GF Machining Solutions - AgieCharmilles Model Cut 200 Dedicated - Aerospace

1. CUT200 Dedicated
GF Machining Solutions
Eric Ostini

2. CUT 200 Dedicated
GF MS NSC NOLA 2014

3. Soaring Travel Demand:
• Increased globalization
• Growing GDP
• Liberalization of air transport
• Decreasing travel prices
Ambitious targets to:
• Reduce hazardous emissions
• Boost fuel efficiency
• Reduce aircraft weight.
By 2020, aircraft are to:
• Burn 50% less fuel
• Emit 50% less carbon dioxide (CO2)
• Emit 80% less mono-nitrogen oxides
• Reduce noise emissions by half
As a result, the aerospace value chain faces
a constrained capacity scenario as production
is expected to increase 45 percent (up to 70
percent) in the next two years.
Immense Challenges in Aerospace
GF MS NSC NOLA 2014

4. Broaching WEDM
Slots / Part 147 147
Time / Part 360 min 1720 min
# of M/C 1 5
CAPEX Investment (USD)
M/C Cost 4,078,000 2,600,000
Footprint 300,000 100,000
Total 4,378,000 2,700,000
Running Costs per Slot (USD)
Tooling 18.35 19.03
Consumables 28.00 5.10
Power 0.07 3.60
Total 46.42 27.73
WEDM versus Broaching
Comparing machining costs
associated with fir-tree slot
production in LP turbine engines
using WEDM and broaching
• Preliminary cost analysis shows that
WEDM is approximately 40% cheaper
compared to broaching while
maintaining similar productivity levels.
In such a case, 5 units of WEDM are
needed to reach the same productivity
of 1 broaching machine.
GF MS NSC NOLA 2014

5. CUT 200 Dedicated
• Removal of work table for increased flexibility
• Expanded work tank for improved dielectric thermo-stabilization
• A-Axis (swivel) for fir-tree slot taper angle
• C-Axis (rotary) for fir-tree slot positioning
GF MS NSC NOLA 2014

6. CUT 200 Dedicated
• Optimal design of lower head to avoid collision
• Increased number of filters for consistent water quality
• Wire remains straight for improved speeds & process stabilization
• Slug-evacuation container to catch falling slugs
GF MS NSC NOLA 2014

7. CUT 200 Dedicated
• Innovative EDM generator with enhanced performance
• Dedicated Inconel technology to eliminate recast layer & micro-cracks
• Relocation of discharge circuit for increased machining speed
• With eTracking module, fully traceable process
GF MS NSC NOLA 2014

8. CUT 200 Dedicated
• Direct connection of discharge circuit cables
• Dynamic fixture offset compensation function for disk concentricity
• Automatic drop-door on work tank side
• External automation (robot) kit available
GF MS NSC NOLA 2014

9. CUT 200 Dedicated
• AC CUT human machine interface
• Ergonomic design for enhanced user-friendliness
• EMC norm compliant
• Small foot print for additional cost savings
GF MS NSC NOLA 2014

10. CUT 200 Dedicated -In process inspection
Probe System provides
• Automate setup
• PWC setup time went from 20
minutes minimum to 5 minutes
 Check flatness in X and Y
 Check if disk is on center of B axis
 Check Z height
 Check A axis angle
• Reduced fixture tolerances – With probe
data the machine can compensate for
X,Y shift.
• Removable with robot
• Adds extra layer of validation to the
process. This information is recorded in
eTracking.
GF MS NSC NOLA 2014

11. 4.81μm
3.26μm
2.66μm
1.86μm
Not Visible
At 500X
3.21μm
1.40μm
1.01μm
0.90μm Not Visible
At 500X
Surface Integrity
No Visible Recast Layer
• Within Aerospace, EDM technology has
typically been considered a “taboo”
technology due to limitations within
spark generators of the past, leaving
recast layers of >3um.
• Advances in GFAC generator
technology ensure surface integrity in
both Titanium and Inconel, with no
visible recast layer or micro cracks after
4 trim cuts.
• No blue discoloration in Titanium.
MainCut
TrimCut1
TrimCut2
TrimCut3
TrimCut4
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Titanium
Inconel
GF MS NSC NOLA 2014

12. Traceability – GFAC Only
• A dedicated software to monitor each
machining process in detail and ensure
traceability, which is essential in Aerospace .
• Real-time dashboard to monitor the entire
workshop.
• Preventative maintenance confirmation and
alert function.
This Includes:
• Monitoring of machining data and
comparing to reference values
• Monitoring of consumable parts and
control items
• Check lists before machining
• Traceability of data during machining
• Monitoring of machine status in shop
GF MS NSC NOLA 2014

13. Traceability – GFAC Only
Cutting Speed
Upper Injection [bar]
Lower Injection [bar]
Upper Limit
Actual
Lower Limit
Upper Limit
Actual
Lower Limit
Upper Limit
Actual
Lower Limit
GF MS NSC NOLA 2014

14. • A dedicated package adapted to the specific
needs within Aerospace.
• Guaranteed repeatability and traceability of
machining process.
• Conducted according to Nadcap AC7116.
This Includes:
• Preventive Maintenance
• Regular inspection & adjustment
• Qualified recommendations
• Generator Calibration
• EDM parameter control
• Spark shape acquisition
• In-depth data analysis and reporting
• Certified Training
• Verification of acquired knowledge
NADCAP Certification Support –
GF MS Only
GF MS NSC NOLA 2014

15. CUT 200 Dedicated - Summary
 Key Characteristics:
• Optimal speed & process stability
• Wire straight at all times
• Relocation of discharge circuit
• Dedicated Inconel techology
• A-Axis (swivel) and C-Axis (rotary)
• Increased work tank
• Thermo-stabilized
• eTracking (traceability) function
• Automation ready
 Benefits:
• No limitations on material hardness
• Surface integrity preserved
• Increased profile accuracy
• Improved surface contact w/ blade
• Narrow slots capable
•  fuel %
• Geometries independent of tooling
• Deburring operations not needed
• High cost saving vs broaching
• Fully traceable & repeatable process
GF MS NSC NOLA 2014

16. GF AgieCharmilles
GF MS NSC NOLA 2014

17. Thank you
Master ScheduleGF MS NSC NOLA 2014