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Wire EDM Machine Operation
INTRODUCTION
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Copyright June, 98
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Sodick Inc.
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Related Manuals for SODICK A530D
Summarization of Contents
Description of the EDM Process
General EDM Factors
Discusses fundamental factors like wire diameter, type, speed, tension, and water resistivity for EDM.
Specific Parameters of the EDM Process
Explains various parameters controlling the EDM process, including oscilloscope display of discharge pulses.
Understanding the Condition File Manual
Guides on using the condition file manual for recommended cutting conditions and offsets.
Machine Layout Description
Machine Components
Identifies key mechanical components like the table, upper head, X, Y, Z, U, V axes of the EDM machine.
Control Panel Overview
Introduces the control panel, its screens, and related soft keys for machine operation.
Keyboard Related Buttons
Details the functions of various keys on the keyboard for program entry and control.
Program Activation Keys
Explains keys used for starting, stopping, and controlling program execution on the NC side.
Program Zero Description
How to Assign Your Program Zero Point
Explains how to set the program zero point and its importance for absolute programming.
Understanding Work Coordinate Screens
Describes how to use and manage work coordinate systems (G54-G959) for multiple setups.
Program Makeup
Preparation for Programming
Outlines essential preparation steps before writing a manual CNC wire EDM program, including math and planning.
The Four Kinds of Wire Motion
G00 Rapid Motion (No Cutting)
Explains rapid motion used for positioning the wire without cutting.
G01 Straight Line Motion (Actually Cutting)
Details straight line cutting motion commands, including automatic machine functions.
G02 and G03 Circular Motion
Covers clockwise (G02) and counter-clockwise (G03) circular motion programming with I/J values.
Circular Motion Using the R Word
Explains programming circular arcs using the R word for constant radius corners.
Description of Programming Codes and Words
Programming Codes (Letter Addresses)
Provides descriptions and uses for key programming words like N, G, X, Y, Z, U, V, I, J, H, A, P, L, C, R.
List of G Codes
A reference list of G codes with their descriptions and modal status.
List of T Codes
A reference list of T codes used for machine functions like wire threader and flushing.
List of M Codes
A reference list of M codes for program control, stops, and subroutines.
Wire Offset Description
Understanding Offsets
Explains what wire offsets are and how they control wire centerline distance from the programmed surface.
Three Advantages to Using Offsets
Details the benefits of using wire offsets, including inputting actual coordinates and simplifying programs.
Initializing Offset
Guides on how to start wire radius compensation using G41 (wire left) and G42 (wire right).
Importance of Test Squares
Emphasizes the necessity of cutting test squares to verify conditions and offsets for accuracy.
Taper Cutting Information
Taper Cutting Considerations
Discusses factors like die land, taper angle size, and calculations for taper cutting.
Maximum Taper Angle
Explains how to calculate the maximum possible taper angle based on workpiece thickness.
How to Program Taper
Outlines the three steps for programming taper cutting: initialize, motion, and cancel.
Description of Operating Aids
Q Routine Techniques (Macros)
Introduces Q routines as powerful programs that automate tasks and simplify programming.
Coordinate System Shifting (G54-G959)
Explains the use of multiple coordinate systems for managing setups and multiple part openings.
Mirror Image and Axis Exchange
Covers features allowing program rotation or mirroring for different part setups without reprogramming.
Scaling
Describes how to easily change the size of a workpiece by inputting a scale factor.
Automatic Corner Rounding
Explains automatic corner rounding using the R word for simpler programming of shapes.
String File
Details how string files act as translation tables to make the machine respond to commands from other machines.
Maintenance
Maintenance Checklist
Provides a list of routine checks categorized by frequency (daily, weekly, monthly, etc.).
Maintenance Descriptions
Explains the function and use of key maintenance components like the resistivity meter and DI bottle.
Quick Reference Section
Power Up the Machine
Step-by-step instructions for powering on the EDM machine and its control system.
Power Down the Machine
Procedures for safely shutting down the EDM machine and saving programs.
Rehome the Machine
Detailed steps to re-establish machine home limits and zero axis displays.
Move Axis by “MDI”
Explains how to manually move machine axes using the MDI mode, similar to programming.
Install Wire on the Machine
Covers procedures and notes for installing wire spools and threading the wire through the machine.
Edge Find by Using the ST Key
Describes a basic method for locating a workpiece edge using the ST key.
Edge Find (Using G80)
Explains a more accurate edge-finding procedure using the G80 code.
Vertically Align the Wire
Provides a procedure for checking and adjusting wire vertical alignment for accurate taper cutting.
CRT Screens
Screen Default Parameters
Introduces CRT screens and parameters considered preference settings affecting machine behavior.
MAL-MDI SCREEN
Describes the MAL-MDI screen for manually typing commands and programs.
DISPLAY SCREEN
Explains the DISPLAY screen showing machine position, axis readouts, and program execution status.
SET SCREEN #1
Details parameters in SET SCREEN #1 affecting graphics and machine settings like scale and digit format.
SET, TRAVEL SCREEN #1
Covers parameters in SET, TRAVEL screen #1 for graphics, approach patterns, and axis modes.
RUN SCREEN
Explains the RUN screen for starting, monitoring programs, and adjusting cutting conditions.
Several Common Alarms & Messages
E111 Same Data are set in taper data T-P and T-N.
Addresses an error when taper data TP and TN are identical, requiring T-Next to be zero or workpiece thickness.
E161 Touching limit switch on stroke end overtravel.
Explains an alarm indicating the machine has reached its travel limits and needs acknowledgment.
E164 Machine overmoved, release from the heat switch.
Describes an alarm for servo motor overload or power loss during jogging, requiring a reboot.
H161 Dielectric level or service tank has dropped from the specified level.
Details an alarm for low dielectric fluid level, possibly due to flushing settings or turbulence.
H164 Machining has stopped due to a short circuit.
Explains an alarm indicating the wire is touching something, requiring correction and restart.
H197 Minus Machine Coordinate.
Describes an alarm when an axis shows a negative number, indicating proximity to a limit switch.
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