Reference system for Wire EDM machining. The standard range.

Reference system for Wire EDM machining. The standard range.

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FOCUS ON THE COMPLETE PICTURE FOR GREATER COMPETITIVENESS It’s a well-known fact that competition in the manufacturing industry is constantly growing. The trend towards shorter runs and more variations means that the total time from order to delivery is the crucial factor in the choice of a supplier. And it’s not just the process time in the various machines that counts here. Profitability is determined increasingly by the ability to minimise dead time in the machines and to have efficient flows of material and information in the workshop. So what really matters is to focus on the complete picture. Total throughput time instead of individual process time! The company that can offer the quickest delivery of small batches of customer-specific products will win out in future competition situations. The solution is a stable and exact reference system. This lets you preset away from the machine and then set up the machine in seconds. In fact, this is an essential requirement for modern production. With System 3R reference systems, you radically increase the capacity of your machines. Partly by minimising setting-up times. And partly because the reference systems are compatible with every machine in your workshop. And – not the least important point – it’s only a short step to automation. You get a reference system that you can build on steadily, bit by bit. Always flexible. Always reliable. Absolutely stable and exact. In addition, there’s no longer any need for skilled operators to waste time on tricky and time-consuming alignments. Instead they are free to do far more stimulating work, where their professional skill really comes into its own. Other advantages: downstream machining time is shorter, because accuracy becomes greater. The number of rejected workpieces is reduced, meaning less raw material to be stored. In other words, with the System 3R’s reference systems, production takes place in a more sensible and more economical way. Both in financial and in human terms.

WORK SMARTER Anyone can get a fantastic machine tool, loaded with every conceivable feature. With modern machines, making complex parts with close tolerances seldom presents any problems. The real challenge lies in raising the profitability of the business at the same time. The truth is, measures to reduce machine downtimes are almost always significantly more profitable than chasing seconds in the actual machining process. What matters is to keep the machines running. It’s simply a matter of working smarter. And helping you work smarter is what we at System 3R are in business to do.

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CONTENTS

System 3R Basic equipment WEDM ........................................................... page 8 Basic equipment Macro ............................................................ page 9 Mounting heads....................................................................... page 13 Mounting heads – holders and vices ........................................ page 17 Chuck adapters ....................................................................... page 24 Chuck adapters – holders......................................................... page 28 Adapter elements ..................................................................... page 30 3Ruler .................................................................................... page 33 3P

.................................................................................... page 37

Presetting and inspection .......................................................... page 38 User kits and supporting elements and accessories .................... page 41 System adapters between System 3R and Mecatool .................... page 44 Mecatool Basic equipment for machine tables .......................................... page 47 Mounting heads and adapters .................................................. page 49 Holders and vices .................................................................... page 51 Presetting and inspection .......................................................... page 53 User kits and supporting elements and accessories .................... page 54 Frame systems ......................................................................... page 55 Automation ............................................................................. page 57 Index .................................................................................... page 58

A green or yellow dot alongside the article numbers in the catalogue means: In stock. Can be dispatched immediately. Not a stocked item. Manufactured to order.

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500

Material removal mm3/min

been significantly improved over the past decades. The table shows values obtained by experience in coarse machining. So over the past 25 years, the material removal capacity has increased almost by a factor of 15. Fine figures, but the question is: does the user exploit this increased capacity, or is it a hidden resource?

Introduction

THE MATERIAL REMOVAL CAPACITY OF THE WIRE EDM MACHINES has

300 250 200

80 35 1980

150

Tooling-up time in a stationary machine

1990

2000

1995

2000

2005

times have remained largely unchanged. Let us take an example with an ordinary machining operation of 4200 mm3.

39

1995

1990

OVER THE SAME PERIOD tooling-up

Active machining time

1985

1985

1980:

4200 mm3/35 + 30 min tooling-up time in the machine = 150 minutes’ machine time.

2005:

4200 mm3/500 + 30 min tooling-up time in the machine = just over 39 minutes’ machine time.

Four times as fast, but far from the 15-fold capacity increase offered by the machine! So only 25% of the capacity increase offered by investing in a modern wire EDM machine is exploited.

2005

IF YOU HAD HAD THE FORESIGHT in 1980 to equip your machine with the System 3R reference system for pre-setting away from the machine, the figures look like this. 1980:

4200 mm3/35 + 1 min tooling-up time in the machine = 121 minutes’ machine time.

2005:

4200 mm3/500 + 1 min tooling-up time in the machine = just over 9 minutes’ machine time.

25 years successful technical development of the machines has meant a huge potential increase in productivity in wire EDM machining. Do you get the full benefit of this potential? 39 or 9 minutes for the same machining operation? The choice is yours.

121 Tooling-up time in a stationary machine

Active machining time

Can your company afford to work without the System 3R reference system?

1985

1990

1995

2000

2005

5

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Introduction

THE ENGINEERING INDUSTRY IS A COMPLEX ACTIVITY in which every company

is unique in terms of type of production, machine fleet, capacity etc. To satisfy all these requirements, System 3R has developed reference systems of exceptional flexibility. With System 3R equipment on the machine table you have access to an exceptional range of products for efficient wire EDM. The systems upgrade the versatility and boost the productivity of your machines by practically eliminating setup times.

0-25 kg Here there are two options: As basic equipment on the machine table you can choose either System 3R reference element WEDM or a Macrochuck.

Advantages of WEDM reference elements • A wide range of accessories for flexible and efficient production. • Ability to machine workpieces up to 50 kg using 3P. • Ability to machine workpieces up to 200 kg using 3Ruler.

Advantages of Macrochuck • A wide range of accessories for flexible and efficient production. • The ability to link together all your machines and freely move the workpiece from wire EDM to the milling machine, to die-sinking EDM without subsequent alignment. • The ability to fit the machine with a robot and carry on production round the clock in an automatic production cell.

Regardless of whether you choose WEDM or Macro, you can now choose a fixed mounting head or, if extreme accuracy is needed, a levelling adapter. The foundation is now laid for rational machining of workpieces weighing 0-25 kg. All that remains is to choose a suitable holder or vice from the catalogue.

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FROM SMALL TO LARGE WORKPIECES For those who are unfamiliar with System 3R’s with range of efficient tools, workpiece weight may seem to be one way of finding the right equipment. Do you still work with workpieces weighing 0-25 kg? Or do they range from 0-50 kg? Or possibly even 0200 kg?

0-50 kg 0-200 kg We recommend WEDM reference elements as basic equipment on the machine table, supplemented with 3P.

We recommend WEDM reference elements as basic equipment on the machine table, supplemented with System 3R’s 3Ruler ruler system.

3P

Basic equipment on the machine table

Reference element

Introduction

The WEDM system

3Ruler ruler system

Holders and vices

Mounting heads

The Macro system Basic equipment on the machine table

Manual or automatic chuck

Holders and vices

Mounting heads

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Basic equipment WEDM

SYSTEM 3R POSITIONS the workpiece in the

working area of the machine and on the machine’s zero line. Whether the workpiece is square, round, small or large, thin or high, it is clamped with minimal risk of collision. There are infinitely many possible combinations in the product range, the only limitation being the user’s imagination. Without doubt, System 3R offers the most comprehensive product range on the market. What is more, it also leads in terms of number of installations – world wide.

Reference element WEDM 3R-200.XJ.X

Reference element WEDM 3R-200.1J-U

Reference elements for machines with zero-line table. The length (L), hole spacing (C) and hole edge spacing (B) of the hardened reference elements are matched to the machine in question.

Universal 140 mm reference element, with oval holes, for all machines that have M8 holes in the machine table, 30 to 40 mm from the edge of the table. • Weight 0.4 kg

Note: When ordering, state machine make and type. • Supplied with end stops

RZ

R 13.7 ±0.5 mm

RY

RX Alignment of 3R reference elements in relation to the machine´s X/Y motions takes place by indexing on, for example, the surface R.

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The 3R reference elements are equipped with end stops, thus giving fixed references in three directions.

Basic equipment – Macro

IF YOU CHOOSE A MACRO CHUCK as basic equipment on the machine table, you can interconnect all your machines to form a single system. Move the workpiece from wire EDM to die-sinking EDM to grinding machine, all without subsequent alignment – quickly and precisely. And if you choose an automatic Macro chuck, you can operate round-the-clock production if you wish.

   Z-references with automatic air-blast cleaning.

Macro – the key to automation.

3Refix Ø10 mm.

X/Y-references in cemented carbide.

Turbo-locking – the blast cleaning air boosts the clamping force.

Macro – the same interface for all your machines.

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Basic equipment – Macro

RZ RX

RY

Recommendations for loading in Macro chucks.

Table chuck with horizontal fixing of the workpiece. Atricel number

Maximum torque

Capacity

3R-602.27-1

18 Nm

12 kg

3R-602.10

22.5 Nm

15 kg

3R-602.10HP

30 Nm

20 kg

3R-602.27

30 Nm

20 kg

3R-602.12

37.5 Nm

25 kg

3R-602.12HP

45 Nm

30 kg

X=150 mm

X

kg

Table chuck with vertical fixing of the workpiece. Atricle number

Capacity

3R-602.4.1

7-8 kg

3R-602.27-1

7-8 kg

3R-600.24-4RS

7-8 kg

3R-60.360-X

7-8 kg

kg

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Basic equipment – Macro

Automatic chucks Macro Pneumatic chucks for Macro holders. Horizontal mounting on the machine table. Supplied with drawbar 3R-605.10 and protective cover. • • • •

Required air pressure 6 ±1 bar. Fixed index positions 4x90° Air-blast cleaning of Z-references. Weight 1.1 kg

3R-602.10HP Note: When clamping Macro mounting heads, type HP only. • Clamping force 7000 N

3R-602.10 • Clamping force 4500 N

Automatic chuck, Macro 3R-602.4.1 Pneumatic chuck for Macro holder. Vertical mounting on the machine table or in the WEDM system. • • • • • •

Required drawbar 3R-605.1RS Required air pressure 6 ±1 bar Clamping force 6000 N Fixed index positions 4x90º Air-blast cleaning of Z-reference Weight 3.7 kg

Machine-adapted B-axes Macro 3R-60.360-X Compact pneumatic B-axes for mounting on the machine table. 0-360° with smallest indexing step 0.001°. Air connections for open/close, as well as turbo-locking/airblast cleaning. Quick-release connections for cabling. Note: The units are controlled by the machine. Therefore, state machine make and type when ordering. • • • • • • •

Required drawbar 3R-605.1RS Required air pressure 6 ±1 bar. Rust-resistant. Indexing accuracy ±0.02° without correction Speed range 0-10 rev/min Automatic air-blast cleaning of the Z-references Weight 18 kg

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Basic equipment – Macro

Automatic chucks for MacroTwin

3R-602.12HP

Pneumatic chucks for Macro or MacroTwin holders with workpieces