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Sep 03, 2023

AgieCharmilles CUT AM 500 Horizontal Wire EDM

Wire-cutting electrical discharge machining (EDM) is a mature technology, but GF

Wire-cutting electrical discharge machining (EDM) is a mature technology, but GF Machining Solutions continues to push the limits of EDM with the new AgieCharmilles CUT AM 500 horizontal, fast wire EDM. This fast, precise and automation-ready machine is dedicated to metal additive manufacturing (AM), making it easy to separate additively manufactured metal parts from the build plate while maintaining geometrical accuracy and ensuring assembly readiness.

The universal AgieCharmilles CUT AM 500—based on GF Machining Solutions’ more than 65 years of EDM expertise—makes a significant contribution to the AM process: It is a fast, precise, affordable and automation-ready alternative to using standard EDM or a bandsaw to separate additively manufactured parts from the build plate. The CUT AM 500 complements GF Machining Solutions’ and 3D Systems’ scalable, workflow-optimized DMP Factory 500, DMP Flex 350 and DMP Factory 350 3D metal printing solutions.

The CUT AM 500 resolves a number of quality barriers encountered by manufacturers who use a bandsaw to separate the workpiece from the build plate. These barriers include geometrical inaccuracy, loss of workpiece material (kerf) and damage to the part. The CUT AM 500 maintains the integrity of the part by avoiding part contamination and damage, an advantage that is particularly crucial in risk-averse sectors such as aerospace and medtech.

Accommodating parts up to 510 x 510 x 510 mm (including the base plate) and up to 500 kg in weight, the CUT AM 500 uses 0.2 mm-dia. wire to separate additively manufactured parts from the build platform at a maximum cutting speed of 300 mm2/m. It delivers ±0.1 mm accuracy and surface roughness of less than 6 μm. This solution brings together horizontal wire orientation, an integrated basket to catch separated parts and a rotary axis to create a robust process supporting the part, easy part handling, prevention of damage to the part, and full Automation readiness.

The CUT AM 500's fast wire technology in combination with the machine's generator ensures a fast EDM process—at least three times faster than standard EDM—and a reliable separation of additively manufactured parts with specific support structures. Low running costs are enabled by the machine's fast wire technology and double wire spool concept.The layout of the CUT AM 500 is designed to accommodate integration of a clamping system for easier clamping and referencing. As AM becomes a mass production manufacturing technology, automated AM processes will be needed.

Machine that utilizes an endless band, normally with serrated teeth, for cutoff or contour sawing. See saw, sawing machine.

Tangential velocity on the surface of the tool or workpiece at the cutting interface. The formula for cutting speed (sfm) is tool diameter 5 0.26 5 spindle speed (rpm). The formula for feed per tooth (fpt) is table feed (ipm)/number of flutes/spindle speed (rpm). The formula for spindle speed (rpm) is cutting speed (sfm) 5 3.82/tool diameter. The formula for table feed (ipm) is feed per tooth (ftp) 5 number of tool flutes 5 spindle speed (rpm).

Process that vaporizes conductive materials by controlled application of pulsed electrical current that flows between a workpiece and electrode (tool) in a dielectric fluid. Permits machining shapes to tight accuracies without the internal stresses conventional machining often generates. Useful in diemaking.

Process similar to ram electrical-discharge machining except a small-diameter copper or brass wire is used as a traveling electrode. Usually used in conjunction with a CNC and only works when a part is to be cut completely through. A common analogy is wire electrical-discharge machining is like an ultraprecise, electrical, contour-sawing operation.