Tooling for electrode manufacturing and EDM

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.

Introduction �?Rough guidance to tooling

	MacroJunior and MacroCombi The MacroCombi chucks accept two completely different types of electrode holder. Both Macro with its immovable stability and precision, and MacroJunior with its highly economical holders�?/p> DOWNLOAD CATALOG
MacroStd and MacroHP Among users world wide, the Macro system is a byword for precision. And with good reason, since very single Macro product is thoroughly checked before it is dispatched�?/p> DOWNLOAD CATALOG
	MacroNano MacroNano system is best described in two words as precise and quick! The MacroNano clamping system links the production chain through an ultra-precision coupling both for workpiece and electrode holding�?/p> DOWNLOAD CATALOG
MacroMagnum MacroMagnum is larger variant of the patented Macro system. The high clamping force and the position of the reference surfaces far away from the chuck centre�?/p> DOWNLOAD CATALOG
	Matrix As well as extreme accuracy, Matrix features low construction height, ultra-precise indexing, a drawbar with through hole. The through hole allows high/long workpieces to be sunk into the chuck for stable/rigid fixation�?/p> DOWNLOAD CATALOG
GPS240 The machining zero point is defined by the centre of the chuck in the GPS 240 system. The system is made for universal use and can be used in all kinds of applications milling, turning, grinding, EDM and measuring�?/p> DOWNLOAD CATALOG
	Dynafix Dynafix permits machining with optimal cutting data, without sacrificing accuracy and quality. The easy-to-handle aluminium pallets have reference elements of high-alloy steel with directly measurable Z-references�?/p> DOWNLOAD CATALOG
Maxi Maxi an especially robust, uncomplicated and user-friendly system for larger and heavier electrodes and workpieces�?/p> DOWNLOAD CATALOG
	Mini The Mini system provides rapid and exact mounting of the electrode holders in hydraulic quick-change chucks�?/p> DOWNLOAD CATALOG
3Refix 3Refix is remarkably simple way to lay a solid foundation from which to view the future with confidence �?tool up without indication and cut your production costs�?/p> DOWNLOAD CATALOG

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Tooling for Wire EDM

Three steps to success �?The route to rational production in Wire EDM machines can be summarised in three steps �?Mounting, Reference system and Automation.

	Basic equipment, Wire EDM Wire EDM positions the workpiece within the working area of the machine and on the machine’s zero line. Whether the workpiece is rectangular or round, small or large, thin or thick, tall or short, it is clamped with minimal risk of collision. DOWNLOAD CATALOG
Basic equipment, Macro With a Macro chuck as basic equipment on the machine table, you can interconnect all your machines to create a single system. Move the workpiece from the wire EDM machine to the grinding machine or the die-sinking machine without subsequent alignment �?quickly and precisely. DOWNLOAD CATALOG
	B-axis, Macro Compact Rotary Indexing Tables with pneumatic Macro chuck. Indexing 0-360° with smallest step 0.001°. Air connections for open/close, as well as turbo-locking/air-blast cleaning. DOWNLOAD CATALOG
Mounting heads Rapid setup is essential if you want to benefit from the material removal capacity and the accuracy offered by modern machines. However, faster machines with increased flushing pressure cause resonance and vibration. DOWNLOAD CATALOG
	Holders và vices trong mounting heads Supervice solves setting-up problems for the most frequently occurring sizes of workpiece �?small to medium-sized. The high repetition accuracy not only allows presetting and fast setup; it also provides a solid foundation for rational series production. DOWNLOAD CATALOG
Chuck adapters A wide range of chuck adapters for clamping workpieces on pallets in the Macro, MacroJunior and Mini systems. An ever-growing field of application is the manufacture of precision parts for the medical industry; another is the manufacture of electrodes for Die-sinking EDM. DOWNLOAD CATALOG
	Holders for mounting in chuck adapters The holders have been adapted for modern machines with high flushing pressure. These holders are mainly intended for clamping small to medium-sized workpieces on the zero line of the machine. DOWNLOAD CATALOG
Adapter elements Adapter elements allow machining of complex geometries, even if the machine is not the very latest model. The range includes products for swivelling or height adjustment, as well as plain spacer elements. DOWNLOAD CATALOG
	3Ruler ruler system The 3Ruler ruler system has been developed for clamping medium-sized and large workpieces in machines with a parallel or U-shaped machine table, as well as for machines with a frame table. DOWNLOAD CATALOG
EconoRuler System The EconoRuler have been developed for clamping medium-sized and large work pieces in machines with a parallel or U-shaped machine table, as well as in machines with a frame table. DOWNLOAD CATALOG
	3P Three-point system Minimal risk of collision with three-point clamping. 3P is equally well suited to rectangular or round workpieces. Clamping takes only a few seconds. DOWNLOAD CATALOG
Presetting and inspection Machine can be used either for active machining or for non-productive setting-up operations on an idle machine. You can optimize machine capacity by presetting away from the machine. DOWNLOAD CATALOG
	System Matrix for Wire EDM Extreme accuracy, Matrix feautures low construction height, ultra-precise indexing, a drawbar with a big through hole. DOWNLOAD CATALOG
Frames Frames are large palletising systems adapted to the Wire EDM machine table dimensions.

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Tooling for parts production

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!

Introduction �?Rough guidance to tooling

Maximum workpiece weight (kg)
Pallet size (mm)	Macro	MacroMagnum	Matrix	GPS 70	GPS 120
�?52-54	5 kg	5 kg
�?54-Ø 75	10 kg	10 kg
Ø 70				10 kg	10 kg
Ø 110-116	50 kg	50 kg	50 kg
Ø 120					20 kg
Ø 142-185	50 kg	100 kg	100 kg
Ø 220-260		100 kg	200 kg

Maximum workpiece weight (kg)
Pallet size (mm)	GPS 240 Square	GPS 240 Round	Dynafix	Delphin	DelphinBig
Ø 256		150 kg
⧄�?40-300	150 kg
⧄�?80-400			250 kg
□�?98				2000 kg
□�?48				2000 kg
□�?50-3000				500 kg / chuck; max 2000 kg
□�?00-10000					2000 kg / chuck; max 10000 kg

	MacroStd and MacroHP Macro is a reference system. A system that minimises the throughput time, and which, thanks to its accuracy, practically eliminates rejects. A system that increases flexibility and profitability�?/p> DOWNLOAD CATALOG
MacroNano Nano-precision machining requires nano-precision referencing of workpieces and tools- a real challenge even with state of the art solutions available in the market�?/p> DOWNLOAD CATALOG
	MacroMagnum MacroMagnum is larger variant of the patented Macro system. The high clamping force and the position of the reference surfaces far away from the chuck centre�?/p> DOWNLOAD CATALOG
Matrix As well as extreme accuracy, Matrix features low construction height, ultra-precise indexing, a drawbar with through hole. The through hole allows high/long workpieces to be sunk into the chuck for stable/rigid fixation�?/p> DOWNLOAD CATALOG
	GPS70 and GPS120 The machining zero point is defined by the centre of the chuck in the GPS 70 and GPS 120 system. The chucks can be mounted on the machine table of any machine tool�?/p> DOWNLOAD CATALOG
GPS240 The machining zero point is defined by the centre of the chuck in the GPS 240 system. The system is made for universal use and can be used in all kinds of applications milling, turning, grinding, EDM and measuring�?/p> DOWNLOAD CATALOG
	Dynafix Dynafix permits machining with optimal cutting data, without sacrificing accuracy and quality. The easy-to-handle aluminium pallets have reference elements of high-alloy steel with directly measurable Z-references�?/p> DOWNLOAD CATALOG
Delphin and Delphin BIG The modular design with the Delphin zero point clamping system offers you the greatest possible flexibility… DOWNLOAD CATALOG

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Tooling for Powder Compacting Technology

Use System 3R tooling when producing punches and dies – Gives an increased productivity in the Tool shop by a reduction of the set-up times, improved accuracy & quality and reduced number of rejections. Use System 3R tooling also in the powder compaction process – Reduces the set-up times in the press and gives an improved accuracy & quality and less repairs.

	The Macro system for punches Choice of reference element is determined by required pressing force.
The Matrix system for dies and punches
	3Refix for dies 3Refix is a cost effective solution.
Positioning accuracy Improved positional accuracy. Closer tolerances for finer grains.
	Angular accuracy Smaller angular deviations. Less wear and damage to punch and die.
Single level configuration – Manual optiion
	Single level configuration – Automatic option
Multi level configuration
	Punch alignment system Enables adjustment of punches within metal powder compacting by Macro system.

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Automation – Palletized handling

Automation keeps production going whatever the time of day or day of the week. The result is shorter lead times, higher productivity and quicker payback of capital invested in machines.

	System 3R WorkPal 1 Designed for automatic changing of pallets in chucks on machine tables in milling machine, wire EDM machine, laser machine or grinding machine. DOWNLOAD CATALOG
System 3R WorkPartner 1+ WorkPartner 1+ is intended for applications in milling machines, grinders, die-sinking EDM, wire EDM and laser machines, and it is just as effective with one-off manufacturing as with series production. DOWNLOAD CATALOG
	System 3R Transformer WorkMaster Scalable Automation solutions for various types of machines. With standardized modules allow for cost-effective yet flexible Automation. DOWNLOAD CATALOG
System 3R Transformer 6-Axis robot The 6-axis robot solution covers applications in terms of transfer weight from 70-700 kg, radial reach, up to 3 400 mm and complexed transfer movements and parts handling. DOWNLOAD CATALOG

Download Catalog System 3R Automation

System 3R WorkPal 1

Designed for automatic changing of pallets in chucks on machine tables in milling machine, wire EDM machine, laser machine or grinding machine.

Automation made simple
With glass doors across one full side, the WorkPal 1 gives maximum access to the magazine. This greatly facilitates the loading and unloading of pallets.

Smallest footprint
WorkPal 1 is a pallet changer that requires minimal floor space.

Different applications

• Max 50 kg handling weight long stroke of 1450 mm
  The WorkPal 1 can lift and handle a total weight of 50 kg including gripper, pallet and workpiece.
• WorkPal 1 can serve max 1 machine
  The WorkPal 1 serves all technologies like EDM, WEDM, Milling, Laser and Grinding
• Supported tooling systems
  The WorkPal 1 supports 1 tooling system in the magazine. There are 20 different tooling systems which can be prepared for in the magazine.
• WorkPal 1 your first step into 24/7 automation
  Prepare an extra shift and make sure you produced 24/7.

Configuration:

Video:

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System 3R WorkPartner 1+

WorkPartner 1+ is intended for applications in milling machines, grinders, die-sinking EDM, wire EDM and laser machines, and it is just as effective with one-off manufacturing as with series production.

Modularity adapted to your needs
One or two magazine capability gives exceptionally flexible capacity.

Open architecture
As with all System 3R products, its open architecture allows it to interconnect and serve different machines.

Different applications

Configuration:

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System 3R Hybrid automation

Concept for mix palletized automation together with parts handling. For Parts Handling, fully automatic change from part A to part B in the machine The system keeps track of NCprogram, cassette, gripper, chuck adapters, quantity etc.

Always easy-to-use and reliable
The software is based on the WorkShopManager/CellManager from System 3R.

Open architecture
As with all System 3R products, its open architecture allows it to interconnect and serve different machines.

Mix to your needs �?Palletized or parts handling automation

Easy step-by-step

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CellManager

1 or up to 12 machines in a cell. Supports different types of machines (e.g. Milling, EDM, Wire EDM, Laser, CMM and cleaning). Makes processes safer and has ID system for identification.

Intuitive and user friendly
Clear, graphical display of magazine content.

System 3R development
Supports System 3R Automation – WorkPal, WorkPartner 1+ and Transformer 6-axis robot

CellManager components

	Workflow: WorkCenter – Preparation + Generate jobs/work orders + Assign operations and NC programs + Request and transfer offset values + Approve and release jobs/work orders for production
Workflow: CellManager -Execution + Manage pallet IDs and magazine positions + Generate priority lists + Automatically start released jobs/work orders based on the priority list.
	Workflow: CellStatistics + Check utilisation in period, time of day + View via various graphical representations + Export statistics into Excel.
Option: CTM-CutterToolMonitoring + Cutters used for an operation are stored in the database + Cutters needed for each job are compared with the machine’s tool magazine + Jobs where the cutters are not available are blocked + Cutters can be assigned estimated lifetimes (if lifetime monitoring is activated on the machine)
	Option: AlarmServer (example) + Robot cell 1 stops due to air pressure failure + AlarmServer receives the alarm + Operator 1 receives an SMS message “Air…
Option: AES �?AutomaticElectrodeSelection Selection is based on the electrode part number, the actual wear status of the present electrodes and how fresh the electrodes need to be for the erosion job…
	Option: CellMonitor Separate software program for monitoring several cells – Cell status, Machine activity and Job status…

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WorkShopManager

Seamless integration of all your processes. Quick and accurate overview of the entire process chain. Management of the entire automation process.

Grows with your needs
Designed for your future (new machines, magazines and options can be added later on).

Open architecture
As with all System 3R products, its open architecture allows it to interconnect and serve different machines.

WorkShopManager package

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EasyCellManager

1 to 4 machine supports (milling and laser only). Easy-to-learn and has touchscreen support.

Prioritise jobs
Easy to prioritise jobs (move up/down or stop)

System 3R development
Supports System 3R Automation – WorkPal 1, WorkPartner 1+ and Transformer 6-axis robot

EasyCellManager package

	EasyCellManager + Easy-to-Use and install + New user interface and colour scheme + Now features loading station support + ID system not needed…
1, 2, 3 or 4 machine support

Video

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Sumitomo AC503U – For General Purpose Cutting of Hardended Steel Materials

This is a general purpose grade for machining of hardened steel. Utilising a new PVD coating with super multi-layered, nanometer thick TiAlN and AlCrN layers that provides exceptional wear resistance, when combined with a carbide sustrate.

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