The DRILL 300 is a new EDM drilling machine manufactured in Switzerland by GF Machining Solutions for machining cooling holes in aircraft engine components. It features a state-of-the-art digital generator that increases drilling speed by up to 40% compared to conventional EDM drilling. The machine also reduces the heat-affected layer to just a few microns for high-quality holes. Optional automatic electrode and guide changers provide long periods of unmanned operation for high productivity.

1. GF Machining Solutions
DRILL 300
AgieCharmilles

2. 2 AgieCharmilles DRILL 300
Swiss design
and quality
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3. The winning solution
High-speed EDM drilling
Fine hole quality
Powerful control
Quick preparation
High degree of autonomy and Automation
GF Machining Solutions
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Contents
DRILL 300
The winning solution for cooling hole machining of components
in aircraft engines
In today’s aircraft engines, the temperature in the combustion
chamber can be close to the melting point of the nickel alloy used.
In order to create a film of cooling air on the
surface of components to prevent the nickel alloy from
melting, cooling holes are needed on the curved surface of com-
ponents such as turbine blades, vanes, and shrouds. Machining
these cooling holes with high quality and pro­ductivity is always
the main concern for aircraft engine
component manufacturers.

4. 4 AgieCharmilles DRILL 300
The DRILL 300 is equipped with GF Machining Solutions’ latest
digital generator, allowing the drilling process to be continuously
optimized with every pulse. As a result the machining speed has
been increased significantly compared to conventional EDM drill-
ing.
Technology is chosen according to the desired results. For exam-
ple, by selecting “quality” technology, the electrode wear will auto-
matically be reduced and the heat-affected layer is reduced to a
few microns. Conversely, the operator can select “speed” technol-
ogy to produce holes with the fastest possible erosion rate.
With six-axis configuration, holes with different positions and an-
gles can be freely programmed and machined, allowing for great-
er part flexibility and design. Single setup machining reduces un-
productive time.
By using the automatic electrode/guide changer (AEC/AGC), multiple
holes with different diameters can be machined automatically and
the machine attains longest autonomy.
Due to wide range of optimized technologies for electrically conduc-
tive material like Inconel, steel and hard metal, the DRILL 300 is a
winning solution for cooling hole machining in aerospace as well as
other industrial applications such as cutting tools, automotive, med-
ical and die plates.
The GF Machining Solutions’
answer

5. 5 AgieCharmilles DRILL 300
With 60 years of experience
building Electrical Discharge
Machines, GF Machining
Solutions has developed
a new EDM drilling machine,
the DRILL 300. This machine
is manufactured in Switzerland
to deliver top performance in
machining cooling holes for
aircraft engine components.

6. 6 AgieCharmilles DRILL 300
100 mm
60 mm
High-speed EDM drilling
Increasing
your productivity
The EDM generator has state-of-the art powerful electronics to increase production output by
utilizing efficiently controlled EDM processes that include FPGA technology, digital data
recording and fully digitized pulse control. The drilling process is continuously optimized with
every pulse, thus the fastest drilling speed is achieved.
Drilling time
Without breaktrough
detection
With advanced
breaktrough
detection
20 mm
100 mm
48 s
280 s
Depth
Electrode: brass, Ø 1.0 mm
Workpiece: steel
Speed technology
Conventional
drilling time
28 s
170 s
DRILL 300
drilling time
DRILL 300
up to 40% faster
Conventional
EDM drilling
DRILL 300
Fast and reliable breakthrough
Without breakthrough detection, the machining time at break-
through is even longer than the entire hole drilling time when the
flushing process breaks down. With advanced breakthrough detec-
tion on the DRILL 300, the process is monitored in a real time; the
technology is adapted automatically to exit technology; the reliable
process is attained and the breakthrough time is shortened by 50-
70 percent.

7. 7 AgieCharmilles DRILL 300
Steel
Hard metal
Inconel 718
Aluminium
Copper
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Optimal technologies
One type of technology cannot meet all of your requirements. Ac-
cording to the workpiece material and your stringent metallurgical
requirements, the DRILL 300 has the optimized technologies to fo-
cus on either quality or speed. The quality technology achieves mini-
mum heat-affected layer and better hole integrity, while the speed
technology focuses on short drilling time.

8. 8 AgieCharmilles DRILL 300
Fine hole quality
The new standard in
hole-drilling EDM
Minimum heat-affected layer
Heated-affected layer has significant influence on the fatigue life-
time of components and the safety of aircraft engines. The DRILL
300 is designed for achieving the best result in terms of heat-affect-
ed layer and avoiding cracks in the components.
The DRILL 300 digital generator allows the finest pulse duration of
a few microseconds. When quality technology is used, the heat-af-
fected layer can be dramatically reduced to a few microns with a
reasonable machining speed.

9. 9 AgieCharmilles DRILL 300
with FirstSpark
without FirstSpark
Electrode: brass, Ø 1.0 mm
Workpiece: steel, 20 mm height
Quality technology
Consistent hole dimension
When machining cooling holes with conventional EDM drilling, the
spatters at the hole entrance are always a problem,
especially if there is a small angle between the hole and surface
of components. The DRILL 300 has a fine pulse applied with the
first spark function, then the technology is automatically adapted
to the standard parameters. Therefore, the spatters in the hole
entrance are avoidable and a perfect profile is achieved.
In order to optimize the machining of the most complex holes, the
DRILL 300 provides the way of programming
parameters corresponding to the machining depth. Multi-
parameters can be used in the same hole.
With advanced breakthrough detection “Breakthrough Strategy”
on the DRILL 300, the hole exit technology is optimized and the
exit electrode length is programmable, and backstriking can be
prevented. Meanwhile the quality technology also helps attain the
right hole dimensions at the bottom of the hole.

10. 10 AgieCharmilles DRILL 300
Powerful control
To manage sophisticated
hole machining
CNC control
In order to meet the demands of different applications, the DRILL
300 can be configured with different kinematics: XYZW, XYZWBA,
XYZWAB, XYZWB1C1, XYZWB1, XYZWAB1. With single setup the
holes with different diameters, positions and angles are freely pro-
grammable and machined.
Control unit
The graphical user interface is based on the Windows operating
system and allows real time control of the EDM process. The sys-
tem works with descriptive picture symbols and conversational
screen pages following one after another in a logical way. This al-
lows even new users to understand the EDM principle quickly and
means time to production is very short.

11. 11 AgieCharmilles DRILL 300
Manual operation – Easy Drill
Main functions include all setup cycles, easy and fast program-
ming for single hole machining (one hole on one page) as well
as electrode and guide management.
Work preparation
The machine can import the entire work in the format of XML.
NCC, ISO.NCC and PAT.NCC (compatible with AC CAM DRILL) di-
rectly or prepare the work manually with TEACH function. The
parameters of every machining can be modified with Edition.
The work can be graphically checked.
Work execution
This page activates the work and executing measuring cycles. All
machining, parameters and hole positions are monitored on this
page.

12. 12 AgieCharmilles DRILL 300
Quick preparation
Single setup machining
With different kinematics of six axes, holes with different
diameters, positions and angles can be freely program-
mable and machined even with single setup, allowing for
greater part flexibility and design. Single setup machining
eliminates the need for additional expensive fixtures and
avoids multiple setups to reduce unproductive time.
Reducing the
un­productive time
Fast setup cycles
The universal console is equipped with the touchscreen based on
the Windows operating system. The setup cycles probe, edge find-
ing, corner finding, center finding, etc., help to prepare the job in a
convenient way.
Less down time
To ensure the longest life and reliability of the electronics,
a closed water-air cooling circuit is contained within a dustproof
cabinet, in which the temperature is also monitored and stabilized
with multi-sensors.
With this design, the lifetime of the electronics is guaranteed even
in the most difficult conditions.

13. 13 AgieCharmilles DRILL 300
High degree of autonomy and Automation
Automatic filtration and conductivity control
With the 200-liter water tank and a 10-liter resin bottle in a stand-
ard configuration, the water filtration and conductivity are auto-
matically controlled and cycled.
For maximizing
productivity
Automatic part changer
With the optional Automation kit, the DRILL 300 can connect to exter-
nal robot to automatically manage part changing.
Automatic electrode/guide changer
The optional linear 16/4 electrode/guide changer and 50/8 rotary
electrode/guide changer are available on the DRILL 300. AEC/AGC
16/4 is affordable solution and AEC/AGC 50/8 is a solution with the
longest autonomy for max productivity.

14. 14 AgieCharmilles DRILL 300
DRILL 300
DRILL 300
Machine
Machine dimensions (L x W x H) mm (in) Without tilting head: 2320 x 1400 x 2180 (91.34 x 55.12 x 85.83)
With tilting head: 2320 x 1900 x 2180 (91.34 x 74.8 x 85.83)
Net weight kg (lbs) 2500 (5512) without variants and options
Machining area
Electrode diameter mm
in
0.3 ~ 3.0 (option: 0.1, 0.2, 4.0, 5.0, 6.0)
0.012 ~ 0.12 (option: 0.004, 0.008, 0.16, 0.20, 0.24)
Max. workpiece dimension mm (in) 1000 x 700 x 500 (39.37 x 27.56 x 19.69)
Max. workpiece dimension
with tilting/rotary axes
mm (in) Ø x L = 350 x 320 (13.78 x 12.60)
Max. workpiece weight kg (lbs) 1000 (2205)
Max. workpiece weight
with tilting/rotary axes
kg (lbs) 25 (55) including clamping weight
Worktable dimension mm (in) 800 x 600 (31.50 x 23.62)
Worktable type 4 bars (2 stationary, 2 adjustable)
Distance from table surface to floor mm (in) 850 (33.46)
Accessibility Front
Axes
Travel X x Y axes mm (in) 600 x 400 (23.62 x 15.75)
Travel W x Z axes mm
in
450 x 450 (650 optional)
17.72 x 17.72 (25.59 optional)
Tilting/rotary axes (option) º ± 100 / 0~360
Max. axis motion speed m/min. (ft/min) 4 (13.12)
Measuring system for Z, W axes Encoder
Measuring system for X, Y axes Encoder (linear glass scales optional)
Lubrication Manual
Dielectric unit
Dielectric type Industrial water or civil water
Dielectric capacity l (us gal) 200 (53)
Max. flushing pressure bar (psi) 80 (1160)
Filter accuracy µm 5
Capacity of deionizing bottle l (us gal) 10 (2.6)
Cooling system Water/water heat exchanger
Technical data

15. 15 AgieCharmilles DRILL 300
DRILL 300
Generator
Generator type ISPG
Max. mean working current A 60
Cooling system inside cabinet Air/water heat exchanger
Numerical control
Flat screen 17” flat touchscreen
Keyboard Standard
Mouse Standard
Storage capacity > 230 GB HD, 1024 MB Ram
Interface port USB and Ethernet
Measurement unit Metric/inch
Command format Absolute/incremental
Coordinates system Machine, part
Max. number of machining in the program 500
Servo controlled axes X, Y, Z, W, A, B
Import files XML.NCC, ISO.NCC, PAT.NCC
Onboard CAD/CAM AC CAM DRILL as standard
First spark detection Standard
Electrode wear compensation Standard
Breakthrough detection Standard
Onboard documentation Standard
Electricity supply
Three-phase input voltage V 380 or 400
Permissible variations from +10% to -10%
Main frequency Hz 50 or 60
Power consumption kVA 4.2
Nominal current A 6
Cooling water when heat exchanger used
Flow minimum required l/min (gal/min) 20 (5.2)
Temperature °C
°F
< Tworkshop – 9° C
< Tworkshop – 18° F
Compressed air
Pressure range between bar (psi) 6 to 8 (85 to 113)
Flow minimum required m3
/h (yd3
/h) 5 (6.54)
Connection pipe external diameter mm (in) 10 (0.4)
Main options
Automatic electrode/guide changer AEC/AGC 16/4, AEC/AGC 50/8
Tilting head ° Max. ~ ± 45
Large travel of Z axis mm (in) 650 (25.59)
Rotary/tilting table

16. 16 AgieCharmilles DRILL 300
DRILL 300
DRILL 300 tilting head
1400/55.12’’ 2375/93.5’’
800/31.5’’
Max. workpiece
1000 x 700 x 500
39.37 x 27.56 x19.68 ’’
600/23.62’’
40/1.57’’
600/23.62’’
400/15.75
730/28.74’’ 1120/44.09’’
1998/78.66’’
700
27.56’’
1260/49.6’’
598
23.54’’
3393/133.58’’
2280/89.76’’
100
3.94’’
583
22.95’’
510
20.07’’
2375/93.5’’
800/31.5’’
Max. workpiece
1000 x 700 x 500
39.37 x 27.56 x19.68 ’’
600/23.62’’
40/1.57’’
600/23.62’’
400/15.75
730/28.74’’ 1120/44.09’’
2280/89.76’’
100
3.94’’
1900/74.8’’
2248/88.5’’
250
9.84’’
1400/55.11’’
348
13.7’’
3392/133.54’’
583
22.95’’
1270/50’’
510
20.07’’

17. 17 AgieCharmilles DRILL 300
The DRILL 300 easily drills
cooling holes in turbine blades.
For this demo blade, 180 through
holes and blind holes (Ø 0.5 mm
and Ø 1.0 mm) were machined
in only 75 minutes, using a single
setup with the automatic
electrode and guide changer.

18. GF Machining Solutions
18 AgieCharmilles DRILL 300
EDM (electrical discharge machining)
AgieCharmilles wire-cutting, die-sinking
and hole-drilling machines.
For over 60 years we have been at the forefront of every EDM de-
velopment: designing and refining the EDM process and building
machine tools that deliver peerless part accuracies, surface fini-
shes, cutting speeds and process reliability. Today, our AgieChar-
milles wire-cutting, die-sinking and hole-drilling machines are
recognized throughout the world as the best in the business. Our
continuous research and development in digital generator techno-
logy, control systems and integrated Automation systems are
evidence of our commitment to keeping your EDM operations on
the leading edge of technology.
Milling
Mikron high-speed (HSM), high-performance (HPM)
and high-efficiency (HEM) Milling centers.
Customers operating in the mold, tool and die and precision
component manufacturing sectors stake their reputations on
being able to quickly and cost-competitively meet their customers’
demands. That’s why they invest in Mikron machines. Incorpo-
rating the latest and most advanced technologies and premium-
performance components, Mikron HSM, HPM and HEM machines
help you increase your production capabilities and improve your
productivity. Designed and built for speed, accuracy and reliability,
the machines, like you, are proven performers.
Liechti Dedicated Aerospace and Energy machining Centers.
Aerospace and power generation turbine manufacturers increa-
singly turn to Liechti dedicated five- and six-axis machining cen-
ters to machine complex, high-precision airfoils on blades, disks,
blings, blisks / IBRs and impellers. It’s easy to see why because
these machines, with their specific profile machining technology,
specialized CAD / CAM software and engineering competence for
ultra-dynamic machining in titanium, Inconel, nimonic, titanium-
aluminide and high-alloy steels, yield productivity gains as much
as 30 percent, thanks to reduced machining times. In the globally
competitive aerospace and power generation manufacturing sec-
tor, that’s definitely worth shouting about.
Step-Tec Spindles.
At the heart of every Mikron machining center is high-perfor-
mance Step-Tec Spindle. Step-Tec Spindles are essential core
components of our machining centers. Highly accurate and
thermally stable Step-Tec Spindles ensure that our machines
can handle everything from heavy-duty roughing to fine-finishing
operations.
Automation
System 3R Automation, Tooling and software.
Productivity is the key to manufacturing success, and automa-
ting a manufacturing process is a proven method of increasing
its efficiency, effectiveness, quality and reliability. System 3R’s
integrated Automation, Tooling and software solutions — simple
workpiece pallet and electrode changers and flexible manufac-
turing and robot handling systems — increase your competitive
advantage.
Customer Services
Operations Support, Machine Support and Business Support.
To help you get the most and the best from your machine tools
and equipment, we offer three levels of support. Operations
Support covers our range of original wear parts and certified
consumables (EDM wires, filters, resins, electrodes etc.) to ensure
that your machines are performing at the highest levels. Machine
Support maximizes, through our best-in-class technical support,
preventive services and quality spare parts, your machine tool
uptime. Business Support is designed to help you make a real
step-change in your productivity and performance with solutions
tailored to your specific needs.
Laser
AgieCharmilles Laser texturing machines.
Laser texturing is a fully-digitized surface engineering process
that has huge potential. The technology enables precise 2D and
3D textures or engravings to be machined accurately and directly
onto complex parts or molds to improve and alter their aesthetic
appeal, functionality and performance. The process is infinitely
repeatable and offers many distinct environmental and economic
advantages over conventional texturing processes.
Laser Additive Manufacturing (AM).
GF Machining Solutions has partnered with EOS, the global
leader for high-end AM solutions, to integrate this innovative
technology and further develop it into its current solutions to
fully benefit the mold industry, by focusing on injection efficien-
cy : optimized cooling design to reduce cycle time, lower energy
consumption, higher quality of plastic parts.

19. 19 AgieCharmilles DRILL 300

20. GF Machining Solutions
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Theyarenotwarrantedcharacteristicsandare
subjecttochange.
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