Spring 2004

www.charmillesus.com

We Push the Limits of EDM

www.charmillesus.com

The New Generation of Diesinkers:

It Takes MoreThan Speed

To Compete

New Ideas in EDM

2

The time it takes to produce a mold has been decreased

in the last few years. Customers of mold houses have

demanded that molds be produced faster and more

efficiently, so that the product reaches the market quicker. In

response, some EDM manufacturers have introduced new

diesinkers that cut faster. However, is this all a mold shop

needs today?

In the midst of a challenging economy, mold shops have been

forced to look for new ways to compete, not just with

American mold shops, but also with competition overseas. This

debate over whether speed is all that is required for a

diesinker to be competitive is pervasive among builders.

However, the need to remain competitive has prompted mold

shops to consider other factors, such as features and control

capabilities of a diesinker, more closely than ever with several

questions.

1. Is this control easy to understand and navigate?

Most controls found on CNC diesinkers can perform the

general tasks that are required to produce molds. However,

user friendliness and navigation have become greater con-

cerns. As more and more operators retire, a new generation

of operators joins the ranks—a generation trained on

Windows™-based PC systems, resulting in the need for

builders to redesign their controls, thus bringing greater

benefits to the customer. Windows™-based operating systems

offer an easily understood graphical interface with interactive

navigation. Some EDM manufacturers have gone so far as to

include the operating, maintenance, and part manual on the

screen. These manuals use a web-type browser, which

incorporates images with the text and simplifies the

research/inquiry process.

Charmilles’ Ro b o f o r m

550 Fe a t u res Dynamic

P rocess Contro l

GENEVA-BASED CHARMILLES HAS UNVEILED THE NEW ROBOFORM

550 series, a die-sinking EDM that integrates a new generation

of numeric controls designed to ease use and improve efficiency.

Similar in most aspects to the previously released Roboform 350,

the new machine can handle much larger parts than its

counterpart. The ample work area accommodates workpieces

up to 47.24" wide by 33.46" deep by 15.75" tall, weighing up

to 3530 lbs. The Roboform 550 can be equipped with a

64-position automatic tool-changer.

To best serve the end user, Charmilles referenced the results of a

recent survey of moldmakers while designing the Roboform 550.

The effort resulted in Dynamic Process Control (DPControl), a

system directly involved in the manufacturing process. The

system features interface functions and screen ergonomics that

provide unparalleled performance and operator comfort .

DPControl incorporates interactive graphics and

embedded e-documentation. Since the system is built

around a standard windows platform, the Roboform

550 series is compatible with existing system

architectures. System integration eliminates the need

for further investments or special training and the

ability to operate on a PC allows for offline

programming. Already a standard in the industry,

user-friendliness has been further enhanced to satisfy

the demand for operator convenience.

With the new system, graphics illustrate all machining

operations, allowing the operator to instantaneously

grasp the details of the machine’s operation. On occasions

requiring more detailed instruction, electronic manuals allow the

operator to instantly receive easy-to-understand information

about the current function by simply pressing the F1 key on the

keyboard. DPControl also suggests ideal electrode undersize,

rationalizes the number of electrodes needed and organizes job

sequencing according to preset priorities. Machining status

information is transmitted to the operator via SMS and full

reports are automatically generated for job evaluation. Contact

your local distributor, or Charmilles at 1-888-CTC-1EDM, to

schedule a demonstration.

3

2. Will this control communicate with other equipment

in the shop?

In this day and age, a diesinker must produce more parts per

day than ever before and automation is one way to increase

productivity. Manufacturing a robot is not a problem for most

EDM manufacturers, however, the robot does not

complete the automation process for most diesinkers. In addition

to the robot, many customers discover they need a control that

can incorporate other equipment such as a CMM, as well as

other PC’s for monitoring and programming. Today, the most

efficient way to locate workpiece locations on pallets and elec-

trode offsets is to use a CMM. To fully automate the process, the

CMM must then communicate this information to the EDM

diesinker control for each of the jobs in the robot or in a tool

changer. Still another way to maximize a diesinker is to know

the status of the machine at all times, which can also be

accomplished using a machine control that can alert the

operator either via phone or e-mail with detailed information

as to any malfunctions .

3. Can this EDM diesinker help me organize electrodes

and workpieces for easy to complex jobs?

Typically, controls today help the operator calculate the correct

generator settings for a burn. However, few controls can truly

program everything required to complete a job. One benefit

offered by more advanced controls is the ability to assist in the

organization of electrodes and workpieces. Once the informa-

tion for a particular job has been obtained, these controls can

suggest the best course of action to produce the job. Should the

operator determine that this course of action requires adjusting,

the control can then assist the operator with adjustments.

The next time you’re in the market for a diesinker, consider the

speed at which the machine burns ribs, cavities and subgates.

However, don’t overlook the importance of an advanced

control. You might just find a Windows™ PC control with features

and options that your operator will use to keep the machine

burning and, in turn, keep you productive and competitive.

Why Settle

for Less?

Make Sure Your Charmilles Remains A Charmilles

AGIE CHARMILLES Group

Obtain information about yo u r

O RI GINAL wear parts by

contacting Charmilles.

80 0 . 28 2 .1 3 36 ext. 153 or 154

or by e-mail:

c o n s u m a b l e . s a l e s @ ch a r m i l l e s u s. c o m

by: Eric Ostini, Product Manager for Charmilles

You expect the best perf o rmance from your ED M

machine. Tests have proven that using Charmilles rec o m-

m e n d ed consumables enhances the perf o rmance of your

machine. The service life of the “imposters” is disappoint-

i n g. Enjoy the quality, reliability and profitability you have

grown to expect from a Charm i l l e s.

www.charmillesus.comNew Ideas in EDM

4

M i k ron HSM 300

G raphite Ma chining Like No Other

TOO OFTEN MACHINING OF GRAPHITE ELECTRODES IS SEEN

in die/mold shops as a necessary evil. This task is

relegated to an old or "throw away" vertical

machining center. These types of machines with spindle speeds

not higher than around 6,000 rpm are extremely slow and

woefully inadequate when it comes to producing high quality

e l e c t rodes for EDM diesinking. With this appro a ch, the

downstream effects on EDM, manual polishing

operations and lead times are ignored or

overlooked in many shops.

Investing in a quality high speed graphite

machining center to complement EDM diesink-

ing operations can dramatically reduce lead

times and costs, improve quality and enhance a

shop’s capability to solicit more complex and

demanding work, which to a large extent is not

sourced overseas. In short, in today’s economic

environment, it can make the

difference to a shop’s very

survival.

The Mikron HSM 300 High

Speed Machining Center can

help make this differe n c e .

Graphite electrodes can be

machined up to 5 to 10 times

faster than conve n t i o n a l

methods. Electrodes can be

p roduced with outstanding

finishes and accuracy, which

can dramatically impro ve

EDM burn and manual

polishing times. More consis-

tent and repeatable multiple

cavity molds can be made.

Electrodes can be machined with thin ribs and fine details that are

difficult to achieve conventionally. More complex electrodes can

be produced by combining multiple details, thereby reducing

setup and burn times for EDM diesinking. Investing in the HSM

300 can yield many benefits and these must be examined from

the viewpoint of the whole process chain to manufacture a die or

mold.

With respect to performance and accuracy, the

Mikron HSM 300 is unmatched in the industry in

terms high speed machining of graphite

electrodes. With an extensive standard equipment

package, including a high efficiency graphite

e x t raction system and a standard laser tool

measurement system, the HSM 300 offers out-

standing value.

The capabilities of the HSM 300 are clearly

d e m o n s t rated in the sample

needle electrode shown (see

image above). The electrode, size

2" by 2," has 3 rows of posts,

3/8" height. The row of posts in

the foreground is triangular in

shape, with each side measuring

.014." This electrode is machined

on the HSM 300 in 18 minutes flat

with an excellent surface finish

and absolutely no breakage of

the needle-like posts.

Contact your Charmilles/Mikron

distributor or call 1-888 - 28 2 -

1336 for a consultation of how

the HSM 300 can make a

d i f f e rence in your die/mold

manufacturing operations.

5

CHARMILLES’ RECENTLY ATTENDED THE 2004 MEDICAL DESIGN AND

Manufacturing West show to present attendees with informa-

tion on the Robofil 240cc/440cc. The show was one of five

design and manufacturing trade shows simultaneously held at

the Anaheim Convention Center on January 6 – 8. Utilizing

the entirety of the center’s 800,000 square feet of exhibition

space, upwards of 40,000 OEM buyers attended.

Charmilles’ Robofil 240cc/440cc uses the ‘zero voltage’

CC-generator to increase machining speed while preserving

surface integrity.

Ideal for medical applications, the CC-generator prevents

oxidation on titanium and maintains surface integrity free of

brass and zinc materials originating during the cutting process

from the wire electrode.

The 240cc/440cc contains ThermoCut, a high-speed,

maintenance-free wire threading system that stretches and

cuts wire under the effect of heat, regardless of wire

diameter and material. The machine features collision

protection on all five axes, which prevents costly repairs

during manual or unattended operation.

Robofil 240/440cc

P resentation Given at

2004 Medical Design &

Manufacturing West show

By Mal Sudhakar, Vice President, Mikron

Trust Our Track Record

• T h e rmocompact, supplier to Charmilles for more than 20 years.

• Full range of products supplied including SWXcc, SWX, Thermo A, Brass, etc.

Pl e a se con t a ct : T he rmocompact • 30 Taun t on St . • Pla in v i l l e , MA 02762 • PH : 508 .695 .0707 • FAX : 508 .695 .4404 • E -mai l : d l ync h@fsp- o ne. c om

www.charmillesus.com

6

New Ideas in EDM

Competing withF o reign Ma n u f a c t u r i n g

With the recent rise in competition from relatively cheap foreign production,

many machine shops have found themselves struggling to find ways to

remain profitable. Liberty Machine, Inc., located in Arab, Alabama,

responded to the challenge by identifying and concentrating on areas in

which they held a clear advantage over foreign rivals. Over the past year, both the shop and its

sales volume grew in a way that demonstrates the potential for success, even in hard times.

Robert and Kenny Cleveland founded Liberty Machine in

1984. Initially, the father and son duo comprised the shop’s

entire workforce. Five years later, the company moved to a

new building and hired its first employee. Over the next

decade, the shop continued to expand and its customer base

grew to include such clients as Boeing, NASA, Southeastern

Technology and Wright Medical Technology. As Liberty

Machine gained experience, it also gained a reputation as a

shop willing to try new things and make them work.

“ We’ve really worked hard to make sure that our group of

employees has a broad variety of capabilities," says Kenny,

who serves as Liberty’s president. "It’s given us the ability to

go after the difficult and complicated jobs in addition to more

standard work.”

It is this ability to perform more specialized work that has

allowed Liberty to rise above some of the difficulties

encountered by the industry as a whole. As more and more

of the standard work went overseas, Liberty began to feel the

effects. In 2002, conditions forced the shop to lay off

employees for the first time in its history.

In an effort to recover, Liberty identified areas in which they

excelled that were unlikely to be sent overseas.

“Medical parts have made

up an ever-increasing per-

centage of our workload,”

explains Kenny. “They

require high levels of

tolerance and extreme

accuracy, and need to look

good as well, which means

they take a little more time.

The quality levels required

make them unlikely to go

overseas and time-

constraints make them

undesirable for a lot of

shops here.”

Liberty began to pursue

more medical work and in

early 2003 earned a con-

tract to manufacture a large

quantity of orthopedic

femoral cutting blocks with

a series of six .060” slots. At the time, the shop did not have

wire EDM capable of performing the work as efficiently or

accurately as required. After reviewing possible options ,

Liberty purchased three Charmilles ROBOFIL 240s.

”When you choose equipment, you have to consider both the

quality of the product and the service that comes along with

it,“ says Kenny. ”We knew the Charmilles machines provided

the best value for our shop.“

The new machines arrived and Liberty established an assem-

bly line with 2 slots being burned at each machine. The shop

soon discovered that the ROBOFIL 240 was so easy to use

that one operator could run all three machines and still have

time to inspect the final parts.

The efficiency of the Charmilles machines proved to be so

much of an advantage as to warrant major changes at

Liberty. To fully maximize the benefits of the ROBOFILs, the

shop added weekend and night shifts and have since had no

trouble finding work to fill the expanded schedule.

“The work’s still out there if you can do a high quality job and

have a fast turnaround time,” explains Kenny. “There’s been a

movement towards reduced inventories by a lot of our cus-

tomers. Now we might run twenty or twenty-five parts for a

customer that used to order lots of one hundred. The fact that

our Charmilles machines are around forty percent faster than

our old wire EDM has helped us adapt to this shift.”

All of this translated into a good year for Liberty. A twenty

percent increase in sales allowed the shop to rehire all of the

workers laid off in 2002

and also add five new

positions to their workforce.

As the shop continues to

grow, they already know

where they will go when

they need to expand their

EDM.

“Once our ROBOFILs were

set up, they’ve run 24/7

for seven months without a

single problem,” says

Kenny. “When we need to

expand our EDM, we’ll be

looking to Charmilles.”

While foreign competition

continues to provide new

challenges to North American manufacturers, shops like Liberty

Machine show that hurdles can be overcome. Those at Liberty

see continued growth in the company’s future and, with the

quality of employees and machinery they employ, they have

every reason to.

www.charmillesus.comNew Ideas in EDM

THIS IS A SNAPSHOT OF HOW CHARMILLES MAINTAINED THE

Market Leader position during the challenging year2003 and plans to strengthen that position in 2004.We appreciate your choosing Charmilles EDM’s andwanted to keep you informed.

Summary 2003

1. CT-US maintained its #1 position in N. Americadespite lower orders, consistent with the 8.5% reduction in the U.S. machine tool market.

2. We ended the year strongly, shipping 35 machines inDecember alone.

3. CT-US was profitable (according to the IRS!) and had positivecash flow.

4. We maintained or improved customer service levels: 95% ofservice calls taken live by a trained service engineer, 99% ofspare parts shipped the same day, 60 service engineers at 30 North American locations.

5. We maintained, in the worst machine tool market in 70 years,CT-US’ capacity to meet your future demand as the marketrecovers. (13 more service engineers than during the ’97-’98market peak!)

2004 Outlook

All indications are that 2004 will see acontinuation of the late 2003 recovery:

1. Preliminary statistics from NTMA(National Tooling & MachiningAssociation) and AMBA (AmericanMold Builder’s Association) surveysshow a dramatic upswing in businessconditions at tooling and machiningshops in December 2003 relative toJuly to September 2003.

2. The improved tax structure, low interest rates and the lower dollar allsuggest continued growth.

a. The Robofil 240cc and 440cc, the world’s first high speedwire EDM’s, are meeting or exceeding users’ expectations.

b. The new Roboform 350 and 550 combine the most modern CNC control with the highest performing generator in the industry.

Conclusion: Charmilles maintained or improved customer support and resources through the manufacturing depression .N. American Manufacturing and Charmilles’ business are nowboth recovering strongly. Call Charmilles, 1 800 CTC-1EDM, oryour local Charmilles distributor to discuss how the newest models can help you get more than your share of the growing market!

Harry C. Moser

8

2003 RE V IEW &

2004 OUTLO O K

Winner, European HighSpeed Machining

Award 2002

AG IE CHARM IL L ES Group

G EORG FIS C HER + G F + M a n u f a c t u ring Tec hn o l o g y

www.mikron-us.com

The award-winning HSM 400 features a standard 7-position

palletchanger that allows you to run 24 hours a day, 7 days a

week, whether it is machining molds, dies, electrodes, or high

precision parts.

The unique polymer concrete bridge design provides superior

rigidity, vibration dampening and

thermal stability, resulting in

outstanding surface finishes,

accuracy and tool life.

Powerful vector spindles up

to 60,000 rpm,

combined with high

axis acceleration of

1 .7 g, deliver

exceptional high

speed machining

performace.

Contact us to join the

winner’s circle.

H SM 400 from Mikron

560 Bond St.

Lincolnshire, IL 60069

Tel: 1-888-282-1336

CHARMILLES WILL SHOWCASE MACHINES AT BOTH THE

WESTEC and EASTEC national manufacturing shows. Both

events are cosponsored by the Society of Manufacturing

Engineers, the American Machine Tool Distributors Association

and the Association for Manufacturing Technology.

The Roboform 350 diesinking EDM will be featured at the

40th annual WESTEC show to be held at the Los Angeles

Convention Center from March 22 to March 25. Charmilles’

presence at this show will be found in booth #3616.

The machine features Dynamic Process Control (DPControl), a

system designed to be directly involved with the manufactur-

ing process. Based on a standard Windows platform, the

software is easily integrated into existing system architectures.

The Roboform 350 will also be on display at the 25th annual

EASTEC show located at the Eastern States Exposition

Grounds in West Springfield, Massachusetts from May 25 to

May 27. The Robofil 240cc and Brother HS70A wire EDMs

will also appear at the show. Charmilles will be located in

booth #5345.

The Robofil 240cc uses the ‘High Speed’ CC generator to

increase machining speed while preserving surface integrity.

The machine contains a CNC based on the standard

Windows NT multitask operating system with an industrial

grade TFT touch screen and standard keyboard. The 240cc

also implements ThermoCut, a high-speed, maintenance-free

wire threading system that stretches and cuts wire under the

effect of heat.

The Brother HS70A wire EDM features the most compact

body in its class and a workpiece capacity of 770 lbs.

Automatic wire threading with a threading time of 15 seconds

and a new spark generator help increase productivity.

The machine also contains a new user/machine interface

with 10MB memory, 3D graphics and a 12.1" large

color display.

9

C h a r m i l l e s

Participates in

Trade Shows on

Both Coasts

www.charmillesus.com

TRADING IN YOUR ROBOFIL 290, 300 OR 310 TOWARDS A NEW ROBOFIL 240CC OFFERS ADVANTAGES THAT WILL INCREASE YOUR

shop's productivity and performance including significantly reduced cutting time and improved accuracy. The Robofil 240cc

features submerged machining, and promises a better surface finish and 3D graphics. The patented CC-generator

eliminates bluing on titanium and offers improved PCD cutting technology. And, the ThermoCut autothreader reduces

thread time by more than a minute. Check the facts...

Given the facts, can you really afford to wait? For more information on trading in your machine, please call your local distributor,

or contact Charmilles directly at 847-955-7112 or info@charmillesus.com.

11

It’s Time to Trade Up

New Ideas in EDM

Some Ma r k e t i n g

Thoughts – Wh o

Should Yo u

Ta rg e t ?

10

Written by Bruce Braker, President of Tooling &

Manufacturing Association

Charmilles Mikron Hosts HSMSeminars Nationwide

Charmilles Mikron will host six HSM seminars at various

locations nationwide during 2004. The HSM Seminar is an

intense one-day information-packed program run by

expert industry engineers for both prospective users and

current practitioners of high speed machining. The seminar

will cover the basics of the HSM cutting process and the

benefits of high speed machinging in a wide range of

applications.

HSM seminar locations:

Lincolnshire, Illinois (Charmilles)

Holliston, Massachusetts (Mikron)

Meadville, Pennsylvania

(Precision Manufacturing Institute)

Yorba Linda, California (Charmilles)

Lincolnshire, Illinois (Charmilles)

Holliston, Massachusetts (Mikron)

THOSE DOMESTIC MANUFACTURERS WHO WANT TO STAY

domestic have to pick their customer industries and com-

panies very carefully so they don’t find themselves

serving an industry that low cost developing countries or

others are likely to target. The small appliance industry, toys,

consumer electronics, and other such goods are largely

produced elsewhere. We’ve been losing those products for

years.

Think about comparative advantage criteria for products and

process that can best be done in America. Following are

criteria to consider:

1. Highly engineered and complex

2. Heavy and/or difficult to ship cost effectively

3. In demand in both the domestic U.S. market and for export

4. Industrial or commercial, not consumer

5. Produced with a high level of automation, capital intensive

manufacturing

6. Produced primarily with skilled labor

7. Products with unique high tech applications

8. In demand in the U.S. for security reasons -- defense,

homeland security, NASA, etc

9. Construction related

10. Packaging related

11. Energy production related

12. Medical related

13. Automation related

14. Transportation industry related

15. Aerospace related

16. Defense related

17. High value added

18. Short run and/or JIT production

19. Products needing considerable service support

20. Products requiring high maintenance

21. Production requirement of extremely tight tolerances

22. Subassemblies, not just discreet parts

23. If not subassem-

blies, kits of parts

that go into a

subassembly

24. “Family of Parts” opportunities

25. Coupled with high valued-added services

26. Subject to frequent change and revisions requiring high level

and frequent communications

27. Short lived

products

Focus on the criteria you believe describes a good customer

industry or product and then target that. Crain’s Chicago

Business recently reported on the strong demand for

Caterpillar’s $500,000 electrical generators. We read that the

town of Geneva bought a number of those generators from Cat

even before the outage in the Northeast. There’s a product that

meets many of the criteria listed above.

3/25/04

4/15/04

4/22/04

5/13/04

6/8/04

10/28/04

For registration information please call

1-847-955-7112. Visit www.charmillesus.com

for a complete list of seminar topics.

Charmilles to Participate in META L FO RM - Louisville SymposiumGisbert Ledvon, marketing manager for Charmilles

Mikron US, has been selected to speak at the upcoming

METALFORM-Louisville exhibition, scheduled to take place

March 30 – April 1 in Louisville, Kentucky. Mr. Ledvon’s

presentation, entitled ‘How to Make Powder Metal Dies

More Efficient Using New Die Sinking EDM Technology,’

will focus on recent advances in EDM, such as high speed

EDM, new generator technology and productivity improve-

ments resulting from twin-wire EDM. The session will also

encompass the basics of high speed machining and its

application in the creation of metalforming tools.

"Technology now moves at such a quick pace that many

significant improvements can be realized in the space of a

year," explains Ledvon. "Hopefully those who attend our

presentation will walk away with a better understanding of the

recent developments in EDM and some new ideas to improve

their companies’ performances."

METALFORM-Louisville is the first regional METALFORM show

to be put on by the Precision Metalforming Association after

over 20 years of annual national exhibitions. In an effort to

best serve those in the metalforming industry, the association

has now made the national show a biennial event, with

regional shows running in the off years. Charmilles’

presentation on EDM technology will be held at

11:30 a.m. on April 1.

12