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Wire and Spark erosion Machine Tools from Agie - Camcraft Ltd

Story added 19 July 2010.

Precision toolmaking specialist – Camcraft Ltd – has recently invested in 3 new EDM machine tools from GF AgieCharmilles.

The machines (2 x FO 550S spark erosion machines and 1 x FI 640CC CleanCut wire machine) were installed at Camcraft’s facility in Bishops Frome, Worcestershire in 2009 and are being used to manufacture high-precision complex mould tools and inserts for gas turbines used in the land based power generation and aerospace (aero-engine) sectors.

The 3 machine tools replace older, less sophisticated EDM technology that Camcraft had at its disposal and were selected for their size (generous working envelopes to handle large parts and/or to handle multiple, smaller jobs); their machining performance (high accuracy, superior surface finishes, and optimum removal rates and cutting speeds), and their autonomy.

Says Steve Pearson, managing director at Camcraft:

‘The mould tools and inserts we manufacture are incredibly complex. They are characterised by their accuracy and intricacy (i.e. delicate and hard-to-machine details and features such as thin walls, tight radii etc.), and by their high value.

‘As a consequence we need access to the most advanced and most productive technologies to help us manufacture tools to the highest quality... to meet the tight delivery times we work to...and to help us control our costs. ‘

The machines

The FI 640CC (CleanCut) machine is equipped with a high-performance digital generator that combines speed (500mm2/min) with excellent machining results (i.e. elimination of the re-cast layer and surface finish realisation of Ra 0.2µm).The machine also features automatic wire thread capability (for long, uninterrupted running), integrated collision protection (for greater process reliability) and linear glass scales for guaranteed accuracy.

The FO 550S die-sink machines (X-, Y- and Z-travels of 600mm x 400 x 450mm respectively), can handle large workpieces (up to 1600kg). The machine is equally adept with Graphite as well as Copper electrodes - and workpiece surface finishes of Ra 0.1µm can be achieved.

Camcraft mould tools (aerospace)

Modern aircraft engines need to satisfy several (often competing) requirements. They must be:

• Lightweight: heavy engines decrease the amount of excess power available.

• Small and streamlined: large engines, with substantial surface areas, create too much drag and waste fuel and reduce power output.

• Powerful: to overcome the weight and drag of the aircraft.

• Reliable: aircraft engines operate at high temperatures, pressures, and speeds - and therefore need to operate reliably and safely under all these conditions.

• Repairable: to keep the cost of replacement down.

• Efficient: to reduce emissions and environmental impact

Constant research and development in aero-engine design, materials science and methods of manufacture are therefore the nature of the game – and it is in this environment of change and constant refinement where Camcraft operates.

Camcraft mould tools are used in the investment casting (lost wax) process.

The Company works closely with its foundry customers (based in the UK and overseas), to design, manufacture high-quality tools which are used to produce a range of performance-critical aero-engine parts such as turbine blades and vanes, as well as a variety of engine mountings and housings.

Investment casting of new, super engine alloy materials (i.e. Titanium alloys) enables the development of more intricate and innovative designs that improve engine performance and deliver greater engine fuel efficiencies. And, because aero-engines run at higher temperatures they must be cooled by ever more complex cooling solutions which must also be accommodated in an aero-engine’s design and manufacture.

Camcraft mould tools start life from drawings and/or models. The mould tools and inserts are machined using GF AgieCharmilles technology from which the wax patterns (expendable) and ceramic cores are made.

To ensure that the patterns and cores produce the desired finished casting result it is likely that a number of design modifications will occur to the mould tool and a number of different iterations made to the patterns and cores as a consequence.

The process can be long and involved – but Camcraft, though its experience and know-how (including access to advanced machine tool technologies), can be relied upon to deliver on-time, in-time and in-budget solutions.


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