System 3R Tooling
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Tooling for electrode manufacturing & EDMing

GF Machining Solutions : all about you When all you need is everything, it’s good to know that there is one company that you can count on to deliver complete solutions and services. From world-class electrical discharge machines (EDM), Laser texturing and Additive Manufacturing through to first-class Milling and Spindles, Tooling, Automation and software systems — all backed by unrivalled customer service and support — we, through our AgieCharmilles, Microlution, Mikron Mill, Liechti, Step-Tec and System 3R technologies, help you raise your game and increase your competitive edge. Design...

Care for the environment and protection of natural resources are key elements in System 3R’s operations + We take all necessary precautions to prevent contamination of soil, air and water. + In our production processes, we continually improve the efficiency of our energy use. + The products and methodologies we offer the market improve the efficiency of our customers’ use of existing resources. Manufactured to meet System 3R’s quality requirements, but partly or completely made in a production plant that is not covered by System 3R’s ISO9000 certificate. Indicates that the product will...

? Experience always shows that measures to reduce the idle times of your machines are significantly more worthwhile than chasing seconds in the actual machining process. The solution is a stable and exact reference system. This lets you preset away from the machine and then set up the machine with minimum idle time. Quickly and precisely! ! Fitting the machines with the same reference system means that electrodes and workpieces can be moved between the machines without subsequent alignment and checking – One Minute Set-up. System 3R tooling for electrode manufacturing & EDMing

Conventional setting-up Machining time Idle time One manned shift – eight hours Pallet system One manned shift – eight hours Higher productivity, calculation example: Conventional setting-up Pallet system Setting-up time per day (hours) Working days per week Spindle time per week Faster payback, calculation example: Conventional setting-up 50 Revenue / week (€) Capital cost of machine (€) Capital cost pallet system (€) Total capital outlay (€) Paybacktime (weeks) A reference system minimises setup times Every minute that can be converted from internal to external setting time increases the...

Introduction – Rough guidance to tooling Maximum size of workpiece or electrode, square or round (mm) MacroStandard MacroStandard MacroHighPerformace MacroHighPerformance Matrix Matrix 110 110 Matrix Matrix 142 142 MacroMagnum MacroMagnum Martix Matrix 185 185 Maximum workpiece weight (kg) Pallet size (mm) Macro Junior Macro Std/HP Macro Magnum Above list is only a rough guidance which may deviate between article number of pallets as well as individual application. Please check with local 3R representative for more detailed confirmation. 6 System 3R tooling for electrode manufacturing &

The references of the pallet are created directly in the pallet and on a single plane. There are no loose parts to be installed and adjusted by the user. The X and Y references of the chuck are made of cemented carbide. The Z-references of the chuck have generouslysized surfaces to ensure the highest stability. The Z-references are automatically air-blast cleaned, through nozzles in the Z-references of the chuck. Turbo locking. Extra locking force is provided by airblast cleaning air which is automatically diverted to the locking piston when the Z-references seal against each other. System...

VDP (Vibration-Damped Palletisation) … reduces cutting forces by up to 25%. Lower cutting forces gives lower power consumption and less tool wear. … lengthens tool life tool wear by up to 30%, giving lower tool costs. … lengthens the life of the machine spindle. Less vibration in the machine spindle extends the life of the spindle by at least 30%. … gives shorter lead times. VDP allows machining with higher cutting data – better utilisation of the existing machine capacity. A 30 % capacity increase is within your reach. With conventional chucks, vibrations of the workpiece caused by the...

Increase your capacity with > +30% WITH Power Conventional clamping 9 mm was the maximum allowed dept of cut for the cutting tool Less tool wear extends the life of the tools = increased revenue. Process Stability Analysis (Swiss machine tool manufacturer) Cutting Speed (RPM) Axial Depth of Cut (mm) Magnum Std Increase in removal rate due to VDP (%) *Depth of cut is limited by the cutting tool used for the tests and not by the VDP. The diagram shows the effect on the oscillation amplitude when machining with the workpiece clamped conventionally and in a damped chuck. 9 System 3R tooling for...

MacroJunior & MacroCombi … gives extreme flexibility … one chuck, two systems … reduces setting-up times. … ensures precision and quality … is suitable for automatic changing with System 3R’s automation program. MacroCombi profitability in tool manufacturing is determined largely by the extent to which machine downtime can be minimised. A reference system which allows presetting away from the machine – followed by super-rapid tooling-up in the machine when the time comes – is a highly efficient way of working. MacroCombi is such a reference system. The MacroCombi system offers extreme...

MacroJunior & MacroCombi – Chucks MacroJunior pallet/holder/reference element Macro & MacroJunior pallet/holder/reference element Spindle chucks Article number machine-adapted machine-adapted Macro pallet/holder/reference element Lathe chuck Article number Macro or MacroJunior pallet/holder/reference element Drawbar MacroJunior pallet/holder/reference element Drawbar Table chucks Article number Built-in chucks Article number 11 System 3R tooling for electrode manufacturing & EDMing