AC Classic V

2

AC Classic V2

<The machines for economic ED wire cutting

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AC Classic V3

Contents Highlights 4Mechanics 6The generator 8The control 10

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0,15 mm0,33 mm

to Ra 0.1 µm

Highlights For progressive ED wire cutting

Thinner wires With an extension kit, wires down to 0.07 mm can be used. All AC Classic V machines are designed for wires with 0.15 mm as the smallest diameter as standard.

Finest surfacesA surface quality of Ra 0.2 µm is achieved as standard with all AC Classic V machines. The SF module option makes it possible to have roughnesses down to Ra 0.1 µm.

Maximum shape accuracy With Wire Bending Control and Ad-vanced Wire Offset, all AC Classic V ma-chines have functions fitted as standard for the best linearity for every workpiece height, for stepped workpieces, for ta-pered cuts as well as for precise interior radii, even with complex transitions.

Optimal technologies With a few data inputs, the best possible technology is generated individually for every machining job and workpiece height.

The proven IPG-V generator with a very high operating efficiency and also the Agievision control system in version 5 are common to all models in the AC series. The new outputs of the Classic V ED wire-cutting machines are:

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Exemplary compact construction The machine, control system, genera-tor and dielectric unit are integrated in a space saving manner in the fully encased system. AC Classic V machines are delivered as a whole on a frame with rollers. The machine can thus be manoeuvred with little effort and, thanks to its small floor space requirement, finds its place even in narrow rooms. The commissioning is as simple as possible with a total of just 4 connections.

Certified quality Every AC Classic V is measured by la-ser and must then ED machine a pallet with practice-related inspection pieces. The machine is supplied with an integrated quality certificate, thus also proving the time taken for the complete certification of an AC Classic V, which is almost twice as much as that taken for the actual assembly.

For high operating convenienceMechanics

Long-lasting mechanical components High static and dynamic rigidity is ensured by the C-frame construction in the cast version. High-precision, large-dimensioned recirculating ball spindles, as well as prestressed, closed and also large-dimensioned guides on all axes ensure a long working life and high precision on the workpiece.

Optimal thermal behaviour All the heat occurring in the ED wire-cutting system is removed by the cooling water. The cooling of the gen-erator, control system and dielectric is regulated by heat exchangers.

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With modern digital technologyThe generator

Controlled process With state-of-the-art FPGA (Field Programmable Gate Arrays) tech-nology and completely digital data recording, the EDM process can be quickly recorded and continuously optimised with a precise servo. In the course of this, the current process state is measured as close to the spark as possible and, thanks to the enormous computer throughput, kept continuously at an optimum level.

Individualised technologies With Teccut, ED wire-cutting tech-nologies are generated individually according to the workpiece features. For this purpose, the workpiece is described with its height, shape, ma-terial, surface quality and accuracy. Teccut then generates the best possible cutting technology, and in addition makes alternative propos-als for the quality targets. The result

is a machining to measure, without any compromises with respect to workpiece height, precision or cut-ting rate. Whether brass or coated, whether thick or thin, with every type of wire, both maximum cutting rates are achieved in full cut and surfaces of the finest and best precision in trim cut are performed on the work-piece.

Precise full cut With the individually generated technologies, precision full cuts can be carried out which, according to the precision and surface quality required, can reduce the number of trim cuts or even allow them to be completely dispensed with.

Balanced profitability With eCut technologies, wires of from 0.1 to 0.15 mm diameter can be used and thus high cutting speeds

achieved. eCut technologies reduce the filter and resin consumption strikingly, and cut down the use of both coated and brass wires. Fewer deposits of material from the wire on the workpiece reduce the number of trim cuts. Cut surfaces on work-pieces have a homogeneous finish according to the roughness value. eCut technologies reduce the spark gap in the case of fine machining jobs so that absolute accuracy is realised in the case of contours and smallest inside radii.

Less power consumption With the IPG-V generator, the energy power consumption falls strikingly do to the modern technology of the fully digitalized generator.

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Wire Bending Control Dynamic Corner Control

Variocut

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System for reliable results

Agievision is a control system spe-cially developed for ED machining that speaks the language of workshop. With Version 5, the operating con-venience has been further improved. A few data inputs suffice in order to prepare the EDM program purpose-fully – with the Microsoft® Windows® just like on your PC at home.

The control

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Problem-free job insertionWith Pieceinsert, in order to carry out an express job, first of all the actual situation of the machining job in hand is determined, including the cutting sequences, and then, after completion of the express job, it is then resumed exactly where it was interrupted. Without changing or inserting data sets.

Management System for flexible planning

Data input adapted according to organisationWith Agievision the data input can take place flexibly in accordance with the infrastructure of the workshop the environment: - All data can be directly input on the machine.- Geometries are imported and completed with the target data on the machine.- Geometries and target data are imported and completed on the machine with measurement and position data.- All the workpiece data, including the measurement and position data are imported directly on to the ma chine.

ED wire cutting is intended to be able to be employed flexibly for the most varied machining jobs in accordance with the workshop’s everyday require-ments. The Agievision control system fits in with this with time-saving and productivity-enhancing modules.

EDM-specific Job Management SystemWith Agievision, priorities can be set flexibly and changed at any time di-rectly on the machine. With the Lotto function, several workpieces can be combined and optimally managed in one lot.

Shortened non-productive timesWith the selectable threading mode: Highest speed (8 - 15 seconds), high-est certainty or a combination of both. With the selectable positioning mode: Depending on the application, one or more possibilities for optimising can be used.

The control

PC AC Classic V

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About GF AgieCharmilles

High-Speed and High-Performance Milling Centers

In terms of cutting speed, HSM centers are 10 times faster than conventional milling machines. Greater accuracy and a better surface finish are also achieved. This means that even tempered materials can be machined to a condition where they are largely ready to use. One essential advantage of HSM is that with systematic integration, the process chain can be significantly shortened. HSM has developed alongside EDM into one of the key technologies in mold and tool making.

Electric Discharge Machines

EDM can be used to machine conductive materials of any hardness (for example steel or titanium) to an accuracy of up to one-thousandth of a millimeter with no mechanical action. By virtue of these properties, EDM is one of the key technologies in mold and tool making. There are two distinct processes – wire-cutting EDM and die-sinking EDM.

Tooling, Automation, Software

Tooling for fixing workpieces and tools; automation systems and system software for configuring machine tools and recording and exchanging data with the various system components.

HSM Spindle Technology

Development, production and sale of the motor spindles that form the core components of modern HSM centers. The spindles rotate at speeds between 10 000 and 60 000 rpm.

Services and Consumables

Service, maintenance, spare parts and consumables for EDM, milling and HSM systems as well as for other machine tools; consumables include filters, wire, graphite, copper electrodes and special resin.

Milling

EDM

Automation

Spindle

Service

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Technical DataAC Classic V

TravelsX/Y/Z axes mm in 350x250x256 13.77x9.84x10 500x350x426 19.7x13.77x16.8U/V axes mm in ±70 ± 2.7 ±70 ± 2.7Max. taper angle 300 28 > 300 28Finishing quality, best roughness Ra µm µin 0.2 8 0.2 8Best Ra with SF modul, finishing power module Ra µm µin 0.1 4 option 0.1 4 option

Threading system AGIEJET Threadable height mm in Up to 250 9.84 Up to 420 16.5Threading nozzle ø mm in 2 0.07 2 0.07 1 0.039 option 1 0.039 option 0.6 0.0234 option 0.6 0.0234 optionWire guides, Standard equipment ø mm in 0.15-0.33 0.0059-0.0129 0.15-0.33 0.0059-0.0129Wire guides, Extension kit ø mm in 0.07-0.10 0.0027-0.0039 0.07-0.10 0.0027-0.0039Combination wire guide system “V” guide cylindrical up to 2° cylindrical up to 2° Toroid guide 2° up to 30° 2° up to 30°Increased accuracy in tapered cut AGIECONIC PLUS option optionWire drive, wire spool kg up to 25 up to 25Wire feed automatic automaticWire disposal chopper chopper

Work area Accessibility front front/topFrontal drop door manual manualUniversal clamping frame for best utilisation of the workzone standard standardMachining in bath mm in 190 7.48 420 16.55High power generator IPG-V integrated ~ A 45 45Wide range of tested tech. for common users work piece materials standard standardFeed control, servocontrolled, fixed feed standard standardCorrection of the cylindrical residual error, AWO (Advanced Wire Offset) standard standardDynamic path optimisation and process adaptation in the radii DCC standard standardReal time detection and correction of the wire bending WBC standard standardReal time detection of the workpiece cross section and automatic power optimisation VARIOCUT standard standardMachine

AC Classic V2 AC Classic V3

Dielectric conditioning unitDielectric conditioning unit integrated l us gal 750 200 1000 264Filter, 4 canisters with 8 cartridge filters standard standardFiltrate quality µm µin 5 197 5 197

Deionizing Deionizing bottle charge volume l us gal 10 2.64 10 2.64 option 30 7.92 option 30 7.92Water conductivity control, automatic µS/cm2 1-25 1-25

Cooling Generator and control unit with air/ water, and dielectric with water/ water heat exchanger standard standard standard

System System dimensions L x W x H mm in 1640x2040x2220 64.5x80.3x87.4 1940x2300x2600 76.4x90.5x87.4Floor-to-clamping plane distance mm in 1075 42.32 1075 42.32Net weight kg lb 2680 5908 3460 7628Weight ready-to-run kg lb ca. 3350 7385 ca. 4200 9260Control unit integrated, modules and functionsRemote control with all setup functions AGIEJOGGER with electronic handwheel and LCD displayOperator interface system 15”-LCD-display, Keyboard and mouseControl unit integrated AGIEVISION object oriented man-machine interfaceOperating system Multitasking Windows XPOperating mode MultiprocessorCPU’s Pentium for CNC and operator interfaceServocontrolled axes X/Y/Z/U/VSupplementary servocontrolled axis A axisSmallest programmable step 0.0001 mm (0.000004 in)Easy preparation of machining programs EASYWORKAutomatic pickup cycles AGIESETUP 3D, for automatic determination of workpiece plane and positionAutomatic technology selection based on machining objectives TECCUTImport of job-specific data from CAD/CAM systems CAMLINKPredefined machining strategies AUTOSEQUENCEPredefined and user defined machining strategies USERSEQUENCESimple 2D on-board geometry programming IGES files AGIEGEO with import of DXF and IGES filesImport in Agiegeo of third party ISO codes AGIEGEO ISOCONVERTERQuickly insert rush orders without effort PIECEINSERTDNC port with Xon/Xoff and LSV2 protocols DNCHelp functions, explanations with text and graphics HELP and online manualMachining simulation 2D and 3D view GRAFICHECKAutomatic instructions and commands execution EASYRUNAutomatic machining sequence def. for multiple workpieces LOTTORethreading on wire break/on «no- thread» detection restart after power failure Rescue strategiesLanguages English, CN, CZ, DE, DK, ES, FR, HU, IT, JP, NL, PL, RU, US, SEStorage capacity > 40 GB HD, 1 GB Ram Interfaces 2 x RS232C, 1 x parallel, 1 LAN (Local Area Network), 1 USBData storage media CD/DVD Rom for updates and on line manual, floppy-disk, USB

ConnectionsLine power 9.7 kWLine voltage 3 x 400 VCompressed air 6 bar, 5 m3/h (85 psi, 6.54 yd3/h)Cooling capacity required 1.5-6 kW

AC Classic V2 AC Classic V3

AC Classic V2

AC Classic V3

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