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Innovative surface Innovative surface Innovative surface Innovative surface GF Machining SolutionsGF Machining SolutionsGF Machining SolutionsGF Machining Solutions
Innovative surface Innovative surface Innovative surface Innovative surface by EDM for the by EDM for the by EDM for the by EDM for the mould industrymould industrymould industrymould industry
EDM-MSS F. Goudard / 24.04.2014
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Table of Contents
SURFACE QUALITY IMPROVMENTS
EDM TECHNOLOGY
APPLICATION
2
INNOVATIONS
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APPLICATIONAPPLICATIONAPPLICATIONAPPLICATIONGF Machining Solutions
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Customers worldwide depend on our technologies, application know-how and process expertise in our five key market segments.
Aerospace and Aeronautics Automotiv e Medical and Dental
Market segmentsMarket segmentsMarket segmentsMarket segments
ICT Electronic components
GF Machining Solutions, company presentation | 20144
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Market segmentsMarket segmentsMarket segmentsMarket segmentsAerospace and AeronauticsAerospace and AeronauticsAerospace and AeronauticsAerospace and Aeronautics
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Market segmentsMarket segmentsMarket segmentsMarket segmentsICTICTICTICT
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EDM TECHNOLOGYEDM TECHNOLOGYEDM TECHNOLOGYEDM TECHNOLOGYGF Machining Solutions
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EDM technologyEDM technologyEDM technologyEDM technology
The principle of EDM (Electrical Discharge Machining) is simple.
The workpiece and tool are placed in the work position so that they do not touch.
A gap remains, filled by the A gap remains, filled by the "dielectric." The workpiece and tool are connected to a direct current power source via a cable.
A switch is inserted in the connection. When closed, an electrical current is set up between the workpiece and tool
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EDM methodEDM methodEDM methodEDM method
In die-sinking EDM, the required shape is formed negatively in the metal with a three-dimensional electrode. By superimposed movements in the main axes x, y, c, z, the most varied shapes, indentations and cavities are created, such as cannot be achieved by any other machining system.
Die-Sinking
machining system.
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FORM 2000 HP
FORM 1000
FORM 2000 VHP
FORM products FORM products FORM products FORM products P
rice
/ Per
form
ance
FORM 3000 HP
FORM 3000 VHP
220 x 150 350 x 250 600 x 400 700 x 500 900 x 700
FORM 400FORM 200 FORM 300
FORM 200 mS
Size
XY travels
FORM 200 Sp FORM 300 Sp
FORM 20 FORM 30
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FORM 200/ 300/ 400FORM 200/ 300/ 400FORM 200/ 300/ 400FORM 200/ 300/ 400
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EDM methodEDM methodEDM methodEDM method
In wire-cutting EDM, the required shape is "computer" stored and passed as comprehensible codes to the machine, which then cuts the shape independently by guiding the wire along the given stretch.
Wire-Cutting
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CUT ProductsCUT ProductsCUT ProductsCUT ProductsP
rice
/ Per
form
ance
CUT 1000 / CUT 1000 OilTech
CUT 3000 SCUT 2000 S / CUT 2000 OilTech
CUT 200 mS CUT 300 mS
Size
XY travels220 x 160 350 x 250 500 x 350 800 x 550
CUT 20 P CUT 30 P
CUT 400 Sp PROGRESS VP2 PROGRESS VP3 PROGRESS VP4 CUT 200 Sp CUT 300 Sp
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CUT 2000 S / CUT 3000 S CUT 2000 S / CUT 3000 S CUT 2000 S / CUT 3000 S CUT 2000 S / CUT 3000 S
Significant performances in term of speed, surface finish and threading
�Increase cutting speeds by 30% for roughness Ra 0.2 µm (productivity increased)
�Better surfaces finish Ra 0.05 µm in Water Machines (CW)
�Threading small holes with THREADING-EXPERT
�Integrated Vision Unit Advance with correction of the contour
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SURFACE QUALITY SURFACE QUALITY SURFACE QUALITY SURFACE QUALITY IMPROVMENTIMPROVMENTIMPROVMENTIMPROVMENT
3D Architecture Texturing
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Who is interested to improve the process?Who is interested to improve the process?Who is interested to improve the process?Who is interested to improve the process?
Customers doing injection plastic
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Process to improve #1Process to improve #1Process to improve #1Process to improve #1
Maintain the shiny homogeneity
Increase the anti-scratches ability
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Process to improve #2Process to improve #2Process to improve #2Process to improve #2Maintenance issues in the injection molding Maintenance issues in the injection molding Maintenance issues in the injection molding Maintenance issues in the injection molding process process process process -> Effectiveness of surface treatments?
Problem: many potential treatments exist which cannot be assessed during process due to long testing times needed
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Impact on the life time of the moldImpact on the life time of the moldImpact on the life time of the moldImpact on the life time of the mold
> 300 Mold shots Compound
� begin to stick.
> 400 Mold shots More compound > 400 Mold shots More compound
� Stick.
> 500 Mold shots More compound
� Stick .
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Mold is coatedMold is coatedMold is coatedMold is coated
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But just before the coating…But just before the coating…But just before the coating…But just before the coating…
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Surface quality and homogeneitySurface quality and homogeneitySurface quality and homogeneitySurface quality and homogeneity
50x
200x
100x
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Customers want to improve the process?Customers want to improve the process?Customers want to improve the process?Customers want to improve the process?
• Productivity
• Less maintenance
• Anti-scratch
• Repeatability
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What are they looking for?What are they looking for?What are they looking for?What are they looking for?Better management
• Friction
•Corrosion
•Sticking effect
Mecanical sticking� Roughness
Phisical- Chemichal� Sticking
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Ejection force measurementEjection force measurementEjection force measurementEjection force measurement
• Series of test samples produced with different treatments
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*
Practical tests (3’000 cycles) showing test correlation with real residue results with used polymer: PSU (yellow)
**
Without treatment a-C:H-W TiAlN
product
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Friction tests between treated surfaces Friction tests between treated surfaces Friction tests between treated surfaces Friction tests between treated surfaces and plastic polymersand plastic polymersand plastic polymersand plastic polymers
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Friction tests PSU (at 20Friction tests PSU (at 20Friction tests PSU (at 20Friction tests PSU (at 20°C)C)C)C)
coef
ficie
nt o
f fric
tion
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**
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INNOVATIONINNOVATIONINNOVATIONINNOVATION3D architecture Texturing
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How to categorize a surface?
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How to categorize a surface?
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INNOVATION
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New AC-TX spark
Traditional spark
From a rough to a smooth surface quality
Same Ra ≠ Rsm
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Electronic microscope imagesACTX 14 compared with standard , same Ra
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How can we help them?How can we help them?How can we help them?How can we help them?1. More than just traditional Ra
2. To modulate surface dimensions (Rsm, etc.)
3. To provide flexible tool for customer needs. AC-TX customer needs. AC-TX parameter
4. By monitoring dedicated parameter we are able to provide different surface texture by keeping the wanted Ra
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3D surface architecture texturing
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3D surface architecture texturing provide
• Flexibility• Quality• Repeatability• Granularity homogeneity
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Solution:Solution:Solution:Solution: friction tests between plastic friction tests between plastic friction tests between plastic friction tests between plastic polymers and machined surfacespolymers and machined surfacespolymers and machined surfacespolymers and machined surfaces
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ExampleExampleExampleExample: Friction tests PSU (at 20°C)
**
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Basic mold performance indicatorsBasic mold performance indicatorsBasic mold performance indicatorsBasic mold performance indicators
Friction test on 3D Architecture TexturingFriction test on 3D Architecture TexturingFriction test on 3D Architecture TexturingFriction test on 3D Architecture Texturing
Ra 1.4 µm Rsm 98 µm
Ra 1.4 µm Rsm 80 µm
Ra 1.4 µm Rsm 214 µm
coef
ficie
nt o
f fric
tion
Rsm 98 µm Rsm 80 µm Rsm 214 µm
➔ Highest productivity potential➔ Highest potential for residue minimization
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ExampleExampleExampleExample: Friction tests PSU (at 20°C)
**
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Basic mold performance indicatorsBasic mold performance indicatorsBasic mold performance indicatorsBasic mold performance indicators
Permability tests on 3D Architecture TexturingPermability tests on 3D Architecture TexturingPermability tests on 3D Architecture TexturingPermability tests on 3D Architecture Texturing
Ra 1.4 µm Rsm 98 µm
Ra 1.4 µm Rsm 80 µm
Ra 1.4 µm Rsm 214 µm
Hyd
ro/ o
leop
hopb
y an
gle
Rsm 98 µm Rsm 80 µm Rsm 214 µm
➔ Highest productivity potential➔ Highest potential for residue minimization
+ -
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3D surface architecture texturing
• Automatic generation settings
• Graphite/Steel technology
• Copper steel on progress
• Basic ACTX scale range: VDI14,18,23,24,26,32,40 and 60.
• Surface range up to 150 x 70 mm
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3D surface architecture texturing
• Our customer already confirm:
• 30% less maintenance costs• Less mold• Cost of reparation
• The quality improve
• The mass production capability
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3D surface architecture texturing
And you?And you?
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THANKSTHANKSTHANKSTHANKS
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