT P 350 Pro, the 550 Pro and the 800 Pro with robust designs and intuitive HMI as well as several automation options for lightsout operation.

At EMO Milano, GF Machining Solutions also announced the AgieCharmilles CUT X series of wire-cutting EDM machines, featuring new technologies that significantly increase operating precision. They are capable of holding extreme pitch positioning and contouring capabilities for superb part quality. The series includes the CUT X 350 and the CUT X 500 machines.

Particularly for mold makers in microelectronics, telecommunications, medical technology, connectors and optical systems, GF Machining Solutions demonstrated its AgieCharmilles FORM X 600 die-sinking EDM at EMO. The machine delivers positioning accuracy within 1 μm, and general machining accuracy on the workpiece down to 5 μm, combining speed and precision.

The new Uniqua human/machine interface (HMI), available for the CUT P Pro and the CUT X series, capitalizes on more than a century of EDM technology, with optimal functionality and ergonomics in a 19" vertical touchscreen, full keyboard and mouse. It is designed for every skill level, every approach and every user. For the utmost compatibility, Uniqua supports legacy file types from various EDM manufacturers. It also creates, imports, modifies and executes sequential (ISO-based) and object-oriented (dynamic) programs from previous versions of VISION and AC CUT. With offline and at-the-machine programming, ISO-based functionality and object-oriented programming, Uniqua provides a powerful graphic tool with integrated CAM and also ensures compatibility with major CAD/CAM programs.

With Intelligent Power Generator (IPG) technology, CUT P Pro series machines deliver surface finishes as smooth as Ra 0.08 μm and heighten accuracy with integrated thermal regulation that allow to achieve an accuracy of ±2μm.

Linear scales and rotary encoders form a double measuring system that protects the X, Y, Z, U and V axes. In the event of a collision, the system differentiates between the linear and the rotary encoder, and the energy absorber system automatically stops the axes without damage to machine or workpiece. This full protection applies at machine speeds of up to 3m/min.

In the QUADRAX mechanical system of the CUT P Pro series, the table, work tank and dielectric liquid remain stable, and the workpiece does not move, accommodating heavy workpieces. Independent U/V and X/Y axes with equal length (X = U travel; Y = V travel), constant, lower mass and completely independent movement produce large, precise tapered cuts. In addition, the Rhenocast machine base offers lower thermal conductivity and a vibration damping system.

Besides the new HMI Uniqua, machines in the CUT X series are equipped with the new wire circuit. Thanks to the unique twin wire plate, the users can choose between Twin-technology (the main cut being faster with bigger wire, the small corners' finishing with thinner wire), longer autonomy (two identical wires' spools for unattended, longer autonomy) and surface care faster erosion (two wires with identical diameter but different coating, to optimize the speed of the main cut and reduce contamination in finishing passes).

GF Machining Solutions is unique in giving the operator the possibility to work with open or closed guides, thanks to a quick and simple system of interchangeable cartridges. The distance from the guide to the workpiece has been reduced to guarantee the highest accuracy. New X-Technologies in GF Machining Solutions' database place an intense focus on high accuracy, high surface quality and high-speed results. The CUT X features all the latest functionalities of GF Machining Solutions' next generation of wire-cutting EDM machines, like ISPS.

From its generator components to its HMI, mechanical design and automation, the FORM X 600 simplifies precision for highly technical processes involved in mold and component production. The machine’s latest-generation Intelligent Speed Power Generator (ISPG) reduces electrode wear by up to 50% for significant savings in electrode costs. Fewer electrodes also mean fewer electrode changes, which translates to shorter cycle times and reduced downtime.

With the Accura-C high-performance axis to absorb very high moments of inertia during machining, an onboard Renishaw optical probe for dimensional measurements and iQ technology for low-wear EDM with reduced electrode consumption, the FORM X 600 paves the way for new mastery of die and component production.

The FORM X 600 delivers superior mechanical stability and precision across the life of the machine, thanks to its short C-axis construction and oversize cast iron frame for accuracy uncompromised by either part weight or dielectric volume. The machine’s robust construction absorbs all machining forces, maintaining the gap between workpiece and electrode for added precision.