Professional Documents
Culture Documents
Fall 2000
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Inside This Issue:
Leading a New Millennium of EDM Technology ...............24 An IMTS 2000 review of the leader in new EDM technology. A New Generator ........5 Advance training proves new Charmilles generator outperforms all others. TechMold Case Study .........................67 Charmilles reliability takes hold in the desert. Selecting the Correct Part .................................8 A top flight parts department is often the key to a happy customer. The Problem Solvers ...........................9 Customer support center efficiently solves problems. Mikron Update ....1011 Agie Charmilles acquires milling machines business from Mikron. Whats New................12 The Roboform 20 Series. 12 Good Reasons to Buy New Equipment ..1416 Charmilles President Harry Moser on why to purchase now!
Fall 2000
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Charmilles Technologies newest offering, the Robofil 230, requires no regular recalibration of the axis due to its glass scales, insuring superior positioning accuracy. The machines U-V axis design allows customers to cut extreme tapers in molds and extrusion die applications. The Integrated Collision Protection (ICP) is another feature that distinguishes the 230 from its competitors. At IMTS 2000, the Robofil 230 was shown with a CT-FANUC 18l control and 3R workpal robot.
Robofil 230
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The Robofil 290P features an interactive graphics interface which allows programming while machining of another workpiece is in progress. CAM-CT enables prompt programming of 2-axis contours, readily integrates the latest EDM technologies from Charmilles and allows ISO programs to be modified. fil290P o b o R The 290P also boasts a powerful generator.
Roboform 35Q C Ri
The Roboform 35 utilizes Charmilles PILOT-Expert 3 system, which adjusts pulsation frequency and pulsation length according to the actual cutting depth. The new motor servo control and 2-microsecond machining loop time allow faster retraction during pulsation. The system monitors each spark and cuts out bad sparks immediately, optimizing the process. At IMTS, the Roboform 35 was featured with a built-in Quick Change Robot (QCRi) to handle workpieces and electrodes. In conjunction with an EROWA presetting station, the new QCRi allows operators to further boost their total hours of EDM productivity. By integrating the new QCRi with the Roboform 35, Charmilles offers a total automation solution.
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The SPS (Sinker Programming System [Roboform]) Kiosk in the Charmilles Booth at IMTS 2000 Penske Nascar
Roboform 55QC
The winners of the 2000 U.S. Grand Prix Tickets were Tim Aoleck of Peshtigo, WI and Tim Piper of Elmhurst, IL!
Also shown with a QCRi and the new Mexcel tooling from Mecatool, the Roboform 55 features an adaptive new generator and three new Expert systems Program Expert, Power Expert, and the newest breakthrough in diesinking technology, the Pilot Expert 3. The Roboform 55 packs a large work tank and tool changer capability to boost productivity. This machine can accommodate one bulky or several smaller parts in one step.
Also featured at IMTS 2000 was the Bostomatic 12G. Built to ensure unprecedented accuracy and an aggressive price point, the 12G is ideal for a wide range of machining tasks including the production of graphite or copper electrodes, hardened steel cavities, medical components, jewelry and other applications. For more information on these and other Charmilles Technologies products, please visit www.charmillesus.com.
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Do you want to trade in your used Charmilles EDM or buy a used Charmilles EDM? Log onto our website under Used Machines.
www.charmillesus.com/prod/used_edm.cfm
Flush Y, N Avg. of 19 Attendees on FO20, FO20A, FO200, FO2000, FO30, FO40/41 CT AE on FO20 User Operator 1st Try on FO35 CT AE on FO35
Attended Machining Y, N
Wear
Surface Finish
Average 5 Hr 25 3 Hr 10 2 Hr 15 2 Hr 10
Average .049
CH-24
Y N N
Y N N
Y N N
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BA sinker and an attached robot results in good generator hours. The Robofil 2030SI wire machine has been designed to operate with increased flexibility and unbeatable accuracy over a long working life. The 2030SI accepts wire ranging from 50 to 300 microns in diameter and has an optional add-on that enables the use of 30-micron wire. No more than a matter of minutes is required to adjust from one wire width to another - only the closed wire guides need to be changed. Operator Moosbrugger describes Tech Molds buying process this way: Whenever we say, We need another wire or we need another sinker, Bill will usually send somebody out, a senior guy, to go out and make test cuts on whats out there. Over the years when weve done that, Charmilles just seems to win hands down. We do go out there and we do look at other products on the market. We find that we still think were buying the best based on test cut results, user friendliness, and ability. That job is often done when nobody is around. One of the great virtues of Charmilles machines, both Kushmaul and Moosbrugger agree, is their ability to run unattended. Kushmaul maintains that type of capability is a necessity in the current super-competitive EDM market. Even during the middle of a workday, that autonomy is important. Like right now, Moosbrugger says, I run four wires by myself. Im successful on a daily basis getting phenomenal hours out of
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Don Geiger, an EDM operator at Tech Mold in Tempe, AZ, works with the Charmilles Robofil 2020, the Robofil 2030SI, and the Roboform 2000 (clockwise starting at left).
them because you have features like the auto rethread feature after a wire breaks. If you maintain them properly youll get good results. It allows one operator to run a lot of equipment. Owner Kushmaul appreciates the service, too. Theyre always willing to send somebody out, he says. Theyve been very cooperative with training and maintenance. Because were out in the middle of the desert, everybody worries about how youre going to get serviced. I think theyve serviced us very well over the years. And I know in our area theyve gone to more knowledge-based sales people and thats helped a lot. They have people in the field selling machines that know the machines. Thats been a big factor. Accuracy, reliability, user-friendliness, good sales and service. Moosbrugger contemplates the Robofil 2030SIs efficiency and sums it up neatly. There are a lot of things that go into it but the bottom line is if the machine was a lesser machine, we wouldnt see those results. Were very happy with it. If we needed another wire tomorrow, I wouldnt even hesitate in getting another Charmilles.
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Stratified Wire Brass Wire Zinc Coated Wire Wire Guides Power Feed Contacts Flush Nozzles and more
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Greg Thomas politely requests his caller hold the line a minute. He puts his headset down and calmly walks over to a bank of eight color television monitors. No, Greg isnt a director for the local stations news show. He is a telephone service engineer at Charmilles Technologies Customer Support Center in Lincolnshire, IL and he has a problem a customer on the East Coast needs a new machine installed right away. Actually, the wire EDM arrived a few days ahead of schedule so the install date has to be moved up. Greg faces the bank of monitors and positions his computer mouse to click on the service engineer who will handle the call. His schedule for the next four weeks is available to Greg with simply a mouse click. Greg sees that with customer approval, a preventative maintenance call can be delayed to early next week to accommodate the installation job. Just another day at the office for Greg. When a customer needs something quickly or needs something changed, he says, we can work it out. The Customer Support Center includes both service and spare parts, the result of a 1999 merger between the two functions.
Kirk has built up quite a rapport with many customers. They pretty much become your friends over time, he says. You are talking to the same guy every time when he calls in and they like to speak with you. Charmilles Customer Support Center is open Monday Friday, 7:00 a.m. to 7:00 p.m. CST.
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The Mikron Standard Machines product group includes the core companies of Mikron AG Nidau (marketing, sales and service) and Comp-Tec AG (research, development, and production) along with the sales and service organizations with companies in Switzerland, Germany, France, Great Britain, Italy, Spain, the USA, Singapore and China. Agie Charmilles will preserve the Mikron brand and add it to its existing range. Supplementing Agie Charmilles EDM product group, the wide range of products which will continue to be marketed under the trademark Mikron, includes milling machines suitable for start-up companies to highly complex HSM machining centers at the top end of the market. For us, this acquisition is a unique opportunity to now concentrate our efforts to turn the strategy pursued in the USA with the acquisition of Bostomatic into a sustainable reality in the most significant European markets with immediate effect, explains Kurt E. Stirnemann, Agie Charmilles Group CEO. The Mikron acquisition brings with it a bundle of market advantages including added technical competence, strong brand
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recognition, an existing customer base and established sales channels. Agie Charmilles, the worldwide leader in EDM technology, is now in position to become one of the worlds leading system suppliers with two complementary technologies and a comprehensive product range. High-speed machining centers are increasingly being used for processing steel and hard metals in die-casting, tool making, and the manufacture of EDM electrodes.
You Can See Your Ad in the Next Edition of New Ideas In EDM by calling Steph Meyers at DGS Group 317-479-3155
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Wall Street Or Asia Got You Worried? Forget It! Charmilles Technologies President
Harry Moser Offers Twelve Good Reasons To Buy New Equipment Now! The best
Lincolnshire, IL With the stock market fluctuating wildly and the Federal Reserve Board repeatedly raising rates, its easy to become distracted. Whats going to happen next? Deciding on equipment purchases is tough enough but in an atmosphere suddenly fogged with economic unpredictability, theres a tendency to panic. At least one top machine tool executive says this is no time to lose focus. Harry Moser is president of EDM manufacturer, Charmilles Technologies (Lincolnshire, Illinois). In the September 11, 1998 IMTS Show Daily, when the markets looked most unstable, Moser predicted that the Fed would loosen monetary policy. Subsequently, the Fed reduced rates on October 2nd, October 16th and November 19th of 1998. He recently updated his analysis, outlining the reasons why the Wall Street rollercoaster should be ignored. If you intend to stay in business, this is a great time to buy new machine tools and manufacturing equipment, he states. Here are his twelve reasons: 1 . Low Cost Financing is Available. Since the interest rate valley in the fourth quarter of 1998, the Fed has raised the short term federal funds rate 1 .75 percentage points but FiveYear Treasuries, the basis for equipment leases, have only increased 1 .58%. Thus, leases are still quite affordable. In fact, aggressive machine tool manufacturers, like Charmilles, often further subsidized rates for credit-worthy customers during IMTS 2000. 2. Its the Best Investment Alternative. Invest in what you know and can controlproductive equipment for your business. Other alternative investments are outside of your control and have uncertain projected returns. In fact, stock returns are likely to be low or negative, probably reverting to the mean after a period of irrational exuberance. 3. Only Productivity and Quality Can Beat Lower-priced Competitors. Low labor rates make foreign companies price competitive. You cant compete against price by not investing. You can only compete by having the equipment that allows your employees to produce at a level above the competition and at a productivity level that overcomes the labor rate disadvantages. U.S. manufacturing productivity increased at a 6.9% annual rate in the first quarter of 2000 showing that U.S. industry can be competitive. Adding a robot to a CNC EDM can increase your productivity by 50% while reducing the fully burdened operating cost per hour by 30%, reaching the operating cost level of low wage, non-robotic, Southeast Asian installations.
companies invest consistently year after year regardless of short-term economic conditions.
4. Consistent Investment Pays Off. The best companies invest consistently year after year regardless of short-term economic conditions. They always have the most recent technology and they have sufficient capacity to deal with increases in demand. If you let your technology fall behind, you may never be able to catch up. 5. Capital Equipment is the Only Cost that is Competitive versus Foreign Companies. In Southeast Asia, the dollar cost of labor can be 10% of North American levels but the cost of imported machine tools is the same as in the U.S. 6. Southeast Asias Short-term Advantage is Gone. In late 98 and early 99, Southeast Asian shops had two special temporary advantages. Costs were cut dramatically due to depressed national currencies and they had huge excess capacity due to their devastated domestic demand. Since
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then, the Southeast Asian currencies have strengthened and their domestic demand and manufacturing capacity utilization are soaring. 7. Booming European and Southeast Asian Economies Will Strengthen U.S. Manufacturing. U.S. retail sales and homebuilding are softening due to the Feds actions. The manufacturing boom in Europe and Southeast Asia will decrease U.S. imports and increase U.S. exports, compensating for any
and June 2000 were the best May and June ever; 33% greater than the same months in 1999. 9. It Makes Your Services More Marketable. Your customers are shrinking their vendor bases. They will stick with the vendors that offer a broad range of processes and that have continued to invest in the most modern technology. 10. To Attract and Retain Top Employees. Skilled toolmakers/precision machinists are always very hard to find. This was true even at the slowest times in early 1999. Top performers are easier to attract and retain with the latest equipment that makes them more productive and demonstrates your commitment to the future of the company and the employees. 11 . 2000 and 2001 Will Probably be Good Years. Inflation is still low, and there are enough signs of moderating growth that the Fed is unlikely to raise rates more than another 0.25%. In fact, NTMA forecasts call for the following increases: moldmaking 6%, diemaking 8%, and precision machining 4%. Capacity utilization rates in the Fabricated Metal Products sector, SIC code 34, is an excellent measure of metalworking activity. The indicator bottomed in May 99 and has since recovered 2/3 of the ground lost since manufacturing was last really strong in the first half of 1998.
Im confident enough in the future that Charmilles-US has hired 15 service engineers since January and ordered as many stock machines in June and July 2000 as in the previous five months combined. We are ready for a continued recovery! 12. Recently Introduced Technology Some recent breakthroughs in machine tool technology can significantly improve a companys competitive position. For example, the newest CNC diesinker EDMs cut the most difficult jobs in 50% of the time, unattended. This is the same result that was typically achieved with earlier models that were attended. New, fully integrated robotic systems help to make the transition towards 24/7 much simpler and affordable. Charmilles Technologies Corp. is the worldwide leading manufacturer of manual and CNC die-sinking EDM systems and wire EDM systems. For more information on the companys products and services, contact Gisbert Ledvon, Charmilles Technologies Corp., 560 Bond Street, Lincolnshire, IL 60069-4224. Tel: 1-800-CTC-1EDM. Fax: 847-913-5340. http://www.charmillesus.com. An earlier version of this story appeared in the IMTS Show Daily, Sept. 2000, published by Gardner Publications, Inc. Redistributed with permission.
drop in domestic U.S. demand. As U.S. interest rate expectations soften, the dollar will drop versus European currencies, further strengthening export demand. 8. Your Domestic Competitors are Investing. U.S. machine tool orders are up 4% YTD May 2000 vs. 1999. Charmilles U.S. and Canadian orders in May
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560 Bond St. Lincolnshire, IL 60069 www.charmillesus.com Tel: (888) CTC 1EDM AGIE CHARMILLES Group GEORG FISCHER GF Manufacturing Technology