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

Table of Contents

SURFACE QUALITY IMPROVMENTS

EDM TECHNOLOGY

APPLICATION

2

INNOVATIONS

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

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

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.

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

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

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

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

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

Process to improve #1Process to improve #1Process to improve #1Process to improve #1

Maintain the shiny homogeneity

Increase the anti-scratches ability

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

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 .

Mold is coatedMold is coatedMold is coatedMold is coated

But just before the coating…But just before the coating…But just before the coating…But just before the coating…

Surface quality and homogeneitySurface quality and homogeneitySurface quality and homogeneitySurface quality and homogeneity

50x

200x

100x

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

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

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

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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**

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

New AC-TX spark

Traditional spark

From a rough to a smooth surface quality

Same Ra ≠ Rsm

Electronic microscope imagesACTX 14 compared with standard , same Ra

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

3D surface architecture texturing

3D surface architecture texturing provide

• Flexibility• Quality• Repeatability• Granularity homogeneity

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

ExampleExampleExampleExample: Friction tests PSU (at 20°C)

**

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

ExampleExampleExampleExample: Friction tests PSU (at 20°C)

**

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

+ -

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

3D surface architecture texturing

• Our customer already confirm:

• 30% less maintenance costs• Less mold• Cost of reparation

• The quality improve

• The mass production capability

3D surface architecture texturing

And you?And you?

THANKSTHANKSTHANKSTHANKS

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