At this year’s Medical Design & Manufacturing (MD&M) West 2020, GF Machining Solutions will demonstrate its MIKRON HSM 200U LP (linear performance) milling machine with pallet changer (PCH) and CUT E350 wire EDM in booth #3413, February 11, at the Anaheim Convention Center. Both high-productivity, high-precision machines represent two key operations within GF’s complete line of medical component processing solutions that provide medical manufacturers with a single source for all their part production needs. Also included in GF’s medical solutions are laser texturing, additive manufacturing, micro laser machining and modular pallet technologies.
For medical component milling, the HSM 200U LP is available in 3 and 5-axis (full simultaneous) versions that bring speed, efficiency and precision to the machining of such small, highly complex components as stainless steel denture bars or orthopedic implants. In addition, its compact size allows the machine to fit into most facilities, a key factor for dental labs and other shops where floor space is at a premium.
The HSM 200U LP generates part surface finishes as fine as Ra 0.05 µm thanks to linear motor technology in its main machine axes and optimized direct-drive motors for the B and C axes. The machine’s powerful 50,000 rpm, 11.4 hp Step-Tec spindle further contributes to precise part details and excellent surface finishes.
Paired with optional MIKRON pallet magazines with System 3R and Erowa interfaces, the HSM 200U LP delivers unattended 24/7 machining for increasing the output of existing workforces. The fully integrated pallet magazines can be loaded without interrupting cutting operations already in progress, and the automation of tool or workpiece handling is possible from three sides of the machine.
A Heidenhain iTNC 530 control system and smart machining modules on the HSM 200U LP provide advanced levels of monitoring – critical for the production of high-value precision medical parts. The system allows the machine to automatically check and evaluate tools and workpieces, inspect tools for breakage and perform measurements of the workpiece. The smart machine modules automatically monitor spindle vibration, calibrate machine geometry and even transmit process status messages to an operator’s cell phone.
To avoid inconsistent loading of small tools and 3D geometry errors caused by inaccurately measuring those tools, the HSM 200U LP features Intelligent Tool Measurement (ITM). ITM records the complete tool tip up to a diameter of 0.47” on image sensors. Special software cleans and measures the recorded tool geometry for repeatability in the micrometer range.
As part of GF’s CUT E Series of wire EDM’s, the CUT E 350, like the HSM 200U LP, also incorporates a broad range of technologies that allow medical manufacturers to increase flexibility and accelerate their time to market. These technologies include a large touchscreen HMI (human-machine interface) that is intuitive in operation and includes onboard Intelligent Collision Protection, built-in machining strategies and flexible job management.
Information about geometries, machining processes and command programs is processed in a single file. This allows jobs to be transferred among different machines in the CUT E Series, with the machines automatically managing all needed modifications. Additionally, more than 10 automated measurement cycles are available to assist with workpiece preparation. The onboard AC CAM Easy allows an operator to prepare an ISO file and post-process it into a job during machining.
The CUT E Series machines also feature GF’s modern Intelligent Power Generator (IPG), which further optimizes cutting speed, precision and surface quality. The machine can use dedicated wire for decreased part cost and increased throughput, and its POWER-EXPERT module automatically determines the optimal power to send through the wire, which is especially beneficial in stepped parts. A Corner Strategy module automatically adjusts parameters during changes in direction to produce sharp angles and small radii. These features combine to reduce cutting times by up to 18% as compared to standard machines.
Also similar to the HSM 200U LP, the CUT E 350 follows the HSM 200U LP’s compact, space-saving design principles, incorporating high-rigidity machine construction to enable accurate cutting. A drop door provides unobstructed, convenient access to the machine’s table, and side-by-side filters are easily accessible to simplify maintenance.
Integrated glass scales preserve long-term, repeatable accuracy, require no recalibration and eliminate errors found in traditional screw systems due to backlash and wear. The CUT E 350 allows the use of an optional large, 25 kg spool to facilitate greater levels of automation and unmanned machining. It also features a reliable wire circuit system for perfect unrolling that does not disrupt the EDM process.
About GF Machining Solutions
GF Machining Solutions is the world’s leading provider of machine tools, diverse technical solutions and services to manufacturers of precision molds and tooling and of tight-tolerance, precision-machined components. The key segments we serve include the aerospace, automotive, medical, energy, information and communications technology (ICT) and electronics industries. Our extensive portfolio ranges from Electrical Discharge Machining (EDM) solutions, three- and five-axis Milling machines and Spindles, Laser texturing machines, Additive Manufacturing and machines for Laser micromachining to solutions for Tooling, Automation, Software and Digitalization—all backed by unrivaled Customer Services and support. GF Machining Solutions is a globally acting Division of the Georg Fischer Group (Switzerland) and maintains a presence at 50 locations worldwide. Its 3,394 employees generated sales of CHF 1,066 million in 2018.
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