Suggestionsto reduce cylce time

October 24, 2012, 5:30 pm

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We have this job that we would like to do on EDM machine but the cycle time is so damn high that we are afraid we might not even get the job or figure out a way to mill it.So,I was curious to see if there were ways I could reduce the cycle time.
8.5" thick material, total length of cut 9.5", 4140 HT material,.001 total tolerance location is not important,the geometry is almost like a 'T' slot and total quantity 16. I calculated the time using tech for HEAT wire,that gave me .019/min for rough and .35 for one skim that would total my roughing time to 8.5hr and skim to .25 min. With that kinda time its better to figure out a way to mill it.But I don't wanna rule out edm with knowing my other options. so, I thought about roughing the slot out leaving .005-.01 on the sides,that will increase my roughing speed quite a bit and then take 2 skims instead of one,that way I will have the speed and no slug to deal with.I understand its nothing to brilliant of a plan,that's why I am here asking for your help.

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Edm training and support worldwide

October 27, 2012, 7:49 am

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HI

I am an ex Agie Charmilles applications engineer.

I offer training and applications support, from basic training, advanced and process optimisation.

Agievision machines.
Classic, Classic 2s, Challenge, Evolution, Excellence, Progress.

Also Camtek peps wire support

Charmilles Robofil Millennium control machines, 440, 240 and cc versions.

Agie Mondo Star EDM Die sink machines

Actspark SP Range of Die sink machines.

I can also support other edm machines please indiacte what type you have when replying.

Please contact me at

enquiries@cnctotalsolutions.com

My new website is CNC Total Solutions


for further details, please specify the type of machine you have.

Regards

Neil

Fanuc Advanced macro programming

October 28, 2012, 10:34 am

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Anyone know what programming language Fanuc uses to write the machine functions on their wire edm machines? I know they use macro programming, but is there another language like c++ combined with it? I have heard they use secret macros that most people don't know about. The macro pickup routines in the newer machines are locked out where you can't see them! Just curious about this advanced programming, anyone have any info about it?

robofil 290 errors and disk reload.

October 28, 2012, 11:37 am

≫ Next: Are service contracts for wire EDM machines worthwhile

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first: I've found and read these two threads, they related but I think my problem is different.
http://www.practicalmachinist.com/vb...reload-174828/
http://www.practicalmachinist.com/vb...-disks-169964/

my 1998 robofil 290 console 2 machine boots up but with errors
SYSERR: B505 B583 B546

My manual suggests for all Bxxx errors to Reload software and run on board diagnostics. It lists nothing for specific B codes.

I have run the on board diagnostics (by holding diagnostics key while powering on).
the results are that the Pilot section fails UPA16 and UPR and Servo PASA tests. It says "power enabling defect" and "not tested" in all of them.
(but the console, communication and execution sections all pass)
It does also say from this diagnostic page SYSERR: D001 D001 , which also means reload the software according to the manual.

none of my upa, upr, etc... boards have any led error (or any) indicators lit

So I tried to reload the software. (although it seems to me that the software is fine if it's doing all this) and I get to the loading screen:
CB06 loading floppy....
Fatal error. system stopped.

floppy light comes on, my floppy doesn't try to spin. I tried to swap out with a floppy drive from an old pc. it also doesn't work. my disks appear in excellent physical shape. and somewhat newer. they are obviously not originals. I shall see if my PC can copy them to my hard drive as backup.

I'm sad. :(

Are service contracts for wire EDM machines worthwhile

November 1, 2012, 5:13 am

≫ Next: Mitsubishi DWC 90SB - Insight

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We have had Mitsubishi wire machines since 1990, several generations of machines. We used to get local service through their distributor (now out of business). Now service comes out of Chicago. We have never had a service contract on any of our machines. I'm interested to know if it's common to have service contract, or do most not use them. I also wonder if it makes a difference on which brand of machine you have. I've been looking at Makino and their threading and guide system looks so much simpler, and simpler is always better for service and cleaning IMO. The drawback I see is Makino does not use a wire chopper which I really like with the Mits machines. Also was looking at Sodik but they haven't had much representation in the southeast recently. Anyway, what brand do you have, and do you find a service contract beneficial?

Mitsubishi DWC 90SB - Insight

November 2, 2012, 7:39 am

≫ Next: Mitsubishi error - interesting (to me)

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Hey guys.

Bought a 1990 Mits DWC 90SB at auction. Took delivery of it yesterday in my small little garage shop yesterday.

First, Mitubishi isn't very customer friendly unless you pay their registration fee to be a customer. As if buying one of their machines isn't enough and as if they wouldn't make enough money off of support, they charge you to be a customer. (I will add, I have noticed many outfits are starting to do this).

Second, I didn't get an electrical diagram for the machine. Not sure where to hook up power.

I found this thread... http://www.practicalmachinist.com/vb...c-help-111052/ it said to hook up the high leg on my RPC on "T" in the power control box. Just want to confirm prior to doing so.

Third, the monitor is out. The machine was under power in the shop that went belly up that I bought it from and they were in the process of replacing it when the doors got closed. So I have to do something with replacing it. I have seen some older machines like this be replaced with a computer LCD. Anyone know how this is done.

There is only a 6 wire plug in to the monitor module, Blue, Yellow, Brown with 3 black. It's an old monochromed tube style deal. Any direction for a conversion would be great.

Anyone have any info on this style machine, please let me know. I would gladly throw a couple bucks around for a copy or borrow/share any information.

Thank you,

Mike in MN

Mitsubishi error - interesting (to me)

November 3, 2012, 9:53 am

≫ Next: If you have a WEDM, Install a secondary resin filter! -ask me how I know.

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90HA

S01 Servo Error being reported as an error 10 (0010) and in X.
This is an undervoltage error.

Oddly, all incoming voltages are good. Checked numerous times and points.

This would seem to point to an error on the servo drive, but noone seems to know WHAT.
I've seen some talk of it possibly being an opto isolator issue, but not which OI.
Also, I cannot seem to find anything that list what the voltages at the terminals of the servo card should be so that I can test at that point.

MitsTech? Anyone?

If you have a WEDM, Install a secondary resin filter! -ask me how I know.

November 5, 2012, 7:03 am

≫ Next: Mitsubishi M35K Error.. any help would be great.

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I just read this from
http://www.edmtodaymagazine.com/AAwe...hTipsS-0-8.pdf

Add a Safety Screen To Your Resin System
Have you ever thought about the nightmare possibility of all those resin
beads in your resin tank being circulated throughout your dielectric system?
You can be sure that those shops who have had to pay a couple thousand
dollars for a factory service engineer to clean those beads from the
solenoids, lines, valves, flowmeters, pumps, filter housings, jet nozzles,
and numerous other components that make up the dielectric system have.
The center lance of a deionizing bottle contains a filter assembly that
keeps the beads in the tank from escaping. Sometimes rough shipping can
either dislodge the filter from the lance, or cause the lance to separate from
the tank head. If this happens, the machine will rapidly pump out the entire
contents of the resin bottle into your machine when the conductivity system
calls for deionizing.
The solution is an inexpensive secondary filter screen assembly that is
inserted between the outlet side of the resin bottle and the hose leading to
the machine. This secondary filter contains a clear bowl which allows you
to monitor the accumulation of resin beads on the screen. If the resin bottle
fails, the machine will cease deionizing, and you’ll see the screen clogged
with beads through the clear bowl.
The secondary filter screen is a cheap insurance policy that you can’t
afford to pass up.

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Mitsubishi M35K Error.. any help would be great.

November 12, 2012, 4:25 pm

≫ Next: charmilles robofil wire aligning ZB Block?

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C7G35 Control. Getting a "515 Transistor destroyed" when the machine strarts to burn. I have narrowed it down to the TP and GM circuits.. the SF works... Not sure where to go from here, do those two circuits share the same power card/board?? Anyone that could lend a hand would be great. Gonna start with fuses and the simple stuff, do the power boards contain fuses or is it just the few in the back.

charmilles robofil wire aligning ZB Block?

November 13, 2012, 7:31 am

≫ Next: Surface finish question

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I have the training guide set-up procedure. I see I need a centering eyelet.

I believe I also need a "ZB block" that holds them at a specifice height and alignment and clamps to table zero.

I cant seem to find any mention of this block online, for sale, etc... even any pictures of what to look for.

I would love the dimensions to make one for a 1998 Robofil 290

edit: a Charmilles engineer sent me a picture. said I could just make it.


so I' only a tiny bit confused about the instruction to "clamp the ZB block to table zero with the eyelet up" I though it meant some special X0,Y0,Z0 location. but I believe it just means to the table top anywhere.

What about "indicate the eyelet flat" instruction? flat in Z? I dont see how I could change that anyway? just verify it is "fairly flat" ?

Thanks, Dan

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Surface finish question

November 15, 2012, 6:31 am

≫ Next: EDM Vise design thread. (yet another)

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Background is we have a part that needs a high surface finish 4 Ra or better on a 0.715" dia ID surface (thru hole) and no one knows, around here at work, if we are going to have to do secondary finishing or if we do how much. So question is what kind of finish could you expect get straight out of a wire EDM?

Almost forgot the material is carbide

EDM Vise design thread. (yet another)

November 16, 2012, 11:17 am

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been playing with vise design today.

this is what I've come up with so far. I bring this up because I want input on thinning the jaw or not,
and I wanted to share the pin "track" I think I want to use so I can accomodate a wider range without screw removal.

I've got .75" x 3" x 12" 17-4 ph comming. the base and jaws are about 75 wide and 18mm? thick (grinding cleanup to nearest reasonable increment.)


I want to put a tapered pocket in it for the m5x.8 shcs to clear yet not wipe out all of the guide/slot feature.

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robofil, how do I do these seeming simple tasks?

November 19, 2012, 6:29 am

≫ Next: design and fabrication of mini wire edm (final year project)

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Thanks in advance, you guys are very nice helping me with my noob wedm questions.
I have read the books, and training manual, searched thoroughly. I spent some serious time with my new toy this weekend. I cant find answer to the following questions. Apparently they are to simple to document.

#1 how can I turn the pumps off? the circulation pump in particular. without shutting the machine off. So that I can idle it for extended periods running only the electronics.

#2 if I manually jog with the pendant into a travel limit, it gives me and error which I look up and see mechanical travel limit. says to move the axis the other way. HOW? (other than shutting off and going around back and turning a screw) It will not allow any pendant moves.

#3 I do not have an auto threader, what is the usual method to cut the wire and thread it. I can snip it and pull some wire out and stretch the curl out of it and snip it again, and thread it by hand, but it is really hard. I do not seem to have a pilot jet, or I don't know how to activate it. or it's not working. sorry this is a big question. the books instructions seem to be written for auto threaders.

#4 edit: removed question, working on curently

design and fabrication of mini wire edm (final year project)

November 21, 2012, 8:17 am

≫ Next: Adjusting wire EDM flush with a voltmeter

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dear all,i want to built a wire electric discharge machine.can anyone tell me from where to start from...its my final year project....
1)i had searched about it on scribd and found some ebooks like one written by ben flemming but it is about ram edm and i want to know about wire edm from beginning till end...
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2)i intend to use 1mm thick workpiece of aluminium,brass of 0.25mm as wire electrode ,any guidance???....

3) can i use the power supply of ram edm built according to plans of ben fleming for my wire edm project????...

4)actually i had designed my project and now starting work on its manufacturing but after that in electronics part i dont know much and i had found very little about feed rate,voltage current etc on net so if some one is willing to share his experience, i would be very pleased with that.....

Adjusting wire EDM flush with a voltmeter

November 21, 2012, 10:16 am

≫ Next: Challenging wire EDM work (micro sized parts)

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We all know how important flushing is with any kind of EDM. But with Wire EDM how do you
know when flushing is maximinzed other than the wire isn't breaking.

Today I got the idea of connecting a digital voltmeter beteen the positive wire to the machine riser or ground. Set the meter to 200VDC. My Hanvedt DS-2 is not equiped with volt or amp meters.
With the spark gap "ON" I had around 98 VDC. As the brass wire wire advanced into the workpiece I could hear the EDM spark and the voltage dropped quickly to under 10VDC. The feed rate was just great. But, after minute or two the feed rate slowed which seems to be a common problem on my machine.

As the feed rate slowed the voltage across the spark rose to 20 to 30VDC. The flush nozzles were set to almost 40PSI. I began reducing the flushing pressure on both upper and lower nozzles. While doing this I could see the voltage dropping and fluctuating less and the feed rate increasing. I continued varying the flush pressure until I reached a point of minimum voltage and minimum voltage fluctuation, between 10 and 17VDC. Flush pressure was about 15 PSI.

Does this make sense? Has anyone else tried this?
Thanks, Jim

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Challenging wire EDM work (micro sized parts)

December 2, 2012, 2:18 pm

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Hi All:
Here's what I've been working on and tearing my hair out over for the last week.
These are parts for a micro surgical instrument.
They are tiny; the pictures will give you a good sense of the scale.
The little tubes threaded onto the copper wire were actually harder to make than the little paddle shaped part. (The tubes are only 0.025" long and needed to be made from scratch: hardened and ground, the bores wire cut within 0.0002: and cut to length dead nuts square and parallel with no burs, no ragged edges and a super smooth finish).
The cutoff stub on the paddle shaped part will be hand dressed under the scope using a shellac chuck to hold them and a tiny diamond file and ruby stones to dress them to shape.

A few parts were lost forever in the worktank or by sproinging them with the tweezers while handling them.
The customer also wanted me to try to laser weld them together but the laser turned the yokes on the paddle shaped part into a blob even at the lowest power settings (the yokes are only 0.008" wide and 0.006" thick)
Pictures will follow in the next post if PM will still let me do it: the program has crashed twice in a row on me as soon as I tried to load the photos.
Bear with me while I try to make it work.
Cheers

Marcus
Implant Mechanix – Design & Innovation - home
Vancouver Wire EDM -- Wire EDM Machining

Hole popper added to wire machine

December 3, 2012, 5:45 am

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Has anyone added a small hole popper/tap extractor to a wire machine for creating starter holes? If it works, I think it would be quite a time saver.
Gary

Increase in MRR for EDM through cryogenic treatment

December 3, 2012, 7:22 am

≫ Next: Sodick A500/Mark21 system disk

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Go to:

http://msep.engr.wisc.edu/index.php/...ring-processes

and go to the 9th title down. Download the pdf file and read about the improvements in machinability and the increase in MRR. Very interesting.

Sodick A500/Mark21 system disk

December 3, 2012, 11:36 am

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Our floppy disk for system (EPSON SMD220) is a canceled and we are afraid that are damaged -system floppy disk medium.Our SODICK EDW M21S/C,ver 1.91T
Does someone from users similar machine, can make us a backup system floppy disk and send by a post mail.
Did anyone had any experience with the product USB floppy drive by PLR Electronics?
Best regards

new mitsubishi mv1200s

December 4, 2012, 12:29 am

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the installer came out to install our new mits mv1200s today. it has been sitting for 4 days and already had a couple chips stuck to the linear motor shaft. it was stated as being a good shop edm and the elements would not be detrimental to the machine, of course edm's are always recommended to be in there own room.
it is unbelievable to me that there aren't covers over the magnetic shaft. although we plan on filtering the heck out of the bottom of the machine i still see issues in the near future.