Published 6/13/2017

New Tech, New Talent at GF Machining

This year’s annual open house marked the debut of not only a new series of wire EDMs, but also an apprenticeship program designed to serve as a pipeline of application and service engineers for years to come.

Matt Danford

Former Senior Editor, Modern Machine Shop

Corey Ocock, right, answered questions from assembled trade journalists about GF Machining Solutions’ new three-year, paid apprenticeship program, which he’ll join upon graduating from high school this year. At the conclusion of this program, he’ll have not only an education and the credentials to match, but also a guaranteed job and a possible future career as a service or applications engineer. At left is Scott Fosdick, the company’s head of Market Region Americas.

The open house event marked the North American debut of the company’s AgieCharmilles Cut P series wire EDMs. In addition to features detailed in the text below, these machines feature new Intelligent Power Generator (IPG) technology that is said to deliver surface finishes as smooth as Ra 0.08 µm while also boosting cutting speeds. This is possible, in part, through various functions that dynamically adjust power levels, spark parameters, cutting paths and more during machining. Other notable capabilities include cutting at angles ranging to 30 degrees throughout the entirety of Z-axis travel (45 degrees optional); positioning and contour accuracies of ±2 µm; collision protection at maximum axis travel speeds of 3 m/min.; and temperature regulation within ±0.2°C to ensure repeatability.

Examples of medical components produced on Cut P series machines, which are also said to be well-suited for aerospace, automotive, mold/die and electronics industry applications.

Milling machines aren’t just for milling these days. With a Hirth coupling locking the spindle rigidly in place, the company’s Mill P 800 U ST (for “simultaneous turning”) can consolidate setups and eliminate secondary operations. Four-axis, simultaneous-turning capability is said to be particularly useful when avoiding tool-shape errors requires positioning the cutting tool at a 90-degree angle to the workpiece surface.

EDMs and milling machines alike are increasingly paired with automation. GF Machining Solutions offers a source for that, too: technology from System 3R, a division of the company that celebrated its 50th anniversary at this year’s open house. In addition to carousel-style robots, System 3R specializes in standardized tooling systems that that enable transferring parts from workstation to workstation without losing references.

As demonstrated by conversations at both ends the machine, compact automation in the form of an 18-position pallet changer was a significant draw for this Mill X 400 U five-axis machining center. Featuring a 42,000-rpm spindle, the machine is designed for the kind of speed, precision and quality surface finishes demanded by modern medical applications in particular.

Crowds were large enough that patience proved to be a virtue when navigating aisles and getting questions answered. This area housed the company’s laser technology, including an expanded line of three- and five-axis laser-texturing machines like the ones in the background. Capable of texturing, micro-structuring, engraving, marking and labeling of 2D and 3D geometries, machines like this potentially have a big future in replacing labor-intensive chemical etching processes common to automotive interior tooling applications.

The AM 290 S additive manufacturing (AM) machine was made possible through a collaboration between the Switzerland-based GF Division and EOS, a German supplier of AM technology. It is designed primarily to enable mold and die manufacturers to build inserts with conformal cooling channels that snake closely along the contours of the insert’s geometry. A stark contrast to the typical network of straight bores, these curving channels provide more efficient, consistent cooling that speeds production, improves part quality and reduces costs.

As a young person interested in manufacturing, Corey Ocock potentially has quite a career ahead of him. Speaking to the trade press at GF Machining Solutions’ annual open house event, the company’s first U.S. apprentice expressed fascination with five-axis milling, a technology that’s far removed from what was available in his high school's manufacturing program and even in many businesses. In addition to the latest in milling, his upcoming apprenticeship will expose him to laser-texturing machines and laser-micromachining centers; automation, such as pallet changers and robotics; standardized workholding systems to go along with that automation; and, of course, the technology that proved to be the biggest draw at this year’s open house: electrical discharge machining.

More specifically, the new Cut P series of wire EDMs made its North American debut at the June 6-7 Solution Days event in Lincolnshire, Illinois. However, this wasn’t exactly a debut for everyone in attendance. On-hand to tout the benefits of the new offerings were Brian and Karl Bernt of Extreme Wire EDM, a Grandville, Michigan-based contract provider of wire electrical discharge machining services that was the first manufacturer on the continent to install a Cut P machine. Thanks in part to this purchase, the brothers are projecting significant growth during the next few years.

One of the main reasons for this growth is extra capacity. The 1250 can accommodate parts weighing more than 6 tons and measuring as large as 31.5 inches thick, 90 inches long and 54 inches wide. As detailed in this case study, that’s significantly larger than any of Extreme Wire’s 10 other wire EDMs, and there’s no need for workarounds like removing and reinstalling upper-nozzle components during setup. Extreme Wire also benefits from features common to the entire Cut P line, such as the ability to cut at taper angles ranging to 30 degrees throughout the entirety of Z-axis travel. View the picture gallery above for details, as well as information on the other technologies highlighted at the open house event.

Meanwhile, the spotlight on the new apprenticeship program demonstrated the company’s understanding that shops like Extreme Wire need more than just the right machines. They also need the right people to help maintain and repair those machines when necessary, and to prove that those machines can do what they’re advertised to do before the deal is signed. That’s where apprentices like Mr. Ocock come in. Becoming one of these service or applications engineers takes years of training, all while technology continues to evolve and seasoned personnel continue to retire. A source of fresh talent is critical to future success.

To that end, GF Machining Solutions has partnered with Harper College on a program that has apprentices alternate between class time and real-world, hands-on experience for three years. Upon completion, they receive nationally recognized certifications and an associate degree, and they’ll be expected to fulfill an additional two-year commitment with the company. In addition to qualifications and a job, they’ll have zero college-loan debt, and they’ll have earned a regular salary the whole time, even during periods of only classroom instruction. Set to begin as soon as he graduates high school, Mr. Ocock joins three other students (possibly four) in the company's first class of apprentices.