Aerospace

Manufacturing
Solutions
Message from the President
Aerospace and aeronautic manufacturing has long been a core expertise of
GF AgieCharmilles. Therefore, we understand that high precision machining and
stringent manufacturing requirements are extremely critical components of this
quickly evolving industry.
As a result, we remain committed to understanding your manufacturing
processes, and working closely with your team to ensure you receive the highest
level of accuracy and productivity when using our milling machines and EDM
solutions to produce intricate, complex parts.
In fact, youll find our diverse portfolio of standard-setting, high-speed and high-
performance solutions can take on difficult-to-machine materials in a wide variety
of applications, from turbine blade repair to heavy milling of titanium. And if youre
not sure what machine is right for you, we have application engineers that can
help select, implement and optimize your equipment.
Furthermore, our source of strength doesnt end with our machines. Through our
Uptime+ program, we provide customers with the world-class service, support and
training needed to ensure your manufacturing processes run smoothly well into
the future.
We appreciate your support of GF AgieCharmilles and look forward to doing
business with you.
Sincerely,
Glynn Fletcher, President
Agie Charmilles LLC
2 3
GF AgieCharmilles
Your partner in constant innovation
Aerospace manufacturing encompasses a wide variety of parts, diverse in
shape, size, design and material. To meet the complex needs of the industry,
GF AgieCharmilles offers complete turnkey manufacturing solutions built
around the worlds most advanced high-speed and high-performance
machines. From turbine blade repair to heavy milling of titanium alloys to
production of very large components, our array of machine and automation
technologies offers unmatched precision and productivity.
All GF AgieCharmilles machines are backed by Uptime+, the industrys
strongest, all-encompassing customer service and support program.
Complex aerospace parts require
Our highly qualified and experienced engineers provide training,
flexible, reliable machines with
technical information and expert application advice on the selection,
impeccable precision and backed
implementation and optimization of equipment. Whatever aerospace
by the best service and support
manufacturing challenges you face, our team of experts works ceaselessly
program in the industry.
to overcome them.
With uncompromised machine performance, turnkey solution productivity
and unmatched Uptime+ service and support, GF AgieCharmilles can meet
all of your aerospace manufacturing needs.
 HPM 450U HPM 800U HPM 1350U HPM 1850U

Work Area
Work Area 600 x 450 x 450 mm 800 x 800 x 550 mm 1350 x 1150 x 895 mm 1850 x 1400 x 905 mm

Milling Tough Materials Swiveling Axis

23.62 x 17.72 x 17.72 in
+45/-120
31.5 x 31.5 x 21.65 in
+91/-121
53.15 x 45.28 x 35.24 in
+16/-120
72.83 x 55.12 x 35.63 in
+20/-120
Tilting Axis 360 360 360 360
Spindle Options 12,000 RPM, 20.12 hp ISO-B40 20000 RPM, 52.3 hp HSK-A63 15000 RPM, 50.96 hp HSK-A63 10000 RPM, 45.59 hp HSK-A100
Aerospace components are often made of hard-to- 20,000 RPM, 40.23 hp HSK-A63 15000 RPM, 50.96 hp ISO 40 15000 RPM, 50.96 hp HSK-A63
24000 RPM, 40.23 hp HSK-A63 24000 RPM, 40.23 hp HSK-A63
machine materials that necessitate a unique approach Feed Rate
X/Y/Z Feed Rate 15m/min (590 ipm) 60 m/min (2362 ipm) 15 m/min (590 ipm) 15 m/min (590 ipm)
to manufacturing. GF AgieCharmilles excels in meeting
X/Y/Z Rapid Traverse Rate 22m/min (866 ipm) 60 m/min (2362 ipm) 32 m/min (1260 ipm) 40 m/min (1575 ipm)
this challenge. Our robust spindles provide the power and Axis Feed Rate 50 rpm (Rotary) 60 rpm (Rotary) 40 rpm (Rotary) 30 rpm (Rotary)
50 rpm (Tilting) 11 rpm (Swiveling) 11 rpm (Swiveling)
speed needed to maintain high productivity while milling Axis Rapid Traverse Rate 140 rpm (Rotary) 60 rpm (Rotary) 40 rpm (Rotary) 30 rpm (Rotary)
difficult materials. 50 rpm (Tilting) 20 rpm (Swiveling) 20 rpm (Swiveling)
Work Table
Clamping Surface 450 mm (17.72 in) 630 mm (24.8 in) 1100 mm (43.31 in) 1600 mm (63 in)
Max Table Load 150 kg (330 lbs) 500 kg (1100 lbs) 1600 kg (3520 lbs) 4000 kg (8800 lbs)

HPM Series Pallet Changer 7, 8 pallets up to

350 x 350 mm (13.8 x 13.8 in)
7, 9, 12 pallets up to
610 x 508 mm (24 x 20 in)
3 pallets up to
1016 x 838 mm (40 x 33 in)
3 pallets up to
1245 x 1016 mm (49 x 40 in)
High-performance 5-axis machining for complex Tool Changer Options 30-tool ISO-B40 30-tool HSK-A63 30-tool HSK-A63 30-tool HSK-A100
60-tool ISO-B40 60-tool HSK-A63 46-tool HSK-A63 175-tool HSK-A100
aerospace parts of all sizes. 30-tool HSK-A63 115-tool HSK-A63 92-tool HSK-A63 46-tool HSK-A63
The HPM (High-Performance Milling) Series offers reliable accuracy with high 60-tool HSK-A63 165-tool HSK-A63 30-tool ISO 40 120-tool HSK-A63
removal rates, even in difficult-to-machine materials. Perfect for aerospace 120-tool HSK-A63 210-tool HSK-A63 46-tool ISO 40 210-tool HSK-A63
170-tool HSK-A63 92-tool ISO 40
production, these machines feature state-of-the-art motor spindles, glass
220-tool HSK-A63
scales for precision machine positioning, direct drive swiveling and tilting
CNC Control Options iTNC 530 Heidenhain iTNC 530 Heidenhain iTNC 530 Heidenhain iTNC 530 Heidenhain
axes for full 5-axis simultaneous machining and uncompromised, rigid and
Siemens 840D Siemens 840D Siemens 840D
ergonomic machine body designs.
Smart Machine Features APS, APS Extended, -APS, APS Extended, APS, APS Extended, APS, APS Extended,
Whether machining airframe components, landing gear parts or turbine blades, ITC, ITC 5X, RNS ITC, ITC 5X, RNS ITC, ITC 5X, RNS ITC, ITC 5X, RNS
HPM Series machines offer turnkey automated system capability for every CAMplete Post Processor CAMplete Post Processor CAMplete Post Processor CAMplete Post Processor
aerospace part application. Through pallet changers and tool magazine options, and Machine Simulation and Machine Simulation and Machine Simulation and Machine Simulation

this series of machines allows for considerable customization to meet specific

production needs and lights-out operations.

Milling

HPM 450U HPM 800U HPM 1350U HPM 1850U

4 5
 HSM 400U LP HSM 600U LP

Work Area
Work Area 500 x 240 x 360 mm 800 x 600 x 500 mm
19.69 x 9.45 x 14.17 in 31.5 x 23.6 x 19.7 in
Swiveling Axis +110/-110 +30/-110
Tilting Axis 360 360
Spindle Options 54,000 RPM, 11.4 hp HSK-E32 42,000 RPM, 18.1 hp HSK-E40
42,000 RPM, 18.1 hp HSK-E40 30,000 RPM, 18.1 hp HSK-E40
30,000 RPM, 18.1 hp HSK-E40 36,000 RPM, 46.9 hp HSK-E50
Feed Rate
X/Y/Z Rapid Traverse Rate 60m/min (2,362 ipm) 60m/min (2,362 ipm)
Axis Rapid Traverse Rate 165 rpm (Swiveling) 60 rpm (Swiveling)
250 rpm (Turning) 150 rpm (Turning)
Work Table
Clamping Surface in accordance with pallet size in accordance with pallet size
Max Table Load 25 kg (55 lbs) 120 kg (265 lbs)
Pallet Changer M.M. 156/18X UPC/Dynafix/7X
ITS 148/20X GPS 240/10X
Tool Changer Options 20-tool HSK-E32 18-tool HSK-E40
40-tool HSK-E32 36-tool HSK-E40
HSM Series 18-tool HSK-E40 68-tool HSK-E40
High-speed 5-axis machining 36-tool HSK-E40 168-tool HSK-E40
68-tool HSK-E40 308-tool HSK-E40
for unmatched productivity. 168-tool HSK-E40 15-tool HSK-E50
308-tool HSK-E40 30-tool HSK-E50
Every aspect of an HSM (High-Speed Milling) Series machine is designed
60-tool HSK-E50
around high-speed machining to maximize productivity of aerospace part
120-tool HSK-E50
processing operations. Rigid structural machine designs, high-speed spindles,
170-tool HSK-E50
advanced control systems, powerful feed drives and axis mechanisms, 220-tool HSK-E50
together with integrated automation features, all combine to deliver iTNC 530 Heidenhain iTNC 530 Heidenhain
CNC Control Options
unparalleled HSM Series machine performance.

For high-speed, full, simultaneous 5-axis machining to achieve superior

contoured part surface finishes, the HSM Series machine features spindle
speeds up to 54,000 RPM and feed rates on linear motor machine axes.

Milling

HSM 400U LP HSM 600U LP

6 7
 1 Extra fine surface can be produced at high
1 2 3
feed rates through Mikrons direct driven
rotary and swivel axes.
2 Automation can easily be implemented to
boost productivity on parts, such as this
aluminum frame component.
3 With a demand for high tolerances and a
perfect visual impression, this component
requires many tools and the utmost in 5-axis
positioning precision.
4 5-axis simultaneous machining is a must
for production of this structural wing 4 5
component.
5 The ability to produce thin support walls is
vital in many aerospace applications.

1
Structural Parts
When producing the structural parts for an airplane, uncompromised quality
is a requirement, not an option. The reliability and support received from
GFAgieCharmilles ensures that every part is a perfect part.
2
3

1 2 3

1 Between machined and molded

components, an airplane cockpit contains
a host of components that benefit from
the efficient and accurate performance on
GFAgieCharmilles EDMs, HSMs and HPMs.
2 This electronic component housing
demonstrates the performance of Mikron

Flight Controls and Avionics Engine Components

machining centers.
3 Productivity and efficiency are important
in machining parts, such as this aluminum
alloy support bracket.
Many of the housings and components found in flight controls and avionics
feature complex geometries with tight tolerances. GF AgieCharmilles high-speed
and high-performance machining centers boost productivity by allowing these
components to be machined in just one or two setups. Additionally, reliable
unmanned operation can be achieved through our Smart Machining features
Aerospace engine components require long cycle times in heavy cutting conditions.
GF AgieCharmilles machines maximize productivity and minimize costs, while providing the high
performance you need, even during extended cutting processes.
1 Tight tolerances are a necessity for parts related to airflow applications,

and automation capabilities, such as large tool towers and pallet magazines. such as this thin-walled component made of 718 Inconel.
2 The Mikron HPM line of machining centers offers the performance needed
to produce parts like this complex combustor machined in 718 Inconel.
3 The fir tree section of this component requires uncompromising accuracy.

8 9
 cut 300 CUT 1000/OilTech

General
Max. Workpiece Dimensions 1200 x 700 x 400 mm 300 x 200 x 80 mm
47.2 x 27.6 x 15.75 in 11.81 x 7.87 x 3.14 in
X, Y, Z Axis Travels 550 x 350 x 400 mm 220 x 160 x 100 mm

Cutting Complex Geometries U, V Axis Travels

21.65 x 13.8 x 15.75 in
550 x 350 mm (21.7 x 13.8 in)
8.66 x 6.29 x 3.93 in
40 x 40 mm (1.57 x 1.57 in)
Max. Workpiece Weight 1,500 kg (3,307 lbs) 35 kg (77 lbs)
Machine Dimensions 2600 x 2540 x 2240 mm 1500 x 2000 x 1970 mm
102.4 x 100 x 88.2 in 59 x 78.7 x 77.55 in
With a trend towards parts with more complex geometries, Rapid Traverse 3 m/min 1-3000 m/min
todays EDM innovations offer an ideal solution for (9.8 ft/min) (3.3-9842 ft/min)
Taper Angle Standard 30 at maximum height 3 at maximum height
many aerospace applications. GF AgieCharmilles EDM Taper Angle Optional 45 at maximum height
Surface Integrity < 2 m (< 0.0001 in) < 2 m (< 0.0001 in)
technology allows for high productivity and accuracy when recast after 4 passes recast after 4 passes
machining intricate and complex components. Surface Finish Ra 0.1 m (4 in) Ra 0.05 m (2 in)
Generator
Generator Type AC Clean Cut IPG-V

CUT 300 Maximum Cutting Rate 340 mm2/min

(32 in2/min)

The benchmark in EDM speed Wire

Standard Wire Size 0.33 to 0.15 mm 0.2 to 0.1 mm
The CUT 300 submerged wire EDM offers unbeatable speed and accuracy in the (0.013 to 0.006 in) (0.008 to 0.004 in)
automatic rough and finish machining of heavy aerospace components. While Optional Wire Sizes 0.33 to 0.070 mm 0.06 to 0.02 mm
featuring a compact and space-saving design, the machine easily supports heavy (0.013 to 0.003 in) (0.0027 to 0.0008 in)
workpieces without losing accuracy. Additionally, features such as in-process Maximum Wire Spool 8 kg (17.6 lbs) ISO standards 8 kg (160 lbs)
inspection and track & trace ensure the quality of every part. 5 kg (11 lbs) JIS standards
Wire Guide Types Closed diamond type without 1 set for all diameters 0.20 to
clearance 0.07 mm (0.0078 to 0.0027 in)
CUT 1000/OilTech Wire
The worlds most accurate wire EDM Processor Celeron Pentium
Display LCD 12" TFT (Touch Screen) LCD 15" TFT (Touch Screen)
The CUT 1000 utilizes the finest possible wires to provide the worlds most Hard Disk Drive Capacity 40 GB 80 GB
accurate wire EDM process. Automatic threading of wires down to 0.02 mm RAM 1024 MB
(0.0008 in) in diameter allows for high levels of autonomy to boost productivity USB Port instead 2 2
and efficiency. The CUT 1000 OilTech offers a dielectric oil option. of Floppy Drive
Ethernet Port RJ45 standard RJ45 standard

Turn While Burn

EDM the impossible
Turn While Burn technology allows for the machining of highly complex 3D
aerospace part shapes and eliminates performing secondary operations
on separate machines. The system uses a high precision, servo-controlled
programmable B-axis indexer that rotates parts in sync with a machines
X- and Y-axis movement.

Wire EDM

cut 300 CUT 1000 AWC

10 11
 FO 350 SP FO 550 SP

General
Max. Workpiece Dimensions 780 x 530 x 300 mm 1200 x 850 x 400 mm
30.7 x 20.9 x 11.8 in 47.2 x 33.5 x 15.75 in
X, Y, Z Axis Travels 350 x 250 x 300 mm 600 x 400 x 450 mm
13.8 x 9.8 x 11.8 in 23.6 x 15.7 x 17.7 in
Max. Workpiece Weight 500 kg (1,100 lbs) 1600 kg (3530 lbs)
Machine Dimensions 1900 x 1690 x 2522 mm 3040 x 2830 x 2960 mm
74.8 x 66.5 x 99.3 in 119.7 x 111.4 x 116.5 in
Max. Electrode Weight 50 kg (110 lbs) 100 kg (220 lbs)
Rapid Traverse 3 m/min (9.8 ft/min) 60 mm/s (2.36 in/s)
Max. C-Axis Speed 100 rpm 100 rpm
Measurement Resolution 0.005 mm (0.000002 in) 0.001 mm (0.00004 in)
Positioning Resolution 0.005 mm (0.000002 in) 0.0005 mm (0.00002 in)
Control/Servo Resolution 0.0001 mm (0.0000039 in) 0.0001 mm (0.0000039 in)
FO 350 SP Table
Clamping Area
High performance in a compact design T Slots
500 x 400 mm (19.7 x 15.75 in)
3
750 x 600 mm (29.5 x 23.6 in)
5
Speed and performance come together in the compact FO 350 SP fixed-table die- T Slot Size 12 mm (0.47 in) 12 mm (0.47 in)
sinking EDM. The high-speed Z-axis pulse rates, together with high acceleration T Slot Spacing 125 mm (4.92 in) 125 mm (4.92 in)
Worktank
speeds provide aerospace manufacturers with faster part processing, longer
Dielectric Capacity 410 l (108 gallons) 498 l (133 gallons)
electrode life and superior surface finishes.
Max. Dielectric Volume 410 l (108 gallons) 820 l (219 gallons)

FO 550 SP Generator
Amps 64 amps standard 64 amps standard
User-friendly die sinking EDM 128 amps optional 128 amps optional
Die-sinking EDM has never been easier than with the FO 550 SP. Through an Type ISO pulse ISO pulse
Control
incredibly intuitive Windows-based control, the FO 550 SP allows operators with
CNC Processor PENTIUM PENTIUM
minimal training to efficiently produce high-quality parts with extreme tolerances.
Display LCD 12.1 TFT (Touch Screen) 12.1 TFT Color (Touch Screen)
Hard Disk Drive Capacity 40 GB 20 GB minimum
iQ TECHNOLOGY RAM 512 MB 40 GB
USB ports 2 2
Near zero electrode wear Ethernet Port RJ45 standard RJ45 standard
iQ Technology builds a protective layer onto graphite electrodes to practically
eliminate wear. iQ Technology allows aerospace manufacturers to use very thin
vane-type electrodes to produce extremely fine, stepped narrow slots without fear
of electrode deterioration.

Die-Sinking EDM

FO 350 SP FO 550 SP
12 13
 Lean, green and blue
Save energy an economic and
ecological necessity
In order to control production costs, saving energy has become a
priority in many workshops. The Econowatt modules manage the
electrical power of the machine so as to never waste energy while
the machine is running unattended. When machining is finished
or interrupted, the power supply is reduced to the minimum,
lower than 1kW, or completely disconnected depending on the
parameters of the machine. Automatic restart is programmed
according to a daily schedule corresponding to the operating
hours of the workshop. The machine is switched on in sufficient
time to be thermostabilized when the workshop opens. The power
consumed is continuously displayed on a screen page.

DRILL 300 drill 300

Quick, simple and precise holemaking

General
The small footprint and up to a 50 electrode / 8 guide changing
Controlled operational costs
Max. Workpiece Dimensions 1000 x 700 x 400 mm
capability makes the Drill 300 a powerhouse for production cooling (39.37 x 27.56 x 15.7 in) The excellence of GF AgieCharmilles
hole applications. The Agie Charmilles ISPG proven generator X, Y, Z-Axis Travels 600 x 400 mm wire EDM technology also resides in
technology provides intelligent technology settings for entry/exit (23.62 x 15.7 in) the control of operational costs. The
machining and cylindrical control. The result is superior surface Z-Axis Travel 450 mm (17.72 in) potential for using less expensive
and profile quality while maintaining high speeds and minimum Optional 650 mm (25.59 in) wires and reduced filtration cost,
electrode wear. Electrode Wear Management is included as a smart W-Axis Travel 450 mm (17.72 in) added to a lower consumption of
feature within the intuitive CNC control, and will change electrodes Max. Workpiece Weight 1000 kg (2,205 lbs) electricity, make machines such as
automatically without any additional programming. The operator Machine Dimensions 1400 x 2320 x 2180 mm CUT 200, 300 and 400 particularly
55.12 x 91.34 x 85.83 in
friendly HMI (Human Machine Interface) is designed to minimize set-up economical to run.
time and reduce the learning curve a must for multi-shift operations.
Electrode
Econotec technology - high
Electrode diameter 0.3 to 3 mm (0.012 to 0.12 in)
Optional small holes 0.1 to 6.0 mm (0.0039 to 0.24 in)
speed, lower cost
Production requirements mean that
savings must be made at all levels,
especially on consumables. Thanks
to complete control of the EDM
wire process, Econotec technology
allows 30 % faster machining times
with a 0.3 mm diameter wire, while

High-Speed EDM Drilling reducing cost by 20 %.

drill 300
14 15
 GF AgieCharmilles automation solutions
Modest demands, maximum benefits
Easy to use pallet changers for EDM and milling machines require minimal
floor space, supervision and operating cost while delivering:
+ Increased machine capacity
+ Increased productivity and flexibility
+ Simple access to pallets or tools
+ Lower production costs
+ Lower unit cost
+ Shorter depreciation time
+ Minimum footprint

Automation for every configuration level

An array of tailor-made options
Whether your application requires 10 pallets or 240, modular magazines can
be combined to offer an unprecedented flexibility that can be adapted to each
users needs.
Light magazine capacity
25-80 pallets
Heavy magazine capacity
of flight-critical engine components for
Continuous Improvement commercial and military aircraft.
10-20 pallets

Peter LaFond, President of Steel

We maintain a healthy fear of our
Tool Engineering, challenges his
competitors and keep up with who is out
employees to be problem solvers when
there and if they are out-manufacturing
it comes to manufacturing jet engine
us. Whether they accomplish that by
components. As an innovative partner
producing in low-cost labor regions or by
to customers, their problems are Steel
way of advanced technology, our strategy
Tool Engineerings problems, and the
is one of continuous improvement,
solutions often originate from advanced
and we are going to always strive to
technology and support from
implement it before the competition
GF AgieCharmilles.
does, declared LaFond.
GF AgieCharmilles automation systems
Continuous improvement at Steel Tool
and electric discharge and high-speed
Engineering isnt based on stand-alone
milling machines (EDM and HSM) give
machines, but on highly complex,
Steel Tool Engineering the means to
automated manufacturing systems.
incorporate innovative techniques.
The company acquires many of these
With a varied toolbox of cutting edge
turnkey systems from GF AgieCharmilles
technologies, Steel Tool Engineering
because, like Steel Tool Engineering, the
routinely overcomes manufacturing
worlds technology leader in EDM and
challenges, reduces part costs for its
HSM partners with customers to provide
customers, and adds to the companys
value through innovative products and
competitive advantage. Through this,
services and is relentless in its drive
Steel Tool Engineering maintains a highly
toward continuous improvement.
regarded reputation as a leading supplier

Automation Solutions

16 17
Global Support and Services GF AgieCharmilles

A world-wide network of support and customer Milling High-Speed and High-Performance Milling Centers
services ensure maximum uptime of your 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
GF AgieCharmilles machine tool 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
Applications alongside EDM into one of the key technologies in mold and tool making.
GF AgieCharmilles customers gain access to dozens of local Application Engineers
providing training, programming and troubleshooting.

Consumables EDM Electric Discharge Machines

A complete range of original wear parts and certified consumables at your fingertips;
all in-stock orders received by 4 p.m. ship the same-day.
Service
Preventative maintenance and repair services to minimize downtime and maximize
productivity.
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.

Laser Laser Ablation

Laser ablation supplements and extends the technologies offered by GF AgieCharmilles.
With our laser technology, we enable you to produce texturizing, engraving,
microstructuring, marking and labeling of 2D geometries right through to complex
3D geometries. Laser ablation, compared to conventional surface treatment using
manual etching processes, offers economic, ecological and design advantages.
Boston
USA

Uptime+ Program Everything Support

Uptime+ provides comprehensive services for GF AgieCharmilles machines. The
program offers the complete range of original wear parts and certified consumables
including wires, filters, electrodes, resin and many other materials. Uptime+
Charlotte machine support covers all services connected with spare parts, technical support
USA
and preventive services, while helping develop manufacturing solutions tailored to
the customers specific needs.

Automation 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.

18 19
 259.804.982
us.gfac.com

Agie Charmilles SA, 2011 560 Bond St.

The technical data and illustrations are not binding.
They are not warranted characteristics and are
Lincolnshire, IL 60069
subject to change.

Tel. (800) 282-1336

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