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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.TABLE OF CONTENTSINTRODUCTIONIDESCRIPTION OF THIS MANUALIIORIGIN OF THE NAME “SODICK”IIICOMPANY PROFILEIVCHAPTER 1 DESCRIPTION OF THE EDM PROCESS 1-1GENERAL EDM FACTORS1-...

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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.DIELECTRIC SYSTEM:2-2CONTROL:2-2CONTROL SCREEN (CRT) RELATED KEYS:2-2KEYBOARD RELATED BUTTONS:2-3PROGRAM ACTIVATION KEYS (NC SIDE ONLY)2-4MACHINE RELATED SWITCHES (SWITCH SUB PANEL):2-5AWT RELATED SWITCHES2-5AMP - VOLTMETERS2...

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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.NC PROGRAM EXAMPLES6-8PROGRAM EXAMPLE 16-8PROGRAM EXAMPLE 26-9CHAPTER 7 WIRE OFFSET DESCRIPTION 7-1UNDERSTANDING OFFSETS7-1THREE ADVANTAGES TO USING OFFSETS7...

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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.GRAPHICS COLORS8-14CHAPTER 9 PROGRAM FORMATTING 9-1PUNCHES9-1DIES9-2FORM TOOLS9-3WORDS INVOLVED IN SUBROUTINES9-3SUBROUTINES INVOLVE FOUR PROGRAMMING W...

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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.DISPLAY MAINTENANCE SCREEN12-1MAINTENANCE CHECKLIST12-2BY THE HOUR CHECKS12-2DAILY CHECKS12-2WEEKLY CHECKS12-2BI-WEEKLY12-2MONTHLY12-2QUARTERLY12-2ANNUALLY12-3MAINTENANCE DESCRIPTIONS12-3RESISTIVITY METER12-3DI BOTTLE:12-3WOR...

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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.MANUALLY ADJUST FLUSHING14-3EDGE FIND BY USING THE ST KEY14-4ASSIST KEYS MARK25 A0 – A714-5MARK25 ASSIST KEYS14-5PROGRAM DESCRIPTIONS14-5EDGE FIND USING G80 (INSTEAD OF THE A3 ASSIST KEY)14-7CHANGING THE AXIS DISPLAY READ A...

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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.REMOTE CONTROL OPERATION 16-1SELECTING A JOG SPEED16-1TO JOG X OR Y16-1TO JOG U OR V16-1TO EDGEFIND16-2REMOTE ASSIST KEYS16-2PROGRAM DESCRIPTION...

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    Wire EDM Machine OperationTable Of ContentsCopyright June, 98Sodick Inc.

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    Wire EDM Machine OperationIntroductionCopyright June, 98Page iSodick Inc.IINNTTRROODDUUCCTTIIOONNWelcome To Sodick Inc and to Sodick Wire EDM training!What is EDM? Contrary to what you may have heard, EDM does not stand for EvilDemon Magic. Electrical Discharge Machining was discovered in the 194...

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    Wire EDM Machine OperationIntroductionCopyright June, 98Page iiSodick Inc.DDEESSCCRRIIPPTTIIOONN OOFF TTHHIISS MMAANNUUAALLIt is the intention of this course and manual to inform beginning and experiencedoperators of the techniques used in programming and operating Sodick Wire EDMsystems. This...

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    Wire EDM Machine OperationIntroductionCopyright June, 98Page iiiSodick Inc.OORRIIGGIINN OOFF TTHHEE NNAAMMEE ““SSOODDIICCKK””“Sodick” is not an English or Japanese word, rather an acronym. It is a combination offour Japanese characters and was created by president, Toshihiko Furuk...

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    Wire EDM Machine OperationIntroductionCopyright June, 98Page ivSodick Inc.CCOOMMPPAANNYY PPRROOFFIILLEEAugust 1976 Incorporated as Sodick Co.,Ltd. with capital of 20 million yen.Toshihiko Furukawa appointed as president.December 1976 First CNC EDM system with microcomputer delivered.December 197...

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    Wire EDM Machine OperationIntroductionCopyright June, 98Page vSodick Inc.November 1984 Announced the PICA-2 ultra-fine-finish circuit for wire cutting.Announced the AIC type CNC EDM system and the CNC power supply unit Mark VII.February 1985 EPOC series announced in Tokyo and Osaka.July 1985 Anno...

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    Wire EDM Machine OperationIntroductionCopyright June, 98Page viSodick Inc.November 1993 Production begun of the Mold Maker 5 die-sinking EDM systems andA530D wire-cut EDM systems in Sodick (Thailand) Co., Ltd.March 1994 Development of PGW series wire-cut EDM systems capable of mirrorfinishing for...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-1Sodick Inc.CCHHAAPPTTEERR 11 DDEESSCCRRIIPPTTIIOONN OOFF TTHHEE EEDDMM PPRROO CCEESSSSThe first key concept that you must understand is the basic principle of the EDM process.One good analogy of what occurs in the EDM process ...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-2Sodick Inc..006 Diameter Wire (.17mm or .18mm wire guide).008 Diameter Wire (.21mm or .22mm wire guide).010 Diameter Wire (.26 mm or .27mm wire guide).012 Diameter Wire (.31 mm or .32mm wire guide)NOTE: There are 2 wire guide sizes ...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-3Sodick Inc.FLUSHING This is the flow of water that surrounds the wire during the EDM process. The sameflushing nozzles are mounted (one around the upper wire guide and the other around thelower wire guide) on machines without AWT. I...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-4Sodick Inc.When finishing, the stress on the wire is very small and therefore the wire speed can bereduced to conserve wire.The wire speed will be set by the “WS” parameter of the cutting condition. The range of“WS” is from ...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-5Sodick Inc.resistivity allows a focused discharge, which allows the machine to cut fast, stable andreduces rusting of the workpiece. Low water resistivity allows the discharge to leak outof the cutting area, which slows down the cut...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-6Sodick Inc.The cutting condition parameters on the following pages can be entered into the NCprogram if desired. The cutting condition parameters affect how the EDM cycle looksand are discussed on the following pages.Figure 1 – 1 ...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-7Sodick Inc.If the on time is too great, the wire will be prone to breakage.OFFParameter Range: (000-063)“OFF” stands for off time. This parameter sets the length of time that the electricityapplied to the wire is turned off betw...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-8Sodick Inc.HRPHRP parameter is typically used for cutting with oil dielectric. When water is used, thiscircuit is not needed.H Parameter Range (0-9)The H of HRP is a high voltage circuit used to increase the open gap voltage. You ma...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-9Sodick Inc.To increase cutting speed on rough cut, reduce “A” and / or increase “O”.Example MAO = 252 adjust to 234If wire breakage is a problem, increase “A” and / or reduce “O”.Example MAO = 252 adjust it to 260S...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-10Sodick Inc.type used. When adjusting “SF” you should see a change in the cutting speed. “SV” and“SF” are factors that allow you to increase or decrease the cutting speed. By adjusting“SV” and “SF” you can keep t...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-11Sodick Inc.WCParameter Range: (∗∗0 or ∗∗8)“WC” set the “ACW” (option) level AND turns on the fine finishing circuit. Thisparameter will be set to “000” for the 1st two cuts, then it will be set at “008” for...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-12Sodick Inc.HEADER CREATED BY CONDITION SET MENU"(***** Mat'l = STEEL : THICKNESS = 3.2inch : WIRE = .010inch );""(***** NOZZLE = close : CYCLE = 4 );""C000 = 014 01...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-13Sodick Inc.1) Workpiece Material. Under each wire diameter available, there are several materialsto choose from.2) Workpiece Thickness. Each material listed will allow you to choose from severaldifferent workpiece thickness.3) Wire...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-14Sodick Inc.Another point to make is that all of these factors work together to form a good cuttingcondition.TIPS ON ADJUSTING CUTTING CONDITIONSThere may be instances in which you would like to adjust the cutting conditions. Use th...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-15Sodick Inc.CHECK FOR WIRE VERTICAL ALIGNMENT OFTEN.It is a good habit to check the vertical alignment prior to machining a workpiece. Youmust confirm that the wire is vertical to keep from machining unwanted taper in the part.MAKIN...

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    Wire EDM Machine OperationChapter 1Copyright November, 98Page 1-16Sodick Inc.

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-1Sodick Inc.CCHHAAPPTTEERR 22 MMAACCHHIINNEE LLAAYYOOUUTT DDEESSCCRRIIPPTTIIOO NNThe second key concept to understand is the basic makeup of the machine. Our intentionfirst is to look at the machine from the operator’s viewpoin...

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-2Sodick Inc.The upper head can also move in two directions parallel to the X and Y-axis. Thesemotion directions are primarily used to create taper. As the upper guide moves left toright, it is moving in the “U” axis. As the upper...

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-3Sodick Inc.KKEEYYBBOOAARRDD RREELLAATTEEDD BBUUTTTTOONNSS::F1 through F10 (function keys) - The F1 key through F4 keys will show you informationabout how the present job is set up. Use the ESC key to turn off these sub-screens orp...

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-4Sodick Inc.INS Key - When in edit this toggles the cursor between insert and exchange modes.DEL Key - When in edit this key will delete the character the cursor is highlighting.U/V On - (figure 2-2 number 11) Mark 25 controls do not...

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-5Sodick Inc.MMAACCHHIINNEE RREELLAATTEEDD SSWWIITTCCHHEESS ((SSWWIITTCCHH SSUUBB PPAANNEELL))::Figure 2-2 section 151) Wire Run Switch - This switch allows you to manually turn on or off the pinch rollersabove the wire disposal ...

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-6Sodick Inc.AADDDDIITTIIOONNAALL SSWWIITTCCHHEESSE STOP BUTTONFigure 2-2 number 1On the control, there is a large red push button. This button turns off the “POWER” andthe “SOURCE” on the control. This will power down the ma...

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-7Sodick Inc.Figure 2-2 Mark 25 control15

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    Wire EDM Machine OperationChapter 2Copyright November, 98Page 2-8Sodick Inc.

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    Wire EDM Machine OperationChapter 3Copyright November, 98Page 3-1 Sodick Inc.CCHHAAPPTTEERR 33 PPRROOGGRRAAMM ZZEERROO DDEESSCCRRIIPPTTIIOONNPart of the second key concept involves understanding something called “program zero”.This feature allows the programmer to choose a convenient poin...

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    Wire EDM Machine OperationChapter 3Copyright November, 98Page 3-2 Sodick Inc.Notice that all dimensions on Figure 3-1 come from the lower left corner of the part.Since this is the case, the lower left hand corner of the part would make an excellent pointat which to place the program zero point. F...

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    Wire EDM Machine OperationChapter 3Copyright November, 98Page 3-3 Sodick Inc.Figure 3-3HHOOWW TTOO AASSSSIIGGNN YYOOUURR PPRROOGGRRAAMM ZZEERROO PPOOIINNTT::In any wire EDM program, you will tell the control where your program zero point is. Todo this, you will be telling the control how fa...

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    Wire EDM Machine OperationChapter 3Copyright November, 98Page 3-4 Sodick Inc.Figure 3-4UUNNDDEERRSSTTAANNDDIINNGG WWOORRKK CCOOOORRDDIINNAATTEE SSCCRREEEENNSSSodick allows you to assign up to sixty (60) different program zero points. This could behelpful when you are machining multiple parts. ...

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    Wire EDM Machine OperationChapter 3Copyright November, 98Page 3-5 Sodick Inc.NOTE: G959 (screen95) cannot be set to a new number as this is displaying the machinecoordinates located from the machine home position. The “A” in the above examplesmeans absolute (G90). An “I” would mean incre...

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    Wire EDM Machine OperationChapter 3Copyright November, 98Page 3-6 Sodick Inc.

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    Wire EDM Machine OperationChapter 4Copyright November, 98Page 4-1 Sodick Inc.CCHHAAPPTTEERR 44 PPRROOGGRRAAMM MMAAKKEEUUPPAnother facet of EDM operation is knowing how the machine will process a program. ACNC program is very similar to giving a set of instructions to a person over the phone.Ov...

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    Wire EDM Machine OperationChapter 4Copyright November, 98Page 4-2 Sodick Inc.Program for figure 4-1N005 G54 (SELECT COORDINATE SYSTEM A00)N010 G92 X.250 Y-.300 (SET PROGRAM ZERO)N015 G90 (SELECT ABSOLUTE MODE)N020 C411 (SELECT CUTTING CONDITION)N025 G42 H061 (SELECT RIGHT OFFSET AND VALUE)N030 T9...

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    Wire EDM Machine OperationChapter 4Copyright November, 98Page 4-3 Sodick Inc.PPRREEPPAARRAATTIIOONN FFOORR PPRROOGGRRAAMMMMIINNGGAnother part of the second concept: You must prepare to write a manual CNC wire EDMprogram. This is one of the most important points, even though it has nothing to do...

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    Wire EDM Machine OperationChapter 4Copyright November, 98Page 4-4 Sodick Inc.Notice that the programmer knows that this die will include an arc-on and off techniqueto get a smooth entry and exit so he sketched in the approach movements and includedthe entry and exit points in the coordinate sheet...

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    Wire EDM Machine OperationChapter 4Copyright November, 98Page 4-5 Sodick Inc.3) CHECK THE CONDITION FILE MANUAL FOR THE NECESSARY CONDITIONS ANDOFFSETSPrior to writing your manual program, you must know the conditions and offsets requiredto produce the part to your requirements. The condition man...

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    Wire EDM Machine OperationChapter 4Copyright November, 98Page 4-6 Sodick Inc.

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-1 Sodick Inc.CCHHAAPPTTEERR 55 TTHHEE FFOOUURR KKIINNDDSS OOFF WWIIRREE MMOOTT IIOONNThe third key concept to wire EDM programming is that there are four kinds of wiremotion. It should be refreshing for beginners to know that ...

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-2 Sodick Inc.The G00 command causes the wire to move at its fastest possible rate. The power supplywill not be switched on so no EDMing will be performed. If two (or more) axes areprogrammed in a G00 command, simultaneous movement o...

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-3 Sodick Inc.GG0022 AANNDD GG0033 -- CCIIRRCCUULLAARR MMOOTTIIOONNG02 is Clockwise motion and G03 is Counterclockwise.These commands are used to cause the wire to move along a circular path in the cuttingmode. They allow you to ...

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-4 Sodick Inc.Figure 5-3Figure 5-4Imaginary line pointing Program Zero1.000"12345678Pnt / G02 - G03 Example G92X0 Y0 1 G01Y.500 2 G01X.400 3 G02X.500Y.400 J-.100 4 G01Y-.400 5 G02X.400 Y-.500 I-.100 6 G01X-.400 ...

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-5 Sodick Inc. CIRCULAR MOTION USING THE R WORD ( CONSTANT RADIUS)Another way to program an arc is by using the R word. To program using the R word,program the SHARP corner of the intersection using G01 then add the R and its value at...

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-6 Sodick Inc.This type of radius is usually referred to as an isometric or constant radius.For die relief, you will want the radius to expand as it reaches the bottom of the die. Forthis type of radius, use the G02 and G03 style of p...

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-7 Sodick Inc. (The wire is cut at the start of this program and there is no AWT):N005 G59 G92X0Y0(VALUES SET FOR G59 DURING SETUP)N010 G00 X.75 Y.5 (MOVE TO POINT 1)N015 M00 (PROGRAM STOP TO THREAD WIRE)N020 G54 (SELECT COORDINATE SY...

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    Wire EDM Machine OperationChapter 5Copyright November, 98Page 5-8 Sodick Inc.

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-1 Sodick Inc.CCHHAAPPTTEERR 66 DDEESSCCRRIIPPTTIIOONN OOFF PPRROOGGRRAAMMMMII NNGG CCOODDEESSAANNDD WWOORRDDSSThis chapter will present most of the codes and words involved with programming. Whilethere will appear to be a great...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-2 Sodick Inc.UUsed to specify exact movements of the upper wire guide (U axis) left and right (parallelto X). Used when writing a program that employs independent UV techniques or 4 axis.U or V 4 axis movements are defined as the inc...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-3 Sodick Inc.RSpecifies the radius of a corner round. A radius of one inch would be written as R1. orR10000 and a radius of 0.010" would be input as R.01 or R100 ( Example NC codeG01 X1.0 R.050 this would cause the intersection ...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-4 Sodick Inc.LLIISSTT OOFF GG CCOODDEESSCode Description ModalG00Rapid Motion (appears as a dotted line in graphics) pg. 5-1YG01Straight Line Cutting Motion pg. 5-2YG02Circular Cutting Motion - Clockwise (CW) pg. 5-3YG03Circular ...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-5 Sodick Inc.Code Description ModalG82Move To Half Of Axis Display pg. 10-7NG83Read Current Position and Store To An H Register pg. 10-7NG90Set Absolute ModeYG91Set Incremental ModeYG92A...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-6 Sodick Inc.would be T84 - T85 to turn on or off high flushing, and T90 -T91 to cut and thread thewireThe other T codes may be used if so desired, but the black switches on the controlnormally activate them.LLIISSTT OOFF MM CCOOD...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-7 Sodick Inc.T91M98P0002M02AADDDDIITTIIOONNAALL IINNFFOORRMMAATTIIOONN FFOORR PPOOSSTT PPRROOCCEESSSSOORR CCRREEAATTIIOONNDISK FORMAT: The floppy drive on the Sodick Mark 25 control is capable of using720KB type 3.5-inch floppie...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-8 Sodick Inc.TRAILING ZERO’S: Trailing zero’s after the output value, when using decimal points,are not required. EX “G02 X.1 Y.12 I.123 J.1234”.NNCC PPRROOGGRRAAMM EEXXAAMMPPLLEESSPROGRAM EXAMPLE 1The below program is a...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-9 Sodick Inc. N0025 G03 X-.25 Y.15 I0. J-.1 N0026 G01 Y-.15 N0027 G03 X-.15 Y-.25 I.1 J0. N0028 G01 X.15 N0029 G03 X.25 Y-.15 I0. J.1 N0030 G01 Y.15 N0031 G03 X.15 Y.25 I-.1 J0. N0032 G01 X0. N0033 G50 A0. G40 Y0. N0034 M02PROGRAM EX...

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    Wire EDM Machine OperationChapter 6Copyright November, 98Page 6-10 Sodick Inc. N0022 T85 N0023 C2 N0024 G41 H2 N0025 G51 A.5000 G01 X.1 Y.15 N0026 G03 X0. Y.25 I-.1 J0. N0027 G01 X-.15 N0028 G03 X-.25 Y.15 I0. J-.1 N0029 G01 Y-.15 N0030 G03 X-.15 Y-.25 I.1 J0. N0031 G01 X.15 N0032 G03 X.25 Y-.15 ...

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-1 Sodick Inc.CCHHAAPPTTEERR 77 WWIIRREE OOFFFFSSEETT DDEESSCCRRIIPPTTIIOONNUUNNDDEERRSSTTAANNDDIINNGG OOFFFFSSEETTSSAn “offset” tells the control how far to keep the wire centerline away from theprogrammed surface to be cut ...

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-2 Sodick Inc.INITIALIZING OFFSETFirst, let’s look at how you instate offset.To instate offset, you will be choosing from G41 (wire left) and G42 (wire right). Youmust be able to decide how the wire will be related to the workpiece ...

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-3 Sodick Inc.OFFSET VALUEIn the initialization block, you will include an “H” word along with the G41 (G42) code.This specifies the register the control will use from the header or from the offset filedirectly. The value in this ...

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-4 Sodick Inc.“APPROACH PATTERN” PARAMETERThe parameter “Approach Pattern” in the “SET” “TRAVEL” screen affects the way inwhich the offset is instated on the first move and how it’s cancelled on the last move. It is...

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-5 Sodick Inc.Program for figure 7-3:H001 = +000000650N005 G54 (SELECT COORDINATE SYSTEM NUMBER ZERO)N010 G92 X1. Y-.15 (SET PROGRAM ZERO)N015 G90 (SELECT ABSOLUTE MODE)N020 G42 H1 (SELECT WIRE RIGHT AND CALL H1 REGISTER)N025 C1 (SE...

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-6 Sodick Inc.machined with the set of conditions and offsets for this material, thickness, and wirediameter.While machining the test square, do not change any of the parameters related to thecondition. If you make changes, another te...

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-7 Sodick Inc.To set the Die clearance, or to adjust all offsets evenly, there is a setting in the “ConditionSet” menu for this called “OFFSET”. Input the value into the “OFFSET” box that isneeded to adjust the offsets by....

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    Wire EDM Machine OperationChapter 7Copyright November, 98Page 7-8 Sodick Inc.

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-1 Sodick Inc.CCHHAAPPTTEERR 88 TTAAPPEERR CCUUTTTTIINNGG IINNFFOORRMMAATTIIOONNNow we will discuss taper cutting. We will limit our discussions about taper cutting tomachining die clearance angles. There are other applications fo...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-2 Sodick Inc.Maximum Taper AngleThe maximum taper angle per side can be calculated for a particular workpiece thickness.To determine the maximum taper angle that can be cut at a given thickness, use thefollowing calculation (angle mu...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-3 Sodick Inc.being machined must be finished to the proper size in the (straight) land area of the die.Then the taper angle must be machined. If several trim passes are necessary, this couldalmost double the production time for the d...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-4 Sodick Inc.Figure 8-1INITIALIZING TAPERFirst let’s discuss initializing taper correctly. To initialize the taper cutting mode, youmust look in the direction the wire will be moving during the cut (rotate print ifnecessary). Looki...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-5 Sodick Inc.maximum possible taper angle on your particular machine based on part thickness. Thethinner the workpiece, the greater the taper angle can be.To initialize taper properly, you simply program the G51 (left) or G52 (right)...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-6 Sodick Inc.N025 G51 A1.0 (TAPER LEFT WITH 1 DEGREE ANGLE)N030 C1 (SELECT CUTTING CONDITION)N031 T84 (HIGH PRESSURE FLUSH)N032 T91 (AUTO THREAD)N035 G01 X.485 (MOVE TO POINT 2)N040 Y.015 (MOVE TO POINT 3)N045 G03 X.5 Y0 I.015 (ARC I...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-7 Sodick Inc.TTAAPPEERR SSEETTTTIINNGGSS IINN TTHHEE CCOONNTTRROOLLAs you can see, there really isn’t all that much to programming taper in a die. You simplyinstate taper, use it, and cancel it. However, there are some machine ...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-8 Sodick Inc.down the value of Table To Limit and keep it (with Table To Lower) posted on themachine. This value should only change if replacing the upper guide, or if the upper headgets crashed.TABLE TO UPPERTable to upper is the di...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-9 Sodick Inc.TABLE TO PROGRAMThis is the distance from the tabletop to where you are holding size in X Y.When taper cutting (G51 / G52)Here are four possible situations when the workpiece is mounted directly on the table.1) Cutting w...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-10 Sodick Inc.TABLE TO DRAWThis value is not used during cutting or dry run 1or 2 or in graphics. But in DRY RUN 3,it will tell the control what surface you wish to see on the plotting table. For example, ifthe value in Table to Draw...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-11 Sodick Inc.screen, to be sure this doesn’t occur. Otherwise the machine may stop while machiningwith the error. “Limit check” in graphics can also be used to check for overtravel.

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-12 Sodick Inc.TTAAPPEERR SSEETTTTIINNGG EEXXAAMMPPLLEESSBelow are two examples showing “SET” screen taper setting values with a manual Z-axis.Figure 8-4Known Values Operator inputT-Limit = .6990” T-Upper = 1....

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-13 Sodick Inc.TTAAPPEERR SSEETTTTIINNGGSS IINN BBRRIIEEFF -- OOPPEERRAATTOORR IINNPPUUTTThe following is what needs to be actually input by the operator for each taper cuttingjob. For complete parameter definitions see prior in...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-14 Sodick Inc.NNOOTTEESS CCOONNCCEERRNNIINNGG TTAAPPEERR CCUUTTTTIINNGGCALIBRATING T-UPPER AND T-LOWERIf you are not cutting accurate taper angles, it is possible that the constants called Table toLimit and Table to Lower in the S...

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-15 Sodick Inc.

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    Wire EDM Machine OperationChapter 8Copyright November, 98Page 8-16 Sodick Inc.

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    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-1 Sodick Inc.CCHHAAPPTTEERR 99 PPRROOGGRRAAMM FFOORRMMAATTTTIINNGGThe fifth Key Concept to operation is that you must understand the formatting of a CNCwire EDM program. We have already looked at several complete programs, but the...

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    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-2 Sodick Inc.Figure 9-1After the punch is machined the operator will tell the control to stop (with an M00). Thiswill allow the operator to apply clamps, magnets etc. These will support the punch duringthe cutoff. Then the operator w...

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    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-3 Sodick Inc.FFOORRMM TTOOOOLLSSWith a form tool, the cutting path is not in an enclosed shape. Generally, a form tool iscut from one end to the other. During the rough pass, the wire could be stopped just priorto reaching the other...

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    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-4 Sodick Inc.At this point, let’s look at some examples.PPUUNNCCHH EEXXAAMMPPLLEELets machining a punch that required three total passes (rough and two trims). Based onthe Material Type, Material Thickness, Wire Diameter and Flush...

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    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-5 Sodick Inc."H003 = +000000540;""H004 = +000000530;"N005 G54 (SELECT COORDINATE SYSTEM IN MAIN PROGRAM)N010 G92 X.3 Y-.2 (SET PROGRAM ZERO)N015 G90 (SELECT ABSOLUTE MODE)N020 C1 (SELECT CONDITION FOR FIRST PA...

  • Page 98

    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-6 Sodick Inc.N2010 G02 X0 Y.1 J.1 (MOVE TO POINT 13)N2015 G01 Y.9 (MOVE TO POINT 12)N2020 G02 X.1 Y1. I.1 (MOVE TO POINT 11)N2025 G01 X.4 (MOVE TO POINT 10)N2030 G02 X.5 Y.9 J-.1 (MOVE TO POINT 9)N2035 G01 Y.6 (MOVE TO POINT 8)N2040 ...

  • Page 99

    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-7 Sodick Inc.NOTE: We are using a 1 cut on size offset for the taper cut, since no trims will be doneon the tapered area. You will have to adjust the offsets in the header created by thecondition set menu MANUALLY! Adjust H1 to a val...

  • Page 100

    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-8 Sodick Inc.Figure 9-3NC Program for figure 9-3N005 G54 (SELECT COORDINATE SYSTEM)N010 G92 X.5 Y.2 (SET PROGRAM ZERO)N015 G90 (SELECT ABSOLUTE MODE)N020 C1(SELECT CONDITION FOR ROUGH PASS)N021 T91 ( AUTO WIRE THREAD )N025 G41 H1 (OF...

  • Page 101

    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-9 Sodick Inc.N030 M98 P1000 (JUMP TO N1000 AND MAKE ROUGHING PASS)N033 T85 (TURN OFF HIGH PRESSURE PUMP)N035 C2 (SELECT CONDITION FOR STRAIGHT PORTION TRIM PASS)N040 G41 H2 (OFFSET LEFT STRAIGHT PORTION TRIM PASS)N043 G11 (TURN OPTIO...

  • Page 102

    Wire EDM Machine OperationChapter 9Copyright November, 98Page 9-10 Sodick Inc.

  • Page 103

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-1 Sodick Inc.CCHHAAPPTTEERR 1100 DDEESSCCRRIIPPTTIIOONN OOFF OOPPEERRAATTIINNGG AA IIDDSSThe sixth and last Key Concept is that you have operating aids available to simplifyprogramming and operating the machine. There are more...

  • Page 104

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-2 Sodick Inc.redundant; meaning the control will simply execute the sub- routine command bycommand, in the same fashion each time the sub-routine is called up.However, a Q Routine does not have to be part of another program. That i...

  • Page 105

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-3 Sodick Inc.have the ability to pass variables to the Q routine and have the Q routine behavedifferently based on the values of the variables.Parentheses after Q filename can be added to allow the passing of values into the header...

  • Page 106

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-4 Sodick Inc.N005 G54N010 G92 X.5 Y-.25N015 G90N020 C[H000]N025 G42 H[H001]In block number N020, the C word is specified by a variable. Whatever condition numberwas passed to the Q routine would be placed in H000 and this value is ...

  • Page 107

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-5 Sodick Inc.5000). Then the value of H000 (5000) will be divided by two (result = 2500). And last,the control will subtract 2500 from 5000 and the result of this combined expression willbe 2500 (.25 inch).These simple commands by ...

  • Page 108

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-6 Sodick Inc.QOVAL(.500,1.000,411,.0061)Now, four values will be passed to the Q routine named OVAL. In this case, you wouldbe making a die button that was .500 inch high and 1.00 inch long, using conditionnumber C411, and offset ....

  • Page 109

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-7 Sodick Inc.N070 G03 X.01 Y-[[H000/2/]-.015] J.015 (ARC OUT TO POINT 9)N075 G01 Y0 (MOVE TO POINT 10)N080 G40 X0 (CANCEL OFFSET AND MOVE BACK TO POINT 1)Once you understand these techniques, it opens the door to many applications....

  • Page 110

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-8 Sodick Inc.The command G83 X005 would load the current X position of the wire into the H005register.CCOOOORRDDIINNAATTEE SSYYSSTTEEMM SSHHIIFFTTIINNGG ((GG5544--GG995599))You know by now that Sodick allows up to sixty differen...

  • Page 111

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-9 Sodick Inc.IMPACT CAD CAM for example is a recommended software that can write the programusing the following machining orders.Rough cut all openings up to the glue tabs.Stop the machineCut off all TABS, with MOO stops for the op...

  • Page 112

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-10 Sodick Inc.machine’s position relative to the limits of the machine. If you are going to be running alengthy job and you are worried about the power in your shop going off, you can use thistechnique to assure your ability to e...

  • Page 113

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-11 Sodick Inc.All of these features can be programmed or set manually in the SET screen. However, ifyou set any of these features in the SET screen, they may be canceled at the completionof the program (by M02.) This means that aft...

  • Page 114

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-12 Sodick Inc.Figure 10-4Mirror Image And Axis Exchange ChartOriginal Shape (G09)X Mirror (G05)X + Y Mirror (G05 G06)Y Mirror (G06)XY Exchange (G08)XY Exchange + Y Mirror (G08 G06)XY Exchange + X&Y Mirror (G08 G0...

  • Page 115

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-13 Sodick Inc.SSUUBBRROOUUTTIINNEE TTEECCHHNNIIQQUUEESSWe discussed sub-routines during our presentation of program formatting (chapter 9.) Wegave the most useful reasons for using sub-routines, which are to repeat motions for tri...

  • Page 116

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-14 Sodick Inc.AAUUTTOOMMAATTIICC CCOORRNNEERR RROOUUNNDDIINNGGThis feature was discussed during our descriptions of motion types (concept number threeabout G02 and G03 circular commands.) Here we will take it a little further. Ho...

  • Page 117

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-15 Sodick Inc.

  • Page 118

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-16 Sodick Inc.AAXXIISS RROOTTAATTIIOONNThis feature allows movements to be rotated about the G92 point in the program. Thisfeature can be used when the part is setup differently than the way it was programmed.The example below sho...

  • Page 119

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-17 Sodick Inc.EXAMPLE OF STRING FILE"G80Y:T80G80Y;" (Multiple code conversion example this line)"G80X:T80G80X;""G80X-:T80G80X-;""G80Y-:T80G80Y-;""T84:T84G104X5.0;""T85:T85G...

  • Page 120

    Wire EDM Machine OperationChapter 10Copyright November, 98Page 10-18 Sodick Inc.

  • Page 121

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-1 Sodick Inc.CCHHAAPPTTEERR 1111 PPRRAACCTTIICCEE EEXXEERRCCIISSEESSThis set of practice exercises was designed to reinforce your understanding of thematerial presented during the Course.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCH...

  • Page 122

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-2 Sodick Inc.________________________________________________________________________________________________________________________________________________4) When would you want the flushing to be set to high flush?______________...

  • Page 123

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-3 Sodick Inc.________________________________________________________________________D) Multiplier for the off time (part of the adaptive control):________________________________________________________________________E) Peak Curr...

  • Page 124

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-4 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR TTWWOOMachine Layout Description1) Give the axis name (letter address) for the following descriptions:A) Table motion in and out (toward you and away from you).____...

  • Page 125

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-5 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR TTHHRREEEEProgram Zero Description3) What is the purpose of using a program zero point?_____________________________________________________________________________...

  • Page 126

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-6 Sodick Inc.and another for the die program. And last, tell what wire diameter would be best tomachine this part.Best wire start point for a die?X_____________Y_____________Best wire start point for a punch?X_____________Y________...

  • Page 127

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-7 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR FFOOUURRProgram Makeup1) What letter signifies line numbers?________________________________________________________________________2) What are the four steps you s...

  • Page 128

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-8 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR FFIIVVEEThe Four Kinds Of Wire Motion1) What is the G code for rapid motion?________________________________________________________________________ Straight line ...

  • Page 129

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-9 Sodick Inc.Program:N005 G54N010 G92 X________ Y________ Z________ (1)N015 G90N020 C1N025 G42 H1N030 T84N035 G01 X________ (2)N040 Y________ (3)N045 G03 X________ Y________ I.05 (4)N050 G01 X________ (5)N055 G03 X________ Y_______...

  • Page 130

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-10 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR SSIIXXDescription Of Programming Codes1) Give a brief description (or use) for the following “letter addresses”. N word______________________________________...

  • Page 131

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-11 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR SSEEVVEENNWire Offset Description1) What are two reasons for using wire radius compensation?_______________________________________________________________________...

  • Page 132

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-12 Sodick Inc.6) Say you had to machine a punch and die, and the die needed .002” clearance. Wheredo you set this value to correct the die offsets? Also, What value do you input?___________________________________________________...

  • Page 133

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-13 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR EEIIGGHHTTTaper Cutting1) What are some popular reasons for taper cutting?________________________________________________________________________2) What are the p...

  • Page 134

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-14 Sodick Inc.PPRRAACCTTIICCEE EEXXEERRCCIISSEESS CCHHAAPPTTEERR NNIINNEEProgramming AidsQ Routines:1) What is a Q routine?_________________________________________________________________________________________________________...

  • Page 135

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-15 Sodick Inc.________________________________________________________________________Automatic Corner Rounding:12) What is the difference between using G02 and G03 as they compare to usingautomatic corner rounding.________________...

  • Page 136

    Wire EDM Machine OperationChapter 11Copyright November, 98Page 11-16 Sodick Inc.String File20) What is the purpose of the string file?________________________________________________________________________

  • Page 137

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-1 Sodick Inc.CCHHAAPPTTEERR 1122 MMAAIINNTTEENNAANNCCEESodick Wire EDM’s are precision machine tools and should be treated as such.Preventative maintenance will eliminate unnecessary problems, downtime, andaggravation and shoul...

  • Page 138

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-2 Sodick Inc.MMAAIINNTTEENNAANNCCEE CCHHEECCKKLLIISSTTBY THE HOUR CHECKS1) Carbide power feeders every 70 Hours. See page 12-4DAILY CHECKS1) Water level in the dielectric tank. See page 12-42) Water filter pressure. See page 12-43...

  • Page 139

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-3 Sodick Inc.ANNUALLYDrain ,clean and refill dielectric tank.MMAAIINNTTEENNAANNCCEE DDEESSCCRRIIPPTTIIOONNSSRESISTIVITY METERThis meter measures the resistance of the deionized water from 0 - 20 and is locatedbelow the chiller. Th...

  • Page 140

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-4 Sodick Inc.WORKTANK AND TABLE:Use AC-500 or equivalent and spray down the tank and table and let sit for severalminutes. A toilet bowl brush works well for scrubing out the tank and a toothbrush for thesmaller areas.If a small am...

  • Page 141

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-5 Sodick Inc. FLUSH NOZZLES:There are 3 sizes of flush nozzles.0 to 10° 6mm Lower (3081674) 6mm AWT Upper (3081604)11° to 20° 10mm Lower (3081675) 10mm AWT Upper (3081606)21° to 30° 12mm Lower (3081867) 12mm AWT Upper ...

  • Page 142

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-6 Sodick Inc.Sodick also offers an optional wire chopper that chops the wire into small bits and dropsthem into the wire bin thus eliminating wire curling in the bin.WAY LUBRICATION:The ways should be greased once every 3 months wi...

  • Page 143

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-7 Sodick Inc.This preguide may get plugged up with brass dust. Clean the guide, install it and installthe cap and feed the wire through the threader. The optimum location for the end of thepipe when it goes down to thread the wire,...

  • Page 144

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-8 Sodick Inc.

  • Page 145

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-9 Sodick Inc.WWIIRREE GGUUIIDDEE AASSSSEEMMBBLLYY DDRRAAWWIINNGGSSFIGURE SHOWING LOWER HEAD ASSEMBLY

  • Page 146

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-10 Sodick Inc.FIGURE SHOWING UPPER AWT HEAD ASSEMBLY

  • Page 147

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-11 Sodick Inc.LLOOWWEERR HHEEAADD AALLIIGGNNMMEENNTT PPRROOCCEEDDUURREELOWER HEAD ALIGNMENT:The top of the lower flush cup should be about .005" below the table .To check it, take asurface gage and an indicator and zero out...

  • Page 148

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-12 Sodick Inc.AWT U AND V ALIGNMENT PROCEDUREFor the AWT to thread correctly, the U & V axis must move to align the water jet to thelower wire guide. This offset is calculated by the following procedure.Remove the lower flange ...

  • Page 149

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-13 Sodick Inc.AWT TYPE This parameter is used to select the type of AWT unit to be used. Normallyset to 40: No AWT unit to be used.1 : Not defined.2 : Not defined.3 : Not defined.4 : All AWT types.S : AWT designed to special specif...

  • Page 150

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-14 Sodick Inc.AWT 2 (thread wire) to fail for each AWT operation. The parameter is to be set in therange of 0 to 255. Normally set to 4WIRE BROKEN RETRY This parameter is used to set the number of times by whichto allow the wire to...

  • Page 151

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-15 Sodick Inc. WIRE SPOOL SETTINGS A320D, A530DThere are 4 settings available in the electrical cabinet located behind the machine tool.These affect how the wire spool shaft, and AWT operate.Wire Rewind: Set between 70 and 80When t...

  • Page 152

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-16 Sodick Inc.WIRE SPOOL SETTINGS A325There are 2 settings available on the side to the LEFT of the wire spool.BB2 (Wire Rewind): Set between 70 and 80 When the wire breaks, the AWT unit must rewind the broken wire above the upper...

  • Page 153

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-17 Sodick Inc.WIRE SPOOL SETTINGS AP350,AP500, AP600There are 3 settings available below the wire spool. These affect how the wire spoolshaft, and AWT operate.BB1 (Wire Rewind): Set between 70 and 80 When the wire breaks, the AWT u...

  • Page 154

    Wire EDM Machine OperationChapter 12Copyright November, 98Page 12-18 Sodick Inc.

  • Page 155

    Wire EDM Machine OperationChapter 13Copyright November, 98Page 13-1 Sodick Inc.CCHHAAPPTTEERR 1133 SSEETT UUPP PPRROOCCEEDDUURREE CCHHEECCKK LLIISS TT1) Power up the machine. (see page 14-1)2) Re-home the machine. (see page 14-1)3) System checks:a) Water resistivity correct? See page 1-4 an...

  • Page 156

    Wire EDM Machine OperationChapter 13Copyright November, 98Page 13-2 Sodick Inc.Note: (A320D & A530D only) If the plotting table is up and the side door is shut, DONOT put the plotting pen arm on or it will hit the cover!!!!!!10) Move machine back to the start point location and check machine ...

  • Page 157

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-1 Sodick Inc.CCHHAAPPTTEERR 1144 QQUUIICCKK RREEFFEERREENNCCEE SSEECCTTIIOONNThe following section will give you step by step instruction for the following commonoperations.PPOOWWEERR UUPP TTHHEE MMAACCHHIINNEE1) Turn on the...

  • Page 158

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-2 Sodick Inc.MMOOVVEE AAXXIISS BBYY ““MMDDII””The Sodick control allows you to move any axis (one or more) by “MDI” in a similarway to how it is done in a program. Any rules you know related to programming will still...

  • Page 159

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-3 Sodick Inc.through the AWT unit and the upper and lower wire guides. If the machine has anautomatic wire threader, flip the switch on the control panel to cut the wire. 2) Sometimes it is helpful to release the wire tension with ...

  • Page 160

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-4 Sodick Inc. EEDDGGEE FFIINNDD BBYY UUSSIINNGG TTHHEE SSTT KKEEYYThis is 1 of 2 procedures used to locate the edge of a workpiece. It leaves the wire flushwith the edge of the part. However, this procedure is not the most a...

  • Page 161

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-5 Sodick Inc.AASSSSIISSTT KKEEYYSS MMAARRKK2255 AA00 –– AA77The keys “A0 – A7” are assigned an NC program to execute when they arepressed. The NC programs are changeable if the operator desires. Thefollowing table sh...

  • Page 162

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-6 Sodick Inc.Key-in 1 : Enter which corner to pickup (corner 1 through 4)Key-in 2 : Enter move distance away from corner.Key-in 3 : Enter the wire diameter.“A3 Key” – Edgefind program: If a wire size is input, it will G92 the...

  • Page 163

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-7 Sodick Inc.EEDDGGEE FFIINNDD UUSSIINNGG GG8800 ((IINNSSTTEEAADD OOFF TTHHEE AA33 AASSSSIISSTT KKEEYY))The G80 code will actually edgefind and touch the workpiece three times and take theaverage of the three touches.1) Ma...

  • Page 164

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-8 Sodick Inc.CCHHAANNGGIINNGG TTHHEE AAXXIISS DDIISSPPLLAAYY RREEAADD AANNYY NNUUMMBBEERRThis procedure will allow you to change the axis display to a value. This is commonlyused when setting the origin.1) Go to the “MAL”...

  • Page 165

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-9 Sodick Inc.VVEERRTTIICCAALLLLYY AALLIIGGNN TTHHEE WWIIRREEThe vertical alignment is extremely important! If the wire is not vertically aligned, theworkpiece will come out with undesirable taper due to the out of alignment cond...

  • Page 166

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-10 Sodick Inc.AdjustingUaxisAdjustingVaxis

  • Page 167

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-11 Sodick Inc. CCEENNTTEERRFFIINNDD OOFF AA HHOOLLEE OORR SSHHAAPPEE ((BBYY QQ RROOUUTTIINNEE))There are Q Assist routines named 0145,0146 and 0155 designed by Sodick to makeoperation easier. Use these programs to pickup...

  • Page 168

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-12 Sodick Inc.CCOORRNNEERR FFIINNDD RROOUUTTIINNEE ((BBYY QQ RROOUUTTIINNEE))This is another Q Assist routine (0165) designed by Sodick to make operation easier.When you are trying to work form a corner of your workpiece (as...

  • Page 169

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-13 Sodick Inc.CCLLEEAARRIINNGG TTHHEE MMEEMMOORRYYThe following procedure clears all NC programs from memory.1) Press the soft key next to ““EDIT””.2) Press the soft key next to “FILE”.3) Press the “Memory Clear...

  • Page 170

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-14 Sodick Inc.SSAAVVIINNGG PPRROOGGRRAAMMSS FFRROOMM MMEEMMOORRYY TTOO UUSSEERR DDIISSKK1) Insert user disk into the drive .2) Press the soft key next to ““EDIT””.3) Press the soft key next to “FILE”.4) Press the ...

  • Page 171

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-15 Sodick Inc.4) To save the changes leave this screen, but when you try it prompts you in the lowerLeft corner, will you reflect changing on disk?5) Press “ENTER” for yes and “ESC” for no.6) If you pressed “ENTER” and ...

  • Page 172

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-16 Sodick Inc.6) The program is now in memory.SSAAVVIINNGG PPRROOGGRRAAMMSS FFRROOMM HHAARRDD DDRRIIVVEE TTOO UUSSEERR DDIISSKK1) Insert user disk into drive 1.2) Press the soft key next to “SET”.3) Press the soft key ne...

  • Page 173

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-17 Sodick Inc.11) Choose the files you want to save to the hard drive by typing the number in red that corresponds with the file you want and press the Return key.12) There is a maximum of 10 files you can save at a time.13) To sav...

  • Page 174

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-18 Sodick Inc.3) Press the soft key below “DELETE”.4) Using the arrow keys, move the cursor to the left side of the screen and highlight the program you want to delete from the hard drive and press “ENTER”.5) The prompt, wi...

  • Page 175

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-19 Sodick Inc.UUSSIINNGG TTHHEE EEDDIITTOORROnce you load a program into memory, you have complete control of the program. Manyediting functions can be performed. All editing functions require that the program beloaded into memor...

  • Page 176

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-20 Sodick Inc. 2) Press the soft key under “AREASET”. 3) Bring the cursor to the last character to be deleted (characters to be deleted will behighlighted). 4) Press the soft key under “DELETE”. 5) Note: To return the delet...

  • Page 177

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-21 Sodick Inc.IINNIITTIIAALLIIZZIINNGG AA NNEEWW UUSSEERR DDIISSKKEETTTTEEThe USER disk is where you can store programs. As time goes on, you will fill the USERdisk with programs and need to use a new one. You should know that ...

  • Page 178

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-22 Sodick Inc.RRUUNNNNIINNGG PPRROOGGRRAAMMSS FFRROOMM TTHHEE AACCTTIIVVEE MMEEMMOORRYY1) Load program into active memory.2) Press the lower right vertical soft key so coordinate screen is showing.3) Check conditional switches...

  • Page 179

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-23 Sodick Inc.CCHHAANNGGIINNGG PPOOWWEERR SSEETTTTIINNGGSS WWHHIILLEE MMAACCHHIINNIINNGGIn the RUN mode, you have complete control of all condition parameters (ON, OFF,IP,,HP,MA etc.) while running a part. However, when you sta...

  • Page 180

    Wire EDM Machine OperationChapter 14Copyright November, 98Page 14-24 Sodick Inc. CCOOPPYYIINNGG AALLLL ““AAPPTT”” FFIILLEESS FFRROOMM TTHHEE FFLLOOPPPPYY TTOO TTHHEEHHAARRDDDDRRIIVVEEMany customers have updated their machines to have a hard drive, or bought a newmachine with a ha...

  • Page 181

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-1 Sodick Inc.CCHHAAPPTTEERR 1155 CCRRTT SSCCRREEEENNSSSSCCRREEEENN DDEEFFAAUULLTT PPAARRAAMMEETTEERRSSThis chapter looks at some of the CRT screens in the control. The screens shown in thismanual describe some of the most comm...

  • Page 182

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-2 Sodick Inc.

  • Page 183

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-3 Sodick Inc.MMAALL--MMDDII SSCCRREEEENNThe “MAL – MDI” screen is blank in the middle allowing the operator to manually typein commands and programs.Choose more in the lower right corner with the key below it and then choose...

  • Page 184

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-4 Sodick Inc.“MORE” to go to the second screen. Press “BACK” and it turns blue. Press the “BACK”button again and it will bring back the last information you typed in and display it on thescreen.

  • Page 185

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-5 Sodick Inc.EEDDIITT,, GGRRAAPPHH SSCCRREEEENNWhen you go to EDIT, GRAPH, CUT N PASS and you get the error message same dataare set in Taper Data TP & TN, you will have to enter either 0 or Workpiece Thicknessin table to Nex...

  • Page 186

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-6 Sodick Inc.LIMIT CHECK: When ON, it will tell you if the machine will hit a limit switch, whenrunning the program. This does not replace dry run. Remember to be at the start pointbefore graphing the program.NC PROGRAM: When ON, i...

  • Page 187

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-7 Sodick Inc.EEDDIITT,, GGRRAAPPHH,, SSCCRRNN FFLLAAGG IINNPPUUTT SSCCRREEEENNREMEMBER: This screen affects graphics, not the machine! The most commonlyused parameters are listed below:MIRRORS - Turn the mirrors on and p...

  • Page 188

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-8 Sodick Inc.TAPER IGNORE - If taper is in your program and this is turned on, Graphics will notshow taper.A CIRCLE POINT - When using G2 & G3, it compares the radius at the start and endpoints. If within the value specified in...

  • Page 189

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-9 Sodick Inc.DDIISSPPLLAAYY SSCCRREEEENNPress the soft key next to “DSPLY”. This screen will show machine movement relative tothe program running under actual position in the upper left corner.This screen will also show machin...

  • Page 190

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-10 Sodick Inc.

  • Page 191

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-11 Sodick Inc.SSEETT SSCCRREEEENN ##11REMEMBER: THIS SCREEN AFFECTS THE MACHINE, NOT GRAPHICS.SKIP - This manually turns on or off the block skip slash code in the program. This isthe G11- G12 code if you want to program it.NOMA...

  • Page 192

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-12 Sodick Inc.3 = Dry run on with XY axis moves of “TABLE TO DRAW” Z plane. Use this toplot out the taper at different Z heights.SINGLE - When ON, the machine executes one line of NC code and stops.X-Y CHANGE - When ON, the X A...

  • Page 193

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-13 Sodick Inc.At 1 - Changes are saved to that power setting while the program is running. (“C”code is updated). Changes are only saved to memory, not the disk or hard drive.AWT REFERENCE0 (G14)= Wire break recovery turned off ...

  • Page 194

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-14 Sodick Inc.

  • Page 195

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-15 Sodick Inc.SSEETT SSCCRREEEENN ##22 ((RROOLLLL UUPP KKEEYY))SCREEN SAVER DELAY (MIN.) This function blanks out the CRT if the soft keys orthe keyboard keys are not pressed within the designated time. Any keyboard key to ...

  • Page 196

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-16 Sodick Inc.

  • Page 197

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-17 Sodick Inc.SSEETT,, TTRRAAVVEELL SSCCRREEEENN ##11A CIRCLE POINT - When using G2 & G3, it compares the radius at the start and endpoints. If within the value specified in this parameter, the program will run.DIGIT - Can b...

  • Page 198

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-18 Sodick Inc.AUTO T UPPER - (For Power Z- Axis) When turned on, it automatically tracks thelocation of the upper head and stores that location in Table To Upper in the SET Screen.TWO LEVEL OFF - Only available on certain versions ...

  • Page 199

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-19 Sodick Inc.SSEETT,, TTRRAAVVEELL SSCCRREEEENN ##22 ((RROOLLLL UUPP KKEEYY))DRY AWT –This parameter affects how the AWT functions during dry run.0 = The AWT simulation does not occur.1 = The AWT pipe lowers down and the w...

  • Page 200

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-20 Sodick Inc.ON - Keeps you from entering a predetermined cube when outside of it.OFF - Keeps you from exiting a predetermined cube when inside of it.

  • Page 201

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-21 Sodick Inc.SSEETT,, SSIIRR//PPTTRR SSCCRREEEENN ##11This is the RS232 parameter screen.SSEETT,, SSIIRR//PPTTRR SSCCRREEEENN ##22 ((RROOLLLL UUPP KKEEYY))This is the calendar screen. Please set up the correct parameters ...

  • Page 202

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-22 Sodick Inc.

  • Page 203

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-23 Sodick Inc. RRUUNN SSCCRREEEENNThis screen is normally used to start and monitor the program. Press the bottom soft key,of the vertical keys. This key toggles between the run screen and a directory screen. Therun screen displa...

  • Page 204

    Wire EDM Machine OperationChapter 15Copyright November, 98Page 15-24 Sodick Inc.When enter is pressed, the machine moves to the G92 location. GRA.NC and GRA.DT isfor graphics. When the picture of the program is on the screen, you can have the NCprogram on or off the screen by using the GRA.NC key...

  • Page 205

    Wire EDM Machine OperationChapter 16Copyright November, 98Page 16-1 Sodick Inc.CCHHAAPPTTEERR 1166 RREEMMOOTTEE CCOONNTTRROOLL OOPPEERRAATTIIOONNSELECTING A JOG SPEEDTo choose one of the “MFR” buttons on the remote to set the jog speed.• 0 - Fastest• 3 - Slowest.TO JOG X OR YTo jog th...

  • Page 206

    Wire EDM Machine OperationChapter 16Copyright November, 98Page 16-2 Sodick Inc.TO EDGEFINDTo pick up the edge of a part, turn the wire run on manually, press the “ST” button on theremote and hold it down. Now jog the machine so the wire bumps into the edge of theworkpiece. Once the wire bum...

  • Page 207

    Wire EDM Machine OperationChapter 16Copyright November, 98Page 16-3 Sodick Inc.“A3 Key” – Edgefind program: If a wire size is input, it will G92 the axisdisplay ½ the wire diameter. If the wire size is zero, it will not G92.The following key-in is required.Key-in 1 : Enter the direction to...

  • Page 208

    Wire EDM Machine OperationChapter 16Copyright November, 98Page 16-4 Sodick Inc.

  • Page 209

    Wire EDM Machine OperationChapter 17Copyright November, 98Page 17-1 Sodick Inc.CCHHAAPPTTEERR 1177 SSEEVVEERRAALL CCOOMMMMOONN AALLAARRMMSS &&MMEESSSSAAGGEESSE111 Same Data are set in taper data T-P and T-N. - T-Prog and T-Next in EDIT,GRAPH screen cannot be the same. Make T-Next z...

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