Ewag Laser line ultra state of the art short pulse laser

Ewag Laser line ultra state of the art short pulse laser 

Creating Tool Performance A member of the UNITED GRINDING Group
LASER LINE ULTRA
State-of-the-art ultra-short pulse
laser technology for maximum flexibility

EWAG
KÖRBER SOLUTIONS
Measuring software Customer Care
Ewag AG
The origins of Ewag AG date back to 1946 when the company manufactured precision tool grinding machines for the Swiss watch industry. Today the EWAG product range includes manual machines for grinding and regrinding tools as well as the production of small precision parts, CNC tool grinding machines for grindíng as well as laser machines for indexable cutting inserts and rotationally symmetrical tools made from carbide.
Ewag AG is part of the UNITED GRINDING Group withín Körber AG which has signifıcant financial strength and well tested processes. Together with our sister company, Walter Maschinenbau GmbH, we consider ourselves to be a supplier of systems and solutions for the complete machining of tools and can offer a wide range of products, including grinding, rotary eroding,laser machining, measurement and software.
Our customer focus and our global sales and service network of company-owned locations and employees has been appreciated by our customers for decades.

EWAG LASER LINE ULTRA 
LASER LINEULTRAata glance
Application The machine
ALL-in-one machining of blades, cavities and chip grooves Ultra-short pulse laser with picosecond pulses followed by Tabelling in one clamping operation Low-vibration cast-iron machine bed
3D machining of all commercially available cutting mater ials 5-axis CNC tool machine plus overlaid 3-axis laser beam guide
Ultimate surface quality for long service lives Direct drives in the linear axes
lndexable inserts from 3 mm inside diameter arıd up to 50 mmTorque motors for B and C axes circumscribed diameter Automatic HSK 63 interface
Holds rotationally symmetrical tools of to 200 Setheirelded machining room for laser protection class and of up to 250 mm in length Beam guide in protective atmosphere
Materials HM, cermet, ceramic, CBN, PCD, CVD-D, MCD/ ND lntegrated laser output measurement and monitoriııg IPC
Automatic focus position detection
Automatic calibration of CNC/optical axes 
lntegrated 30 measuring probe
FANUC control unit, the global standard
Automation peripheral equipment includes FANUC 6-axis robot
LASER LNE ULTRA by implementing ultra-short pulse laser technology with a pulse duration of 10 picoseconds, all commercially avaílable materials, in particular cutting materials such as CVD-D or MCD, can be machined.
EWAG LASER LINE ULTRA
Software
EWAG LaserSoft combines laser and machine control
Direct 3D CAD/CAM interface
Fastest programming starting with the shell contour DXF
Simplest definítion of laser removal paths
Various User Levels available
Simple program structure using standardized modules
Management of laser status, hardware, tools, production and order processing
Uitra-short pulse laser with direct vaporisation wíthout heat input maintains material properties
The uitra-short pulse laser works with direct vaporisation without any signifıcant heat input thanks to laser pulses of 10 picoseconds cold ablation . The tool is therefore not subjected to thermal damage during erosion, which sígnificantly increases its service life. Furthermore, the ultra-short pulses in combínation wíth high repeat rates generate
hígh-quality surfaces.
Thanks to the uníque 8-axis kinematics concept, the LASER LINE ULTRA machines highly complex geometries in just one clamping operation. The 6-axis robot guarantees ultimate productivity during minimally manned multí-shift operation. LASER LINE ULTRA and robots are coordinated via 
FANUC control technology.
EWAG Laser Touch Machíning
Tangential laser beam machining generates top-quality cutting edges and cutting geometries in an efficient manner. In this process, the surface is shaped with the outer surface of the laser beams. The cutting groove is produced by the repetitive hatching pattern of the laser scanning unit and by the símultaneous travel movement of the CNC axes. This unique, patented machining technology is marketed under the brand EWAG Laser
Touch Machining LTM .
O 2D scanning unit; moves the beam in the X/Y plane
Laser beam
Repeating 20 pattern
O Workpiece movement via 5-axis CNC X/Y/Z/B/C
Machined erosion paths
Final geometry/free surface
EWAG LASER LINE ULTRA
Ultimatesurfacequalityforall materials
EwAG
LASER LINE ULTRA
Conventionai machiníng Laser machining Concave blade
Excellent cuttíng qualíty
The effortless erosion process with the picosecond laser prevents cracks on the blade unlike in conventional procedures. It also enables a higher level of flexibility; for instance, concave cutting cycles aгe possible. 3D machining of diamond or carbide allows tools to be manufactured that have advanced functionality. Moreover, the cutting material can be selected as required. State-of-the-art CVD-D tools, with which very popular materials like carbon-fibre composites or aluminium alloys are currently being machined, can be produced with outstanding results on the LASER LINE ULTRA.
HM applications CBN applications PCD applications PCD applications CVD-D applications

EWAG LASER LINE ULTRA
Kinematics and laser pulses shape each geometry

High-end laser source
The picosecond laser achieves ultimate erosion performance and surface quality, while causing ałmost no thermal damage to the workpiece.
Stable beam environment

The beam guide ensures ultimate process stability and constant beam properties. The beam path is fully encapsulated and is guided into a protective atmosphere under excess pressure.
The deflection mirrors are monitored and sensitive optical components are integrated into the cooling circuit.
Uníque machíne concept
The intelligent kinematics concept with 5 CNC axes and one overlaid 3-axis laser beam guide guarantees the highest possible 1evels of flexibiłity when machining highly complex tools.
0 Workroom Flute groove machining
EWAG  LASER LINE ULTRA
HSK 63 interface Clampíng índexable inserts Automatíon of cylíndrical workpíeces
The highly accurate tool holder is decisiveln fdoerxable inserts can be clamped with a cTlahme pd-ouble gripper of the robot automatically a precise machining result and it is compaintigb lsetation oг using a nail clamp. feeds the cylindrical workpieces, drills and
with a wide range of clamping devices on the milling cutters, from pallets.
Automatic calíbratíon 3D measurements

The machine is designed to self-calibrate for highly precise machining. It employs a fully automated process to measure and adjust its parameters, including the five CNC axes and the 320 mechanical axes of the deflection system. These adjustments are crucial for optimizing the laser output and ensuring the focus position is accurate.

An integrated measuring probe detects errors and communicates with LaserSoft, EWAG’s proprietary laser software, to automatically compensate for plate misalignment. This system also accurately identifies the plate height, enabling real-time readjustment of the focus position for superior machining accuracy.

The LASER LINE ULTRA is designed for highly efficient and precise tool handling, focusing on reducing change times while accommodating diverse customer requirements. Indexable inserts are clamped automatically with a triple gripper head on the FANUC robot, which identifies the tool and its associated clamping system. This system ensures smooth placement of tools, whether individually or in alternating series.

Rotating tools equipped with HSK 63 holders can be loaded automatically using a double gripper head. The machine integrates advanced storage systems, including racks and automatic pallet stackers, to facilitate seamless handling. These systems ensure that tools are transferred accurately to the clamping station, optimizing the machining process.

Q HSK 63 interface Pallet system and doble gripper for cylindrical workpiec0e Asutomatic calibration, CNC axis alignment and focus
O Clamping station for clamping indexable inserts posítíon via camera, laser output v a sensor head
3D measuríng probe
 EWAGLASER LINL ULTRA
Flexible automation
Robot integration
The efficient EWAG rotating drum solution for integration of a FANUC 6-axis folding-arm robot  with various gripper systems enables automatic robot cells have a beam-proof design and are integrated to save space. Transformer substations and automatic part detection also support automatic operation.

Customer-specific tool handling Tríple grípper

EWAG LASER LINE ULT
How to get optimum use out of the LASER LINE ULTRA
In order to get optimum use out of your laMsoedr uplreo -3, Machíne structure:
cessing machine we offer a customised trDaiensincrgiption of machine-model constraints of session. At the end of the training sessionE yWouAG LASER LINE series, technical questions are given a certificate showing the trainingsu hcahs as general operation and maintenance of been successfully completed. This providtehse y mouachine.
with evidence of the solid practical training your employeès have received. Module 4, CAD/CAM:
Basic tool-production skills and basic machining
The training lasts one week and is held ond athtae for machining your geometries. Training on EWAG site in Switzerland. consists of tah esi mfopl-e geometry, direct implementation in thelowing modules: course.
Module 1, Laser princíples: Module 5, Cutting edges:
General laser technology, structure of a laCsreeration of a typical cutting geometry, direct ap system, principles of optical systems and pplircoapt-ion on a typical workpiece.
erties of laser beams.
Module 6, Advanced strategíes:
Module 2, Laser ablation: Generation of negative chamfers, chip breakers
Erosion mechanisms in 2D and 3D erosioann, dp гoapb-elling of workpieces.
erties of short and ultra-short laser pulses, differences in machining quality.

EWAG Laser Academy

1 2 EWAG
LASER LINE ULTRA
EWAG LaserSoftTechnology
BASIS Level
x lntended for users with no knowledge of laser Y
Z 80 0034 machining, the second or third shift.
STANDARD Level
Ideal for regular users with knowledge of tool  machining. Pre-defined calibration and setup data of the machine parameters, which are specified by the H1GH Level user, caп be modified.
HIGH Level
The surface for the machine operator trained by Y  EWAG with existing knowledge in the design of tools and laser-based machining procedures.
The HIGH Level user sets up new tools and can perform modifications on the tool and laser parameters.

From the contour to the tool
New tool idea
The idea for a new tool typically arises from a desired workpiece contour, from a contour
to be milled. This profile is often described as a 2D contour line marked in red in the form of a file in DXF format.
Laser Pгo 3D
In a first step, the desired contour line is supplemented with the remaining contour lines of the PCD plate to be soldered in.
The clearance angles are now being modelled.
Axia1 0г radial angles of the plate are not required for this process.
Next, three measurement points for the measurement of the solder error are set directly in the 3D model blue points . These are then saved in a file in EWAG EG1 format .
Next, the CAM calculations are performed and the corresponding pathway points red points are also saved in a file EG1 format .
Ø, 39 EWAG LaserSoft
Now a setup program is created on the machine 49 HIGH Level . The measurement points and Ø 52
PCD 5, the CAM pathways are now linked directly as 53 machining file.
After the production of the tool, it can be viewed directly on the machine for visual inspection 
 EWAG LAŚER LINE ULTRA
FANUC control unit, 

With the FANUC control unit, EWAG relies on the global standard of control technology. For the user, tłiis means the highest degree of reliability, availability and operating comfort.
EwAG 
LASER LINE ULTRA Customer Care
WALTER and EWAG deliver systems and solutions worldwide
for all areas of tool machining. Our leadership is based on suring maximum availability of our machines over their entire Commissioning service life. For this we have thus bundled numerous services Extension of the guarantee in our customer care program.
From Start up through Prevention to Retrofıt , our customers enjoy tailor made services for their particular machine configuration. Around the world, our customers can use helplines, which can generally solve a problem using remote ser addition to that, you will also find a competent service Support for production team in your vicinity around the world. For our customers, this means:
Our team ìs close by and can quickly be with you.
Our team will support you to improve your productivity.
Our team works quickly, focuses on the problem and its Preventíon work is transparent. Maíntenance
Our team solves every problem in the field of machining lnspection tools, in an innovative and sustainable manner.
Servíce
Customer servíce
Customer advice
Helpline
Remote service
Material
Spare parts
Replacement parts
Accessories
Rebuíld
Machine overhauling
Refurbishing of assemblies
Retrofit
Conversions
Retrofitting parts
Taking machines back
 ÉWAG LASER LINE ULTRA
Technical data, dimensions
Mechanical axes Tool data
X axis 440 mm Automatic clamping system for iııdexable inserts
Y axis 140 mm
Z axis 170 mm
Max. circumscribed circle of indexable insertszl 50 mm
Rapid motion 1 15 m/min
B axìs 110 Automatic cIamping system for rotationally symmetrícal tools
C axìs 
lnterface HSK63A
Optical axes Max. diameter of rotating too1s213 200 mm
Max. toollengthz131 250 mm
Max. scanning field size 50x50mm2 Options
Automatic focus position displacement 4 mm
Max. beam deflectíon speed 10 m/s
Water reverse-flow cooling unit
Laser source Automation with FANUC robot
HSK 63 rack
Performance of industrial ultra-short pulse lasersstandard/Hígh Powe Pallets for rotatíng tools
Wave length 1,064 пm Pallets for indexable inserts
Repetition rate 1 MHz Pa11et changers
Pulse duration Customísed clamping solutions
Beam profile and quality   Shaft tools usíng douЬle gríppers and WALTER pallet system
Accuracy Services
Linear resolution mm LASER LINE ULTRA training
RadiaI resolution Development of customised tools
Development of spiralísed tools in the diameter range of 3 mm
Smoke gas suction/filter system
upon customer order
Volume flow 170 m31h
Low pressure 2,800 Pa
Dust filter/Filter module HEPA  
Others 3524
Power consumption at 400 V/50 Hz appгox. 11 kVA
Weight inc1. robot ce11 appгox. 4,000 kg
all brands marked with OO are at least registered
as a basic brand in Switzerland oг in Germany,
legally qualifying them to carry the symbol. LASER LINE ULTRA with stacker LASER LINE ULTRA
Linear max. CNC śpeed in X/Y, 2E The maximum tool dimerslcns depend on the type of tooS1ubject to modífıcations due to tećhnical progreśs and errors.
thís ís límíted to 5 m/miп. and its geometry, as V.,as the type of machining. No guarantee ís províded for thís information.
From surface contact NSK 68 lnterface.
LASER LINE
Creating Tool Performance
WALTER and EWAG aгe globally leading market-oriented tecshonloultoiognys a fnodr practically all tool types and materials typical for the market service companies, and are system and solution partners for all areas of with a high degree of added value in terms of quality, precision, durability tool machining. OuE range of services is the basis for innovatiavned m parocdhuincitnivgity.
Gríndíng Grinding of rotationally symmetrical
Grinding Grinding of indexable inserts
tools and workpieces
Tool dimensIons lndexable inserts
WALTER machines Use Materials max. Іеngth21/ dіамеtег EWAG machines Use Materials Inscribed / circumscribed circle
σσ omσ σσ omσ σ HELITRONIC ESSENTIAL 255 mm / Ø 1-100 mm EWAMATIC LINEÁR 
HELITRONIC M1N1 POWER  
HELITRONIC MINI AUTOMATION  
σσ HELITRONIC BASIC 
σσ HELITRONIC POWER  
EWAG machines Use Materials / diameter
Tool dimensions
EWAG machines Use Materials / diameter LASER LINE ULTRA 
EWAMATIC LINEAR 200 mm / Ø 200 mm
EWAG machines Use Materials 
LASER LINE ULTRA QO
LASER LINE PRECISION QQ 
Erodíng Electrical discharge machíníng and gríndíng bof rotationally symmetrical tools
Measuríng Contactless measurement of tooIs,Tool dimensions
max.Iengtht / diameter workpieces and grinding wheels WALTER machínes Use Materials
Customer Care Comprehensíve range of services HELISET σ 400 mm / Ø 1 350 mm
Use: oProduction Q Regrinding Measuring
Meteríals: σ High speed steel Tungsten  Polycrystalline diamond ı Chemical vapour deposition
MonocrystaIIine diamond/natural diamond
Maximum tool dimensions are dependent on the tool type and geometry, as well as the type of machining.
Eгom the theoretical taper diameter of the workpiece holder.