05.

2006

Contents

1 Single Cavity Erosion .................................... 3

1.1 Presentation of the example .............................3

1.2 Preparing before erosion ..................................4

1.3 Procedure .........................................................8

1.4 Start erosion ................................................... 11

1.5 During EDM .................................................... 12

1.6 Complete Erosion ........................................... 13

SA Series 2 Screw thread erosion ................................... 13

C6. Application Examples 2.1 Presentation of the example ........................... 13

2.2 Procedure ....................................................... 14

3 Circular cavities distributing ......................... 19

3.1 Presentation of the example ........................... 19

3.2 Procedure ....................................................... 20

3.3 Start erosion ................................................... 23

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1 Single Cavity Erosion

1.1 Presentation of the example

z Purpose：Machine a cavity using the most simple method. The position of the cavity is in the
center of the workpiece.
z Machining demand：

Workpiece：
material: St 1.2343
Shape Size: 50 x 50 x 30 mm
Cavity Size: 15 x 15 x5 mm
Surface Roughness: VDI 25
Ra 1.78
Rz 12

Electrode:
Material : copper
Dimension: 14.3 x14.3 mm
Frontal Area:2.25 cm 2
Number: 1
Undersize: 0.7 mm

z sequence
The following steps should be finished for this example:
1．Preparing before erosion
2．Create erosion program
3．Inspecting during erosion process
4．Erosion completing

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1.2 Preparing before erosion

1.2.1 Workpiece mounting

Fix the workpiece on the worktable or corresponding clamps, and make its basis side
Parallel to axis X or Y
and level the upper surface .

z Preparing:

Notice while fixing the

workpiece:
• The workpiece should be
installed in the allowable
range of the machine.
• The clamps can not be
interferential during the
machine moving or erosion.
• Clear out the burr and oil on
the aligning surface of the
workpiece.

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z Aligning：
Fix gauge like dial indicator in the
head of the principal axis, and
contact the head of the indicator to
the aligning surface of the
workpiece . Then move the
corresponding axis repeating by the
handbox, and adjusted the position
of the workpiece.

Notice:

• Avoiding collision during

operation.
• While moving the axis,
press the enable button
first, and then press the
corresponding axis button.
• The jog has two types:
High/s low speed; the value
of each type and speed can
be adjusted
On the Configuration page
• your dial indicator support
should beinsulated, if not, short
circuit warning will happen. Then
press the collision protection key
(lamp lit) on the handbox to
allow the axis to move. But the
axis move one time with one
press .

z Fixing the workpiece

After aligning, fix the workpiece , and make sure it is stable and reliable.

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1.2.2 Electrode clamping

Fix the electrode in the clamp.

If necessary the electrode should

be adjusted.
First make the lateral side (Z
direction) of the electrode upright

Then make the lateral side

parallel to X and Y direction.
Align Electrode is available
If the C axis is installed.

Front view plan form

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1.2.3 Set zero point of the workpiece

z Outside center find

z Select Outside Center Find ico

• Enter the sensing accuracy
and speed
• Enter the traverse X and Y
• Enter Z distance to descend
• Select Zero Axes
• Don’t select Rotate Scanner
• Press Cycle Start button to
start

• Sense the workpiece surface

• After Outside center finding,

click the Edge Find ico.
• Select -Z direction(The ico turns
yellow)
• If want，the sensing accuracy and
speed can be altered.

Note：

Don’t select Rotate Scanner

• Press Cycle start to start

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1.3 Procedure

1.3.1 Create a new job

• Enter Create job page

• Click Job name area

• select New

• Enter a New Job Name

• Select Next
• The system ask whether
creating workpoint or
not .Select No here, and
select Next.
• The system ask whether
creating erosion or
not .Select Yes here, and
select Next.
• Enter the Process Data
page.

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1.3.2 Creating a program with the help of AEP

• This page can also be

entered through editing AEP.
• During the operation, the
numeric keypad will appear if
the data field is clicked. Then
click the data field of the
numeric keypad, a convenient
calculator can provide you a
convenient calculate.

• Select the Process Data

Page
• Select the Application page
Enter the Frontal Area of the
electrode
= 2.25 cm 2 .

• Set Erosion Vector to

Z= –5.000 (mm)

• Select the Orbit Data page.

• Select 2D or 3D vector.
• Enter the start angle= 45°.
• Enter the number of vectors
= 4.

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• Select the Impulse page

• Material = Copper – Steel

• VDI Finish = 25
• Only select one electrode.
Here the impulse lines
combine to one line.

• Select complete, The AEP is

stored and the EDM program
automatically created.

• Actual Undersize
▼ = 0.700mm
• Enter the number of
electrode =0

• After all input, all page labels

turn to natural colour. Here
can select Complete directly
because of no workpoints
being created.

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1.4 Start erosion

• Set the first line to start, then the line turns yellow.
• Click Cycle Start to startup the erosion。
• First the system open the pump to oil. During the oil process, the flush ico is always
flashing till the oil level up to the specified position.
• Note: the specified oil level should be above the up-surface of the workpiece at least
50mm.
• After reaching the level, the machine open the fan and impulse generator in the
cabinet, and the servo system moves the electrode to close to the workpiece, then
the erosion starts.

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1.5 During EDM

From the Process Optimizer page

you can check the stability and the
progress of the erosion process.
You can also modify some
parameters during erosion in order
to optimize the process. All
modifications will be save in the Job
program, and they are available in
the next erosion.

• From the Program

Page you can check the
execution of the program, the
current program line will turn
yellow, and exchange next
step automatically following
the erosion.
• You can also enter the
Diagnostics –Event History
page to check the records of
the former erosions or the
executions of the current
program.

• Press Cycle Stop button

during erosion to stop, the
machine will withdraw the
electrode from the workpiece
if a continuous erosion is
necessary, press Cycle
Stop button again, and the
erosion continue from the
interrupted program.

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1.6 Complete Erosion

• After complet erosion,

the discharge ends, the electrode

withdraws, and erosion complete
information will appear.

2 Screw thread erosion

2.1 Presentation of the example

z Purpose：The purpose of the example is to cut a fastening thread correctly.

In this particular case a thread is to be cut which entails the correct input of the
compensation values M/2Gap as well as the correct programming of the escape
strategy.

z Workshop drawing: Two through threads M10 with final roughness VDI 27 are to be
machined on the mounting plate.

2.1.1 Workpiece drawing

material: Steel 1.2767 15

Measurements: 134 x 30 x 18 mm 30

Final roughness: VDI 27

Ra 2.2
30 74
Rz 13.2
134

M10

18

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2.1.2 Electrode drawing

When a through machining (through thread) is performed, just one electrode, such as roughing or
finishing electrode, can be used. This is possible if the electrode in question (the threaded part in
our case) is with length at least twice the workpiece height plus a small safety margin (1-2 mm).
Double utilization of the electrode is obtained merely by positioning (with correcting) the finishing
electrode at another height.

Material: Pure copper

Undersize:
1 electrode ∇∅ 2 mm
2 electrode ∇∇ ∅ 2 mm

Note: various types of threaded

electrodes, differing in size, pitch and materials, are offered on the market.

z Sequence

1 Create a new Job.

2 Create a description of the workpiece and Workpoints
3 Add an AEP program and describe it
4 Modify the technology parameter M2Gap Compensation
5 Set Start

2.2 Procedure

2.2.1 Create a new job

• Click Job Name field to

appear the Create Job page，
select New.

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z Enter new Job name

z Click Complete

2.2.2Enter the workpoint

• Select Workpoints from the menu list

• Enter the coordinates of the

machining position in the existing
Workpoint 1:
X = 30.000 mm and
Y = 15.000 mm
• Create Workpoint 2 and enter the
coordinates of the corresponding
machining position:
X = 104.000 mm and
Y = 15.000 mm

2.2.3 Creating a program with the help of AEP

• Select Program from the menu

list
• Click Add, select Automatic
Erosion Programming step.

• Select the Process Data page

• Enter Frontal Area of the electrode
= 1.00 cm2
• Set Erosion Vector to
Z= –20.000 (mm)

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• Select the Orbit Data page

• Select planetary mode Circular

and set Retract Strategy to 90°
towards center

Note:

This is a very important

parameter absolutely necessary
for this type of machining.

• Select the Impulses page

• Material = Copper – Steel
• VDI Finish = 27
• Actual Undersize
▼ and ▼▼ = 2.000 mm
• Enter the number of electrodes

• Select the Erosion Points page

• Select the workpiece and the 2
workpoints
• If necessary, select the machining
sequence Finish each
workpiece sequentially.

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• The AEP is stored with OK and

the EDM program automatically
created

2.2.4 Setting the frontal M/2G Compensation to 0

• Select Erosion 1 in Program and

open the Edit Erosion Step
window by double-clicking the
left mouse button

• Select the Process Data page

• Click the Frontal Scale field
• Select 0 in the Numeric Keypad
window and confirm by pressing
OK
• Repeat this Frontal Scale to 0
setting with all EDM impulses by
pressing Next

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2.2.5 Setting the correction of electrodes

Enter the correction in Z of

electrodes 1 and 2

Thread

Note:

When defining the correction value

between both electrodes, the thread
pitch must be also taken into
account.

2.2.6 Defining the Workpiece

• Save the Workpiece Reference.

If not known, plot the reference
by means of the Measuring
cycles.

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3 Circular cavities distributing

3.1 Presentation of the example

z Purpose：If machinings are arranged on an arc, the information about the starting
angle (= first cavity position) can only be given with a positive angle. That means in
our example the first machining lies at 45°. The information about the part angle is
also possible only with a positive preceding sign. That means that all machinings,
from the first to the last, are thus arranged in an anticlockwise direction.

z Workshop drawing

On a workpiece made of steel 1.2436, three square cavities must be executed with a final
roughness of VDI 21.

45 45

45

13 Y+

35
X+

Workpiece material St 1.2436

Final roughness required VDI 21 / Ra 1.10 µm
Electrodes 2 electrodes made of copper:
1 ∇, planned undersize ∅ 0.7 mm
2 ∇∇, planned undersize ∅ 0.5 mm

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3.2 Procedure

3.2.1 Create a new job

• Enter Create Job page

• Click Job name area

• Click New button

• Enter the new Job name

• Click complete

3.2.2 Describing Workpoints

• Select Workpoints from the

menu list.
• Click on the Name field and
erase the existing workpoint with
the Cut button.
• Click on the Name field once
again and add a new workpoint
with New. Then press the Next
button so that the Create
Workpoint window opens.
• The Centre Location lies at the
centre. That means all axes
remain at 0.000.

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• Select the option Circular and enter the following data from the drawing in the appropriate
fields:
Radius = 35 mm
Start Angle = 45°
Angular Spacing = 45°
Number of Points = 3
Rotate C = Yes

• With the Complete button confirm the points created

3.2.3 Creating a program with the help of AEP

• Select Program from the menu

list
• Click Add, select Automatic
Erosion Programming step.

• Select the Process Data page

• Enter the Erosion Vector with
Z = –5.00 (mm)
• elect the Application page
• Enter the Frontal Area of the
electrode= 1.5 cm 2

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• Select the Orbit Data page

• Select planetary mode 2D Vector
• Enter Start Angle = 45°
• Enter Number of Vectors = 4

• Select the Impulses page

• Material = Copper – Steel
• VDI Finish = 21
• Actual Undersize
▼ = 0.700 mm
▼▼ = 0.500 mm
• Enter the number of electrodes

• Select the Erosion Points page

• Select all workpoints
• If required, select the machining
sequence Finish each
workpiece sequentially.

• The AEP is stored with OK and the

EDM program automatically
created

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3.2.4Definition of the workpiece reference

• Store the workpiece reference.

If it is not known, determine the
Reference by means of the
measuring cycles.

3.3 Start erosion

Set the first line to start, then click Cycle start to startup the erosion. The electrode can
move to the first workpoint and exchange the correspond electrode automatically, as
long as having no collision in the moving path.

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