EDM Today EDM FORUM
Date: 11/18/08
Subject: Burning Dowel Holes
Question:
Currently we burn our dowel holes .0005 undersize and lap them after burning. We have found on larger die sections this method reduces the chance of a hole being too large and scraping the entire die section. Have you seen or heard of this practice from other companies?
Thanks,
Bob
To reply to Bob, use the Subject:
Burning Dowel Holes
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Date: 10/20/08
Subject: Copper or Graphite Electrode
Question:
Good day to all,
I have a requirement to sink a cavity into copper.
Can this be done using a copper electrode, or should I use graphite for this?
Are there any special considerations when sparking into copper?
Your comments and answers will be most appreciated.
Theo Marnewick
To reply to Theo Marnewick, use the Subject:
Copper or Graphite Electrode
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Date: 10/20/08
Subject: Manual / Charmilles Form 220 NC
Question:
One of our customers in India purchased a used Charmilles — make Form 220 NC machine from Europe. Unfortunately, the machine was supplied without Operator and Electrical manuals.
The customer is very badly in need of this manual. Can anyone help to get a copy of the manual?
Thanking you.
Best Regards,
S.N.Mallanna
To reply to S.N. Mallanna, use the Subject:
Manual / Charmilles Form 220 NC
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Date: 10/7/08
Subject: Bearing Replacement Tips
Question:
Does anyone have any experience or tips for replacing a bearing in my grundig motor on my Charmilles Robofil 230F.
Thanks
Timothy
To reply to Timothy, use the Subject:
Bearing Replacement Tips
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Date: 10/7/08
Subject: Wire Capacitance and Polarity
Question:
Does anyone happen to know how to calculate a wires capacitance and polarity?
Thanks,
Jason
To reply to Jason, use the Subject:
Wire Capacitance and Polarity
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Date: 10/7/08
Subject: Challenges in EDM
Question:
I recently found EDM Today Magazine online. I think your articles are very informative and easy to read.
As a student of master of technology, I have a project on EDM, so I am intrested in doing some innovative work in this field.
I would be greatful if anyone could provide information regarding challenges in the EDM process.
Thank you,
M.B.W.
To reply to M.B.W.,
use the Subject:
Challenges in EDM
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Date: 9/8/08
Subject: Dielectric Disposal
Question:
Has anyone ever burned the fluid in a waste oil burner…I ran some through a small oil burner detached from the unit…and it burned very clean, does anyone know if this acceptable or has anyone disposed of the fluid in this manner.
Thank You,
Craig
To reply to Craig, use the Subject:
Dielectric Disposal
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Date: 9/8/08
Subject: Code Transfer
Question:
I need help regarding Agie CNC 100/3 code and transfer from PC to wire EDM.
Thanks,
Nikolay
To reply to Nikolay, use the Subject:
Code Transfer
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Date: 7/14/08
Subject: AGIECUT 50
Question:
Hi,
I am currently using an AGIECUT 50. We bought it second hand, years ago, and we have only learned enough of the machine to get us by. We are starting to look at making dies and punches and need to learn a lot more of the machine. We are using 0.2mm brass wire on 8-20mm thick tool steels. If anyone is familiar with this machine or generation of machine, early 80's, I would be most grateful for your help.
• I am interested in things like the program code (syntax), the machine uses a code called CNC100/3 but I have yet to find any specifics
• The effects of changing each setting and what it is responsible for doing, power, current, % of idle pulses, etc
Thanks for your help,
Andrew
Andrew Sidey
Student Mechanical Engineer
Alcoa Fastening Systems
Clayton Business Park
1508 Centre Rd Clayton 3168 Australia
To reply to Andrew, use the Subject:
AGIECUT 50
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Date: 7/11/08
Subject: Surfcam post for Charmilles 310
Question:
Hello:
We recently added a ’97 Charmilles 310 WEDM to our shop. The difficulty I’m having is to get a post that will work with Surfcam. The tech from my software vendor is trying his best, but surely there has to be someone who has gone through this before. Generating the toolpath radiuses using I & J values seem to be the major sticking point. We haven’t even ventured into automatic threading or tapered cutting which will have it’s own issues.
It also seems that Surfcam does not share posts from techs nor does it have a sponsored site to post and get answers to questions. In my opinion, Surfcam works great for 2&3d milling but still needs some work on the WEDM side.
Thanks for your time and I look forward to your reply.
Roland Hermann
To reply to Roland, use the Subject:
Surfcam post for Charmilles 310
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Date: 7/11/08
Subject: Cutting conditions and electrode material for cutting zinc
Question:
Sirs:
I have a zinc workpiece and am unfamiliar with cutting conditions and the best electrode material to use for this job.
We have Sodick ram machines, Mark 11 and Mark 21.
Ideally, a chart showing settings, spark gap and wear would be the best solution.
I am thinking aluminum and magnesium would have similar conditions.
Any suggestions would be very much appreciated.
Wm Short
FisherCast Global
To reply to William, use the Subject:
Cutting conditions and electrode material for cutting zinc
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Date: 7/11/08
Subject: Copper Impregnated Graphite Application
Question: I have a Charmilles Roboform 350, and I would like to try using copper impregnated graphite electrodes, what technology do I use on the machine? Do I tell the machine the electrode material is copper or graphite?
Thanks,
Tyler Royce
To reply to Tyler, use the Subject:
Copper Impregnated Graphite Application
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Date: 6/26/08
Subject: EDM Sinker Workload
Question:
I don't know if you can help me with this situation or if you know someone that can. I work for a plastic injection mold shop dealing with mostly automotive. Over the last few years, our EDM (Sinker) workload has dropped off tremendously. Due to the fact that our CNC machines are capable of cutting more fine detail than ever before. I would like to find some kind of work that we can utilize our machines and make some profit and not worry about losing the work to CNC machines. I don't know if there are any metals out there that can be EDM'd and not machined due to there hardness?...Etc...
If anyone has any ideas, please let me know.
Thank you,
Scott
Electrode Department
To reply to Scott, use the Subject:
EDM Sinker Workload
Answer: Scott,
Your plight is shared by a number of sinker houses. Two areas to be considered are medical and aerospace.
Both utilize metals that are very difficult to machine:
• Titanium
• Inconel
• Waspalloy
• Hastaloy
• Stellite
For example, Sinker EDM is the only method for putting in the driving slots in bone screws and Sinker EDM is used for putting in the seal slots in gas turbine blades. For these applications, copper graphite is often the electrode material of choice.
Good luck in your search for new sinker applications.
Roger Kern
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Date: 6/16/08
Subject: Wire EDMing Graphite
Question:
I would appreciate reading your thoughts on wire EDMing graphite. I’ve had my share of problems doing it.
Thank you,
Bert
To reply to Bert, use the Subject:
Wire EDMing Graphite
Answer:
Bert,
While the Wire EDMing of graphite can pose some challenges, it is readily accomplished by many EDM'ers on a daily basis.
The key to successful Wire EDM'ing of graphite is in the selection of the correct graphite grade.
The most common problem encountered when Wire EDM'ing graphite is that of pitting of the graphite surface and blowing off the external sharp corners. This problem occurs due to the relatively weak bond between the graphite grains in the less expensive materials. It has been my experience that these problems generally disappear when fine grain, high quality, graphite grades are utilized, since these grades are characterized by significantly enhanced structural integrity (small grain size and low porosity) leading to enhanced transverse rupture strength. Specifically, I recommend the following grades (or their equivalents) for Wire EDM:
Fine Grain Graphites (most cost-effective solution for general purpose work):
Poco EDM-3
Toyo Tanso TTK-4
Copper Impregnated Fine Grain Graphite (Recommended for Carbide and Aerospace materials or where delicate sections benefit from the added strength resulting from the impregnated Copper):
Poco EDM-C3
Sub Micron Grain Graphite (Ultimate for fine detail, but most costly)
Poco AF5
I have also found that coated wires produce superior results in cutting graphite.
Finally, be sure to consult with your machine manufacturer for the most appropriate cutting technology and cutting strategies for graphite.
When the correct graphite grade, wire type, and cutting technology are combined, productive Wire EDM'ing of high quality graphite electrodes is readily accomplished.
Roger Kern
Answer:
Hi Bert,
Roger did a great job of covering all of the pertinent points of wirecutting graphite… follow his lead. Meanwhile, I'd like to elaborate on his point: “I have also found that coated wires produce superior results in cutting graphite.”
One of the best-kept secrets in EDM is using CobraCut-B wire against graphite. CCB has a zinc oxide coating over a copper core instead of brass. The zinc oxide coating is "rough and porous" compared to pure zinc and will cut faster and flush better with fewer wirebreaks. The copper core has higher conductivity than brass which is needed to wirecut graphite successfully.
Note that CCB's tensile strength is only 600 n/mm2 (hard brass is 900 n/mm2), reducing threading reliability and possible increased difficulty in skim cutting. Despite these two issues, CCB is my choice against graphite.
Regards,
Bud Guitrau
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Date: 6/16/08
Subject: EDM Wire Cleanliness Testing
Question:
Hello Roger;
I recently found EDM Today Magazine online. I was going through your Table Manners article, and noticed a procedure that you perform. What is EDM wire cleanliness testing and what are you looking for when your testing the wire?
By the way, your articles are very informative and easy to read.
Thank You,
Spencer
To reply to Spencer., use the Subject:
EDM Wire Cleanliness Testing
Answer: Spencer,
Cleanliness testing is performed on EDM wire to determine the amount of contaminant (which can consist of powder, flakes, drawing lubricant, and paraffin) remaining on the surface of the wire after the manufacturing process. "Dirty" wire can have serious ramifications with regards to the reliability and maintenance of the Wire EDM guide and threading systems.
While there are no internationally recognized standards for wire cleanliness, GEDMS has developed two systems for the evaluation of the cleanliness of the wire we purchase from our suppliers.
The first method is a quantitative test developed by Dr. Dan Tomalin, a metallurgist. This test accurately measures the amount of contaminant deposited on a pair of standardized cleaning pads after 1,000m of wire is passed through them under controlled conditions. The result is measured in mg/1000m.
The second method is a qualitative method I have developed in which 1,000m of wire is passed through an actual guide system on a Wire EDM (upper and lower cartridges containing pre-guide, power feed, and diamond guide). In this method, each of (7) guide system components is "rated" for contamination and entered into a spreadsheet which determines a "cleanliness score" for the wire under test.
We are still researching the correlation between the two methods.
Please refer to the two PDF documents below.
Cleanliness Test Status
Wire Inspection Procedures
Best regards,
Roger Kern
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Date: 6/16//08
Subject: Wire Selection & Guide Alignments
Question:
I get a lot of good information from your articles in EDM Today, and especially enjoyed the March/April edition on Wire Selection.
The timing of that article was perfect for me because, at the time, I was experimenting with one of the newer wires. I might add, your opinion on the high quality,hard, plain brass wire for ultra precision work makes a lot of sense. I've always used CCA on our Agie, and Stratified on our Charmilles, and have had good results.
I was wondering, if you have already, or plan to do any articles related to guides — styles, maintenance, performance , the importance of guide alignments, and maybe some suggestions and methods to double check that you are perpendicular to the table, etc.
Thanks,
Jim S.
To reply to Jim S., use the Subject:
Wire Selection & Guide Alignments
Answer:
Jim,
The subject of guide alignments is an interesting one. It is especially critical to assure that the wire cut surface is square to the work piece top & bottom on punch holders, since while the punch holder may only be 1" thick, the punch itself may be 2-1/2" long and any out-of-square positioning error is multiplied by the ratio of punch length to holder block thickness.
The first step in squaring the wire is, of course, to use the machine manufacturer's standard solution. Usually this consists of a "squaring block" which presents two insulated contacts to the wire that are square to it's base. A variant is picking up a hole in a blade fixture and comparing the result at two different Z heights. This squaring solution, while adequate for 90% of wire work, is limited due to a number a factors:
• How square are the contacts to the base of the fixture?
• How parallel to the machine datum is the surface that the fixture is sitting on?
• Is the clamping that's holding the fixture to the machine influencing it's squareness?
• Are the contact's etched from previous pickups with wet wire?
• Is the wire wet or dry?
• How accurate is the machine's pick-up system?
If tenth's really count, a better solution is to square the wire to an edge of the block you plan to cut that has been accurately ground square. For this method, I use a magnetized, half round, 1/8 diameter piece of HSS Drill blank. I use a drill blank because picking up the over a roll is more accurate than picking up a flat surface. I pick up the drill blank at the bottom edge of the block and at the top edge of the block and manipulate the respective U-V axes until both pickups occur at the same position. The accuracy of this method is limited only by the accuracy of the EDM pickup system which may or may not be affected by whether the wire is wet or dry. To address this problem, I developed a patented pickup system that repeated to .00001" and was accurate to .00005". This pickup system is no longer in production.
The only other issue, and this is not inconsequential, is whether the wire will burn square once it has been squared in the pickup mode. This is not assured, since there is 5 microns of guide clearance as well as minute cutting and flushing forces which can slightly deflect the wire, even in skims.
Thus, the only final assurance that the wire will burn square, is to actually skim the edge of the workpiece and check it off the machine for squareness, manually offsetting U&V until the desired degree of squareness is obtained. This process is quite tedious and subject to errors induced by how repeatably the block is returned to the machine after each removal for measurement.
An alternative method, is to skim a hollow dowel set in a jig ground hole in the work piece block. The parallelism of the hole to the dowel OD in two axes can then be checked on a surface plate and the U&V adjusted accordingly. This is probably the most accurate and repeatable method for assuring perfectly square wire burns, since the block does not have to be removed from the machine. This method can also be used to assure that the positional pickup is absolutely correct.
Admittedly, these are all tedious processes but are occasionally justified by the requirements of a demanding job.
Best regards,
Roger Kern
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Date: 5/1/08
Subject: New EDM Room
Question:
I am an EDM technician. We are in the process of moving our entire Toolroom to a new building that will begin construction soon.
The plan was to combine the grinding, mill, and wire EDM in one 2500 SQ ft room. I explained that this was a bad idea,
and that it was not normally done this way. So I was asked to acquire documentation to support my position.
Presently, the Wire Room is separate from the Toolroom, with its own
heating and cooling and water supply. The new owners are unfamiliar with
the needs of a Wire Dept., and feel that what we have set up now might be
unnecessary. Can you help? I have an opportunity to set up something
great — I just need documentation to support it.
We are a Fine metal Stamping facility our normal tolerance is +/- .0002.
If you need any more Info about us feel free to ask.
Could you provide me with any Information in regards to a properly set
up tool room with 3 wire EDM's?
Thanks,
Jay
To reply to Jay, use the Subject:
New EDM Room
Answer:
Jay,
Sorry for the delay in my reply.
I fully agree that the EDM room should be a separate environment from other machining operations in the shop for the following reasons:
• Temperature control — The tight tolerances required of the Wire EDM operation require temperatures to be held to 68° +/- 2°, which is probably tighter than necessary for the other operations. Also, the dust collection systems required for the grinders will often upset the delicate balance in a temperature controlled room due to the air flow they take out of the room.
• Noise control — Often, being able to monitor the sound of the sparking is important to "keeping a close eye" on the wire machines, especially during skims. The noise generated by adjacent machining and grinding operations will interfere with this process. Also, the degree of mental concentration required to plan jobs and set up wire machines requires a non-distracting, quiet environment.
• Cleanliness — Metal chips, grinding dust, and coolant smoke are often by-products of most machining and grinding operations. They have no place in a high precision wire room. For high precision work, cleanliness is very important.
Most successful high precision wire rooms are set up as laboratory type environments, not only because of the wire machines, but also because measurement activities often take place there. Usually, the wire EDM process is one of the final steps in producing a tool.
Your management has a great opportunity to "do it right" with your new facility. A few extra dollars spent now will pay quality and productivity dividends for many years to come.
Roger Kern
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Date: 5/9/08
Subject: Sinker EDM Purchase
Question:
I would like to know which kind/type of Sinker EDM to purchase for 40 K or less.
Does anyone have any ideas? It must have at least Z programmable.
Dave R.
To reply to Dave R., use the Subject:
Sinker EDM Purchase
Answer: Dear Dave R.,
Please send an email to jeffm@mcwilliamsedm.com and he can help you with some suggestions.
Brett McWilliams
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Date: 3/7/08
Subject: Hitachi WEDM Tech Support
Question:
Is there anyone giving tech support for the older Hitachi WEDMs. I have lost my phone numbers and we have a machine down. If anyone could point me in the right direction It sure would be appreciated.
Robert B.
To reply to Robert B., use the Subject:
Hitachi WEDM Tech Support
Answer:
Robert, I`m from Germany and an owner of 10 Hitachi WEDM Q-series.
Send me Your special questions by email hschiedung@sparctec.de.
Regards!
Harry
Answer:
Hi my name is Jim Brannick, and I worked for Hitachi for 16 years. I now work for Agie Charmilles I might be able to help you. You can call me at 815 347 0833.
Jim
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Date: 2/5/08
Subject: Genspark Manual
Question: Hi:
5 years ago we received a GENSPARK Model 36P, in my university in Mexico (Instituto Tecnologico de Zacatecas www.itz.edu.mx). We tried to find the instruction manual, however, it was stolen. Therefore, the machine has been never used. We would like to know if anyone has this manual or if could give us information about where we can find it. Perhaps someone may have some electronic information about how to use this or a similar machine .
Can anyone tell me where I can find the manual for the 36P Model of GENSPARK?
Thank you,
Jose Alonzo
To reply to Jose Alonzo, use the Subject:
Genspark Manual
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Date: 1/30/08
Subject: Genspark Arc protection settings
Question: Is Genspark out of business? I tried calling the number and got a number not in service message.
I have a Genspark ZNC sinker and need help figuring out the Arc protection settings.
Thanks,
JP
To reply to JP, use the Subject:
Genspark Arc protection settings
Answer: I am sorry; I was unable to find any resource for Genspark.
There is a website, www.gensparkamerica.com but the link is dead. I found the following e-mail addresses and/or contact info:
Debbie Bascom
EDM Supermarket
Riverside, CA
909-786-4140
genspark.america@worldnet.att.net
EDM Supermarket, Inc.
334 Oak St.
San Bernardino, CA, USA 92401
800-783-0923
909-889-8820
FAX: 909-889-8826
Contact: Deborah Bascom
Genspark America EDM
3443 Durahart Street
Riverside, CA 92507
909-786-4140
909-786-4144
I don’t know if any of the info is valid, but it is all I could find.
Best Regards,
EDMUND
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Date: 1/11/08
Subject: What factors determine the amount of material removed?
Question: I am looking to build a relaxation circuit for the generator of an EDM.
What factors determine the amount of material removed each time the spark fires? I assume that there must be a relationship between the amount of energy in each discharge and the amount of material removed.
If so, what is it?
Regards,
Mark
To reply to Scott, use the Subject:
Surface Finish
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Date: 11/27/07
Subject: Surface Finish
Question: I am trying to find a good comparison for a 12 RMS surface finish with a Charmilles VDI or Ra guide.
We have a mold that is called to have this finish and find that it will not release the molded parts.
Please let me know where I can find a definitive resource for this finish.
Thanks for your help!
Scott L. Peters
To reply to Scott, use the Subject:
Surface Finish
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——————————————————————————— EDM Forum——————————
Date: 11/20/07
Subject: Agie repairman
Question: I am looking for any former agie repairman around the Pittsburgh area in PA.
Thanks,
Mike Y.
To reply to Mike Y., use the Subject:
Agie repairman
Answer: Mike,
I worked on AGIE's in the area years back. What are you looking for ?
Larry McNamee 630-248-7068.
Larry McNamee
EDM Network, Inc
1974 Bucktail Lane
Sugar Grove, IL 60554
P:630-466-5588
C:630-248-7068
F:630-466-5599
larry@edmnetwork.com
Answer: Mike,
The only AGIE repairman that I know is Scott Panzek. He works for AGIE and is right in Pittsburgh. He is an outstanding service tech, with tons of knowledge on old machines, and new machines. AGIE’s phone number is 1-800-438-5021.
Good luck, and hope this helped.
Tony
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Date: 11/14/07
Subject: Selling Used Hitachi EDM 355R
Question: What would be the best way to sell a used (3000 hours max) EDM machine. Where would be the best place to list it for sale?
Thanks,
Stan Kroll
To reply to Stan, use the Subject:
Selling Used Hitachi EDM 355R
Answer: I have sold several pieces of equipment over the past few
years that for one reason or another needed to go. Each of them was
not that old or used that much. In each case, I actually received
help from the manufacturer of the equipment or from the dealer who
sold it to me. Of course, you have to remember that you will likely
not receive anywhere near what you paid for your machine. But if the
machine is not right for your business, then that shouldn't really
enter into the formula.
As always, if you want someone to do "work" for you you have to allow
them to make some money as well. Another option, to at least get
exposure, would be to list your machine up on ebay. Just some of my
thoughts and some of the things I have done in the past.
Best Regards,
Bill
Answer: Stan,
I don't think there's any "right" way or easy way to sell a machine. I have sold 3 different pieces of EDM equipment for
different reasons over the last 5 years. In most cases I had received from help from the manufacture or the place that sold the
equipment. This can be the best way. Of course, I'm assuming the machine is relatively new and still a "current" model being sold.
This approach depends on your relationship with the dealer or manufacture. If it's good and you have a good reason to sell it they
may be willing to help you.
Of course, you can talk to the different used EDM machine dealers and they will try and sell it for you as well. At the end of
the day, you want your machine in front of as many people as possible. The next question is how much do you want for it and
unfortunately I have not been as lucky to get a "lot" of money for a machine even if it was only a year or so old. So if you paid $100K
for your machine you will not likely receive $80K for it used, even if it only has 3000 hours on it. At least that's my opinion. Also
remember if you want to receive help in selling a machine you have to allow the people to make some money on the deal. I have not had
any luck selling a machine on my own. You could look at putting it up on Ebay. You will likely get a lot of people looking at it and
you never know what might happen.
Bill
EDM Express
Buffalo, NY
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Date: 10/21/07
Subject: Wire EDM newbies
Question: Hello all, I am pretty new to EDM,and I was hoping to find some suggestions on purchasing any literature
on the subject that would help me learn more. The company I work for is pretty good overall but to make a long story short,
I was hired to work in their Fourslide dept, and since I had worked at virtually each end of the machine at one point or another
in my "career" they asked me to keep an eye on overnight and weekend burns since I work 3rd shift. If a machine stopped due to a broken wire, reverse error, or something similar and hopefully simple, I could "reset" and "restart" and hopefully a nice long weekend burn could finish prior to monday morning.
Now, to try and keep it short, they asked me to try and learn what I could about the machine. After going through the manuals and asking many questions, I am pretty much able to setup, program, and run the 3 machines we have at our company.
I was even able to program and cut a few 4-axis models. Now, I am given a few jobs here and there, and they even sent me to the
GlobalEDM conference in New Britain, and it was GREAT btw. However, I want to take in anything and everything
EDM related. Although both our machines are FANUC wire models and the company just bought a 3rd,
I am interested in all the aspects of EDM. Any thoughts, ideas, and comments welcome...
--Wesley
To reply to Wesley, use the Subject:
Wire EDM newbies
Answer: EDM Publications sells many good books on their website. Look for Books & Products on the home page at www.EDMtodayMagazine.com
Best Regards,
EDMund
Date: 11/14/07
Subject: Wire EDM newbies
Answer: Thanks for the reply EDMund, I have the Sept/Oct. 2007 issue in front of me right now and they list 3 that look good right off the bat. The EDM Handbook, Complete EDM Handbook, and EDM (a book written for everyone in the industry).
Now, they look like decent books, but I was wondering if anyone has had any experience with any of these...? I am going to be buying 1 or more of these on my own and right now I'd hate to blow several hundred without checking into them first. Thoughts...?
Thanks,
--Wesley
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Date: 9/27/07
Subject: water ph level
Question: Does anyone know how to safely raise my ph level in my Agie 250HSS tank?
I have tried ph plus, but it killed my resin tanks. Any help would be great.
Thanks,
Chris Masi
To reply to Chris, use the Subject:
water ph level
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Date: 8/22/07
Subject: Power Feed Cables
Question: Does anyone know the source to buy power feed cables for my Hitachi CNC Wire EDM?
Thanks and Regards,
Harish
To reply to Harish, use the Subject:
Power Feed Cables
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Date: 8/13/07
Subject: Using Small Hole TC Electrodes
Question: Does anyone have any experience using tungsten carbide tubes with Small Hole EDM? We are looking to try some on cast stainless using DI water — and, we have no idea where to start as far as parameters. All of our experience is with brass and copper tubes.
Thanks,
Woody
To reply to Woody, use the Subject:
Using Small Hole TC Electrodes
Answer: Woody, you should ask the manufacturer of the machine you are using. If I give you the setting for our machine, it won't mean anything, as each power supply has different settings.
Greg Langenhourst
MC MACHINERY
Date: 9/27/07
Subject: Using Small Hole TC Electrodes
Answer: Thanks Greg ... and, yes, I realize that parameters are specific to machine manufacturers, and sometimes even on machines of the same model. I was looking more for general guidelines ... short vs. long on/off times, high/low amperage, capacitance, etc. Neither the machine builder nor the electrode manufacturer has been much help.
Thanks,
Woody
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Date: 7/27/07
Subject: Genspark America EDM
Question: I am looking for a instruction/operation manual for a Genspark America model CY-H32A High Speed EDM Hole Driller.
Can anyone help?
Thanks,
Steven
To reply to Steven, use the Subject:
Genspark America EDM
Answer: I have an instruction/operation manual that I could copy and send to you if you haven't found one.
Harlan
hjohnson@commandtool.com
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Date: 7/25/07
Subject: Joemars EDM Machines
Question: Did you find someone to service Jomars EDM's? If you did please send us their contact information.
Thanks for your help!
Jerry
To reply to Jerry, use the Subject:
Joemars EDM Machines
Answer: I’m afraid that in this case all I can offer is my condolences on this purchase. There is a Joemars company website in Taiwan, but it does not give any USA referrals. In the event you don't have the web address, it is:
www.joemars.com.tw
Best Regards,
EDMund
Answer: I just found someone to do service for Jomars EDM's.
Thanks for your help!
Jerry
Answer: I found an end user that has a Jomars EDM on the internet. I called him, he said, Fortune International Inc. in Somerset, NJ was the importer for Jomars. I contacted them and a guy by the name of Jack Wang called me back to say they do service.
The phone number for Fortune International is: 732-214-0700
The website: www.fortune-cnc.com
Thanks!
Jerry
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Date: 6/19/07
Subject: Mitsubishi Sinker 727 Alarm
Question: Hi, I have a Mitsubishi M25K and it has a 727 “over run” alarm. Can anyone tell me what this is and/or how to correct it?
Thanks,
Jeff
To reply to Jeff, use the Subject:
Mitsubishi Sinker 727 Alarm
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Date: 6/5/07
Subject: Tooling for Holding Multiple Round Parts
Question: Our company makes a lot of components that are round. Just about all the wiring I do is round taper holes. These are very tight tolerance holes. I was wondering if anyone can help me get tooling that meets our requirements below.
1) We are in need of Wire EDM tooling that can hold multiple parts of .3937 dia. x .500 tall.
2) It has to be able to hold a minimum of 12 pieces at a time.
3) Locations of the fixture must repeat within .0001
4) T.I.R. of the I.D. in each part must repeat within .0003
We are in need of 2 fixtures. One will be used in the machine and the 2nd will be used for setting up outside of the machine. I am thinking of something that can be used with 3R Tooling, Erowa or anything else that will work. Currently I have to wire my own fixture. I've been looking and having a hard time finding any tooling that will meet our needs.
Any suggestions would be greatly appreciated.
Thanks,
Scott
To reply to Scott, use the Subject:
Tooling for Holding Multiple Round Parts
Answer: Although we do not show a specific fixture in our standard catalog we do and have made many different types of fixtures. We would be able to meet your needs by designing something similar to the attached drawings. Any fixture we would design can be easily exchanged from set-up to the machine using our standard pallet system that guarantees .00008” repetitive accuracy from set-up to machine.
Click on the icons below to see enlarged drawings.
Feel free to E-mail or call me at: pknowles@hirschmannusa.com or call 847-468-9700 to further discuss your needs.
Regards,
Peter Knowles, President
Hirschmann Engineering USA, Inc.
Hirschmann Automation LLC
Answer: We often encounter situations such as this, where a multiple part fixture is required that must retain tight tolerances.
We generally offer no off the shelf solutions, as each requirement is very different relative to size, shape and quantity of parts to be cut. Therefore, we usually offer to build these fixtures per the customer’s specification. The attached photos show generic solutions that are designed for a range of sizes. However, these types of fixtures are rarely sold.
Nests that are more specifically sized with a pinch-style clamp are better suited to secure the parts as compared to the set screws shown in the photos. However, the clamping should be very minimal since movement of material or undue force will move the parts off location and/or distort the entire fixture. A wrench with a preset torque limit should also be considered to eliminate human intervention.
The .0001” repetition accuracy of the fixture can be easily maintained using a suitable pallet/chuck combination. However, it can be very difficult to construct a single fixture to hold (in this case) twelve individual parts and retain the necessary TIR location of the parts. This is due to the accuracy inherent in the WEDM, thermal issues and other cumulative errors that stack up along the way.
We have had much better success using smaller more bite-sized fixtures set up on multiple chucks in the machine. In this way, a subset of, for example four parts can be loaded on each of three locations in the machine with a fourth fixture loaded and ready to go. Parts are more immediately available as each set is finished and if something happens to a fixture, there are still two or three remaining intact.
The fixture should be solidly mounted to a pallet and set in the WEDM for the machining of the final details that will ultimately locate the workpieces. Each fixture should be identified with a unique marking and each nest should be numbered so that if any slight programming adjustments are necessary to “dial in” a particular nest location, the programmer will be able to identify the fixture and/or nest that has a unique “personality”.
The Chuck(s) used to hold the fixtures in the machine should be aligned and located using a Master Tool. Since you cannot tram the center of something that is mounted to the table of a WEDM, this tool will allow you to find the theoretical center of the Chuck(s) relative to the Wire. Knowing this data and having wired the final details into the fixture relative to this location, the electronic position of the program can be related to the physical position of the parts in the fixture. These values can also be routinely checked and qualified.
Housekeeping and maintenance of the entire machine is critical in order to keep the environment precision-friendly. Control over ambient temperature is also essential. Remember to consider the temperature that the chiller is set to, relative to the shop air temperature. If you are working on a summer day in an 80-85 degree environment and you plunge your fixture into 70 degree water, parts will move.
I hope these random thoughts are of value to you. If you would like to get a more thorough dissertation, please feel free to call me.
Best 3Regards,
Jack Sebzda Jr.
Northeast/Mid-Atlantic Regional Manager
System 3R USA Incorporated
55 Fox Hill Road
Lafayette, NJ 07848
Phone: 201-214-7088
Fax: 847-439-4888
www.system3r.com
Answer: My name is Mike Stevens. I am the Manager of Applications with EROWA Technology at our North American Headquarters in Arlington Heights, IL.
After reviewing your project requirements I am confident we can provide you with a solution. All of EROWA’s WEDM work holding systems offer better then .000080” repeatability. These standard products would be the interface between the machine table and fixture that will hold your parts.
As for the actual clamping fixture that will be specific to your work pieces, I believe a custom solution would be most efficient, most cost effective and provide the highest degree of accuracy. EROWA is unique in the fact that we offer full engineering, design and production of such fixtures in-house. We need not involve a third party for custom solutions.
I am eager to start working with you on this project. Please contact me directly to discuss which standard product will best fit your needs. We can then review options for the custom workholding fixture.
Thank you for your interest in EROWA. We look forward to providing you with the quality and customer service that has made EROWA the worldwide leader in workholding solutions.
Mike Stevens
Manager Applications & Technical Support
EROWA Technology, Inc.
2535 South Clearbrook Drive
Arlington Heights, IL 60005
Office: (847) 290-0295
Fax: (847) 290-0298
Cell: (847) 922-5737
Answer: Thanks everyone for your responses to our problem.
Thank you EDM Today for publishing our topic in the magazine. It surprised everyone in our company to see our topic in the magazine.
All the suggestions were excellent. We had already pursued something very similar to the suggestions from the magazine.
Sincerely,
Scott
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Date: 6/5/07
Subject: EDM Services in New Jersey
Question: Is there anyone in the northern New Jersey area that does RAM EDM as their only business? Many of the tooling shops do it as part of their business, but I have not found anyone who does it as their ONLY business.
Thanks,
Ed
To reply to Ed, use the Subject:
EDM Services in New Jersey
Answer: Ed, I can think of three choices in northern NJ for you. Each one has been in the EDM business for a long time. Though Sinker EDM is not the only process they offer, the process is a key component in their overall service. Any one will be a good choice:
New Jersey Precision
Mountainside, NJ
Bob Tarantino
800-409-3000
Olympic EDM-Waterjet
Butler, NJ
Don Ferrante
973-492-0664
HP Performance
Ringwood, NJ
Frank Patricola
973-962-0800
Best Regards,
EDMund
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Date: 5/25/07
Subject: McWilliams 3E Data Cassette Recorder
Question: I'm trying to keep alive my Japax LS500A's. I'd like to know if anyone has a 3E recorder gathering dust somewhere that we could buy?
Thanks,
Dominic
To reply to Dominic, use the Subject:
McWilliams 3E Data Cassette Recorder
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Date: 5/22/07
Subject: Ultra Sonic Cleaner
Question: I currently operate a WEDM and need some help with purchasing an Ultra Sonic Cleaner for maintenance of the upper and lower heads. I do not have any idea what type of solution that I would need to fill the Ultra Sonic Cleaner. It would be very nice if someone would walk me thru each step of the ultra sonic cleaner process because I am not familiar with it. Below I have several things in general that I am looking for answers to my questions.
1. Make and model of ultra Sonic cleaner.
2. Type of solution recommended in the industry.
3. The correct mixture of solution if any at all.
4. The amount of time for cleaning of brass parts.
5. The amount of time for cleaning diamond guides.
6. Should I use this process to clean ceramic parts?
Any help would be greatly appreciated.
Respectfully,
Larry
To reply to Larry, use the Subject:
Ultra Sonic Cleaner
Answer: We bought a ultrasonic cleaner from McMaster carr ( they have locations everywhere, I think) We also bought the cleaning fluid from them, which mixes with water. The only parts it seems a little hard on are rubber. I've left guides to our Agie in it overnight without a problem.
Thanks,
Gregg Verstraten
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Date: 5/22/07
Subject: Machining Speed Classification
Question: I am looking for information regarding the classification of range of machining speed (material removal rate), into very high, high, medium, low, etc. for both EDM and Wire-EDM.
Thanks,
Ramesh
To reply to Ramesh, use the Subject:
Machining Speed Classification
————————————---------------------------------------------------------------------------------------------— EDM Forum———————————————
Date: 5/22/07
Subject: Moving Tables/Columns
Question: What is the difference between a machine with moving tables and one with moving columns?
What type of machine is suitable for good accuracy?
Thank you,
Yogeshdorwat
To reply to Yogeshdorwat, use the Subject:
Moving Tables/Columns
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Date: 5/22/07
Subject: Wire Feed Speed Effect
Question: Can anybody explain to me about the effect of wire feed speed on material removal rate during machining and surface finish?
Thank you,
V Suresh
To reply to V Suresh, use the Subject:
Wire Feed Speed Effect
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Date: 5/2/07
Subject: Training - Mastercam/CNC
Question: Love your magazine, but maybe you could give me some help. I was just laid off, and have many years in the moldmaking trade, especially EDM. The problem I am coming up against is I need some training in Mastercam/CNC. I have run some CNC but I need to know where I can go for some training so I can get another job. The employers only want someone who has time on the machine or can hit the ground running with the latest software.
Thank you,
William
To reply to William, use the Subject:
Training - Mastercam/CNC
Answer: Our sales guy contacted Cimquest and they are offering their training at 50% off for those that have been laid off. They are doing this now. It is just a matter of when they might be having classes on Wire, but you could take classes on almost anything.
I encourage you to contact your state and see if you can get reimbursement for this training. I think most, if not all states offer this.
The information for Cimquest is below. They are really good people. They also sell and support Solidworks, which might also be a good thing for you to get experience with.
Thanks,
Rose
Rob Hassold
Cimquest Inc. | 1545 Route 206 South| 2nd Floor | Bedminster | NJ | 07921 |
Phone: 732-699-0400 x220 | Fax: 732-699-0404 | www.cimquest-inc.com
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—————----------------------------------------------------------------------------------------------— EDM Forum———————————————
Date: 4/5/07
Subject: 954 Bronze
Question: Can anybody recommend wire burn parameters for this material? Would copper be a close start point?
Thank you,
Omteco
To reply to Omteco, use the Subject:
954 Bronze
————————————-----------— ————————————-------------------------------------EDM Forum———————————————
Date: 3/30/07
Subject: Filter Disposal
Question: I would like to know what the common practice is for filter disposal from the wire machines. Who takes them, and how much does it cost? We are in PA. Thank you in advance.
Tom
To reply to Tom, use the Subject:
Filter Disposal
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Date: 3/23/07
Subject: Photo Etching Definition
Question: I'm looking for information / definition of the grain done by photo-etching. Ideally, I need a sample to choose the grain correctly. Also, I'm interested to understand how is it done.
Thank you for your cooperation,
Denis
To reply to Denis, use the Subject:
Photo Etching Definition
Answer: I’ve used a photo-etching vendor in Youngstown, Ohio, called Mold-Tech. They photo etched prescribed textures on an embossing roll, used in our extrusion process.
There is (I have) a Visual Texture Standards book from them that has samples of their grains. They’re identified as MT-XXXXX. Each “plate” within the book shows the grain, as well as the measured depth of the grain.
Mold-Tech is a Standex company, a division of Roehlen Industries. Their Ohio phone number is
330-792-7677. If this helps with your question, call them, or visit their website, or
E-mail: ohio@mold-tech.com
Good Luck,
Bill
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Date: 3/14/07
Subject: Joemars EDM Machines
Question: I am looking for a company that can service Joemars EDM equipment. Can anyone help?
Thanks,
Larry
To reply to Larry, use the Subject:
Joemars EDM Machines
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Date: 2/23/07
Subject: Various Dielectric Oils
Question: I think there are many people new to the EDM Industry that may have some of the same questions. Can you help clarify some of these questions?
- What are the various kinds of dielectric oils available?
- What are the sources of the insulated electric cabling that is compatible with the dielectric oils?
- What are the sources for sealable electric connectors also compatible with the dielectric oils?
I hope someone can help us with these questions.
Thanks,
Clair
To reply to Clair, use the Subject:
Various Dielectric Oils
Answer: I think you need to decide if you want to use a
synthetic or mineral based oil. I have used both, and have not found a great deal of difference. They both perform well on small to medium size jobs. I don't know about some of the new stuff available. I do know for sure the synthetic is a whole lot better for the shop environment — no odor. Some of the mineral oil is bad. It is very important to use good quality filters. The oil has to stay clean, or your performance will suffer. As far as the cables, I am not sure.We are using hoses and tubing From Mc Master Carr chemical resistant. It holds up really well. You might try them.
Larry
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Date: 1/29/07
Subject: Re-deposit of EDM Debris
Question: Our mold shop has been struggling with a problem for a long time and I hope someone can lead us in the right direction.
We often get a buildup of metal on the workpiece “near” where the erosion is taking place. This deposit can be scraped off with moderate effort, but occasionally it breaks off and gets into the active burn area and causes us to burn areas which we shouldn't.
We also occasionally get a buildup on the graphite electrode which looks like graphite, but also can be scraped off.
We have spent countless hours and dollars re-working mold components and I would like to get to the bottom of it.
The situations I am describing happen frequently when we are burning thin ribs in mold cores made of various tool steels and using I-75 (I think). The dielectric oil in our machines has never been totally replaced ... We just keep adding to it.
Can anyone help us out?
Thanks,
Matt
To reply to Matt, use the Subject:
Re-deposit of EDM Debris
Thanks for the reply's guys. I will pass your information to the powers that be.
Matt
Answer: With not fully understanding what you are working with as far as the size of the cut or amperage you are pulling during the cut, the following is all I can offer:
1. Flushing, Flushing, Flushing will eliminate a lot of this so called debris / arcing. This will also allow the spark length to work better, washing away EDM particles as it burns the material. You must have flushing through the electrode as well as on the outside of the cut. To eliminate spike, drill the flushing holes in three separate patterns. Example: A, B, and C and mark them as such alternating them each burn.
2. Empty the oil — clean the base of the machine out of all the black jello sludge in the bottom. Pulling the front or side covers off with a big vacuum present will prevent spills to the floor. Suck all of this out into a 55 gallon drum and let it sit for about 6 months. Then you can suck the excess oil off and sell the sludge for the metal that it holds.
3. Filtering the oil — Paper filters work best and do not waste the oil. Here are my guidelines for the particles. I use a 1/2 micron filter of metal only cuts such as brass and or copper. I use 5 micron for use with high quality graphite. I use 25 micron for the BIG burns such as dies and larger surfaces.
4. Replace the oil.
- A Clean machine base
- Flushing, Flushing, Flushing
- Filters
- New Oil
- and ... Bill has some very good points as well.
Mickey
Answer: The buildup you are getting on the electrode is
caused by poor flushing conditions in the gap. You didn't say what type of machine you were using, but this condition can and does happen even with the new CNC machines. You need clean filters and clean oil. Think of the dielectric oil as the oil in your car's engine, don't change it and what happens? You can also add a jump to bring the trode up which this causes a plunger type action which again gets oil to the gap. A lot of times you can detect this buildup by poor machine performance. If you have a CNC sinker try making a rougher rib trode which has more over burn to get a bigger spark gap to get a bigger orbit (more movement) to get the waste out and oil in. The rule is flush, flush and more flush. I still will drill flush holes on occasion.
Try directing a separate flush hose to wash the burn sand away from the opening. You also might have to stop and check the burn more often. Cleaner oil will allow you see better.
I once had a deep thin rib burn which we ran overnight. We discovered that it developed a build up and burned a deep undercut into the side wall.
Copper electrodes won't get buildups like graphite, but you need more of then. A copper plus is you get great finishes that require a lot less polishing.
Bill
Answer: I hope I can help you here. I have seen this build
up over the years. I have found depending on how large you EDM area is. Try to not have a flat bottom for the debris to accumulate. Sometimes roughing out too much takes longer in the long run. I used to tell the machining guys just take a ball cutter and plunge it in the largest area. I know the newer machines are much better than what
I am used to. We have a early Agie semi CNC. But if you want to keep your machine running unattended this is what we found. Cut a channel the length of the rib — use screen flushing running down one side only. I am not sure how small or how deep you want to go — this has always been pretty good. As far as your build up on the graphite,
I would first change your oil. It took me many years to convince ownership that sometimes spending is saving. Clean oil is a must. We once had two large cavities. One machine had new oil, the other did not. This goes back pretty far, but I still think its true today. The one with the new clean oil was much faster with better finishes. Good filters are a must. I like the Frams myself. If this does not solve the problem, try switching your graphite.
If your electrodes are too large, try to find a multi purpose graphite — something with good hardness small grain size. Also, if your parameters are set too high, back off your on time a little. Also, break all sharp corners for the first hit. I hope this might help. I am a little old-school. People would probably think the the dinosaurs were still here when I started EDM but its what I do.
Thanks,
Larry
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