Page 1: Table Of Contents
Wire EDM Machine Operation Table Of Contents ABLE ONTENTS INTRODUCTION DESCRIPTION OF THIS MANUAL ORIGIN OF THE NAME “SODICK” COMPANY PROFILE CHAPTER 1 DESCRIPTION OF THE EDM PROCESS EDM F ENERAL ACTORS WIRE DIAMETER AND WIRE GUIDES WIRE TYPE RECOMMENDED WIRES...
Page 2 XAMPLE ROGRAM HOWING HREE OTION YPES CHAPTER 6 DESCRIPTION OF PROGRAMMING CODES AND WORDS ODES ODES ODES ESCRIPTIONS DDITIONAL NFORMATION ROCESSOR REATION NC P ROGRAM XAMPLES ROGRAM EXAMPLE ROGRAM EXAMPLE CHAPTER 7 WIRE OFFSET DESCRIPTION Copyright June, 98 Sodick Inc.
Page 3 (G74-G141) 8-13 APER ETTINGS RIEF FOR UTTING 8-13 ANUAL ACHINES 8-13 OWER ACHINES 8-14 OTES ONCERNING APER UTTING 8-14 LUSH OZZLES 8-14 YPE CONSIDERATIONS 8-14 ONVERTING ECIMAL DEGREES 8-14 RAPHICS OLORS CHAPTER 9 PROGRAM FORMATTING Copyright June, 98 Sodick Inc.
Page 4 HAPTER 11-10 RACTICE XERCISES HAPTER 11-11 RACTICE XERCISES HAPTER EVEN 11-14 RACTICE XERCISES HAPTER IGHT 11-15 RACTICE XERCISES HAPTER CHAPTER 12 MAINTENANCE 12-1 12-1 ISPLAY AINTENANCE CREEN 12-2 AINTENANCE HECKLIST BY THE HOUR CHECKS 12-2 Copyright June, 98 Sodick Inc.
Page 5 OTES ABOUT INSTALLING WIRE AWT S 14-3 PECIAL MANUALLY ADJUST FLUSHING 14-3 EDGE FIND BY USING THE ST KEY 14-3 EDGE FIND (USING G80) 14-5 CHANGING THE AXIS DISPLAY READ ANY NUMBER 14-6 VERTICALLY ALIGN THE WIRE 14-7 Copyright June, 98 Sodick Inc.
Page 6 MAL-MDI SCREEN 15-3 MAL SCREEN 15-3 EDIT, GRAPH 15-7 SCREEN EDIT, GRAPH, SCRN FLAG INPUT 15-9 SCREEN 15-11 ISPLAY CREEN SET SCREEN #1 15-13 #2 ( 15-17 CREEN ROLL UP KEY SET, TRAVEL 15-19 SCREEN Copyright June, 98 Sodick Inc.
Page 7 ROLL UP KEY RUN SCREEN 15-25 CHAPTER 16 REMOTE CONTROL OPERATION 16-1 16-1 ELECTING PEED 16-2 16-2 16-2 DGEFIND 16-2 ENTERFIND 16-2 ISPLAY 16-2 ISPLAY 16-2 LIGNMENT CHAPTER 17 SEVERAL COMMON ALARMS & MESSAGES 17-1 Copyright June, 98 Sodick Inc.
Page 8 Wire EDM Machine Operation Table Of Contents Copyright June, 98 Sodick Inc.
Page 9 Wire or sinker EDMs can cut any material that conducts electricity. The Sodick wire EDM control has two sides, the CNC side and the conversational side. This course will teach you the CNC side and machine operation. Many operation procedures will be practiced in class.
Page 10: Description Of This Manual
It would be wise to familiarize yourself with the above manuals when you return to your shop. There are many different types of Sodick controls. One of the latest types is the MARK 21 and EX21 controls. These are the two controls discussed in this training course.
Page 11: Origin Of The Name "Sodick
” ” “Sodick” is not an English or Japanese word, rather an acronym. It is a combination of four Japanese characters and was created by president, Toshihiko Furukawa. The name “SODICK” is based on the belief that “everyone should be creative and take initiatives to overcome hardships”.
Page 12: Company Profile
Machine Promotion Association for development of an electric discharge machining system with 4-axis and spindle numerical control. December 1983 Merged Sodick Inc. and Sodick Ltd. in the U.S. to form Sodick Inc. September 1984 Developed and announced the High speed small hole drilling EDM.
Page 13 March 1993 Announcement of NF series CNC power supply units for die-sinking EDM systems eliminating CNC codes. October 1993 The good will of Sodick Inc. and that of KGK International Corp, in the U.S. integrated into one. Copyright June, 98 Page v Sodick Inc.
Page 14 April 1994 Established Sodick Singapore Pte.,Ltd. in Singapore. November 1994 Established Beijing Sodick Machinery-Electronics Co.,Ltd.in China. December 1994 Established Suzhou Sodick Special Equipment Co.,Ltd. in China. March 1995 Development of PGM series die-sinking EDM systems. January 1997 Relorated corporate headquarters to 3-12-1, Nakamachidai, Tsuzuki-ku, Yokohama,Kanagawa.Established Sodick (Taiwan) Co.,Ltd.
Page 15: Chapter 1 Description Of The Edm Process
Sodick allows the following wire diameters and wire guides sizes, on most machines. .004 Diameter Wire (.11mm or .12mm wire guide)
Page 16: Wire Type
Sizes are stamped in metric (see page 12-5). WIRE TYPE The second consideration is what type of wire to use. Sodick has developed the power supply to cut at satisfactory speed with plain brass wire. Stratified and coated wires are needed to cut at maximum speed .
Page 17: Flushing
This also results in pitting on the wire and reduction of the wire diameter you can reduce wire breakage by increasing the wire speed. Copyright November, 98 Page 1-3 Sodick Inc.
Page 18: Wire Tension
However, if tap water is used that contains a great deal of iron, this will use up the DI bottle quickly. For this reason, companies will Copyright November, 98 Page 1-4 Sodick Inc.
Page 19: Workpiece Material And Hardness
You may want to make a test cut if you are going to be machining a new material that you have never cut before. Sodick application engineers will be able to help you with the specifics of cutting many kinds of materials if you need assistance.
Page 20: Oscilloscope Display O F 3 Discharge Pulses
EDM machines, some of these will be familiar. However, each type of EDM machine will have many things that are specific to that machine. Here we discuss how Sodick does it. NOTE: These can be entered into the NC program if desired. Example cutting condition : "(...
Page 21: Off
MA until the problem is cleared. Then it goes back to its normal setting. We must point out that you don’t actually see the off parameter change, it does Copyright November, 98 Page 1-7 Sodick Inc.
Page 22 You may find this being used on workpieces thicker than 7 inches, especially for the skim cuts. The A320D machines do not have this circuit because the thickest part that can be cut by the A320D is 7 inches.
Page 23 If it is set at 25, then the machine will maintain a gap voltage of 25 volts. This method of setting the gap voltage directly allows for finer settings. This is required for fine surface finish cutting. Copyright November, 98 Page 1-9 Sodick Inc.
Page 24 “C” stands for Capacitance. On the Mark 21, capacitance is no longer necessary, but it can still be used. Capacitance is a way of adding more power to the wire. It is only used during skim cutting on the Mark 21 control. Copyright November, 98 Page 1-10 Sodick Inc.
Page 25: Wp - Wc
Before writing a program, you must determine the required cutting conditions and offsets to use by looking in the cutting condition manual. Sodick has done much of the research required to develop cutting conditions and offsets. To get the proper conditions and offsets, all you will have to do is select from list in the cutting condition manual.
Page 26: Surface Finish Expected
“first cutting only” in the manual. We must point out that it would be impossible for Sodick to document the conditions and offsets necessary to machine every conceivable material. If you find that the material you intend to machine or wire diameter you intend to use is not included in the condition manual, you should contact Sodick to obtain their recommended conditions and offsets.
Page 27: Other General Tips About Wire Edm
If the die clearance is quite large, you may get away with not doing this, but the die clearance will not be uniform throughout the punch and die shape. Copyright November, 98 Page 1-13 Sodick Inc.
Page 28 Wire EDM Machine Operation Chapter 1 Copyright November, 98 Page 1-14 Sodick Inc.
Page 29: Chapter 2 Machine Layout Description
While the configuration may change from model to model, you will find that there are many consistencies from one Sodick wire EDM machine to another. This section is intended to acquaint you with the components of the machine and control. Here is a drawing that shows the A320D, one of the popular machine models: This model is made up of three basic components;...
Page 30: Machine
Manual Mode, Edit, Set, Run, etc. and to control the sub-modes of each major mode. When used, the control screen itself will actually show you the function of each soft key, so you can easily tell what each key does at any particular time. Copyright November, 98 Page 2-2 Sodick Inc.
Page 31: Keyboard Related Buttons
ALPHABET Keys - These keys are used to input the various letters on either the NC side or conversational side. NUMBER Keys - These keys are used to input the various numbers on either the NC side or conversational side. Copyright November, 98 Page 2-3 Sodick Inc.
Page 32: Program Activation Keys (Nc Side Only )
Then, if you still want to completely stop the program, press the OFF and ACK key. ENT - Means enter. For program operation, it activates the program to be run. Copyright November, 98 Page 2-4 Sodick Inc.
Page 33: Machine Related Switches ( Switch Sub Panel )
9) AWT W/ C - W position turns on the AWT water jet . The C position (clutch) frees the AWT pipe so it can slide up and down manually (C is not used on A320D). 10) Tub Fill Switch- This turns on the worktank fill pump.
Page 34: Lamps
15) Submerged lamp - This LED shows the status of the worktank float switch. On indicates that the worktank is filled up to the floats. Figure 2-2 EX21 control with AWT Copyright November, 98 Page 2-6 Sodick Inc.
Page 35: Amp - Voltmeters
To reset the meter to zero, slide the switch up and press it in. To lock the reset switch, leave it in the down position. Copyright November, 98 Page 2-7 Sodick Inc.
Page 36 Wire EDM Machine Operation Chapter 2 Copyright November, 98 Page 2-8 Sodick Inc.
Page 37: Chapter 3 Program Zero Description
(not from program zero). Here are two drawings that show how to determine your program zero point: Figure 3-1 Copyright November, 98 Page 3-1 Sodick Inc.
Page 38 X and Y motion. This means that to cause the wire to move to the right (X+), the table actually has to move to the left. Think of the WIRE movement and you will not get confused. Copyright November, 98 Page 3-2 Sodick Inc.
Page 39: How T O Assign Your Program Zero Point
Y. If you do not want the G92 in the program, position the machine at the start point location. Go to “MAL”, ”MDI” and type the value of the start point and press enter to change the CRT displays so the machine knows where it is on the part. Copyright November, 98 Page 3-3 Sodick Inc.
Page 40: Understanding Work Coordinate Screens
N0005 G92 X.500 Y-.500 Figure 3-4 Sodick allows you to assign up to sixty (60) different program zero points. This could be helpful when you are machining multiple parts. However, most of the time you will only be interested in one of the available work coordinate screens. You will usually start with coordinate system number zero, which is commanded by a G54.
Page 41 Figure 3-5 When setting up these two parts on the worktable, the operator would use G54 when corner finding workpiece 1. G55 work coordinate would then be used when corner finding workpiece 2. Copyright November, 98 Page 3-5 Sodick Inc.
Page 42 Wire EDM Machine Operation Chapter 3 Copyright November, 98 Page 3-6 Sodick Inc.
Page 43: Chapter 4 Program Makeup
You will find it much easier to “recognize” these commands in format than it is to come up with the proper format off the top of your head. Figure 4-1 is a print to cut a square. Figure 4-1 Copyright November, 98 Page 4-1 Sodick Inc.
Page 44 The “N” words are sequence numbers. They are not required to be in the program, unless your using sub routines. However, we recommend that beginners use them in each program and keep them in a logical order for program line identification purposes. Copyright November, 98 Page 4-2 Sodick Inc.
Page 45: Preparation For Programming
Then, on your coordinate sheet, write down the X and Y coordinates of each point number. Figure 4-2 shows an example of how to use the “coordinate sheet”. Copyright November, 98 Page 4-3 Sodick Inc.
Page 46: Decide Upon The Wire Diameter
“overburn” that is involved in the EDM process. A .010 diameter wire will cut a radius of more than .005 inch (depending on the condition and number of skim passes), so if the .005 inside radius is critical, a wire diameter of .008 inch or less must be used. Copyright November, 98 Page 4-4 Sodick Inc.
Page 47: Check The Condition File Manual For The Necessary Conditions And Offsets
Prior to writing your manual program, you must know the conditions and offsets required to produce the part to your requirements. The condition manual from Sodick is broken down into four basic categories as described during chapter one. Review the information presented earlier when deciding which cutting conditions to use (see page 1-11).
Page 48 Wire EDM Machine Operation Chapter 4 Copyright November, 98 Page 4-6 Sodick Inc.
Page 49: Chapter 5 The Four Kinds Of Wire Motion
Look at the following examples. 2.000" Program Zero A dotted line will be shown in graphics 0.690" Exmple Command N0150 G00 X2.000 Y-.690 Figure 5-1 Copyright November, 98 Page 5-1 Sodick Inc.
Page 50 4) Electricity to the wire turns on using current cutting condition (C value displayed) As you can see, the G01 command will actually get the machine ready to cut as well as make the straight line cutting motion. Graphics will show solid lines. Copyright November, 98 Page 5-2 Sodick Inc.
Page 51: Specifying The Xand Yvalues In A Circular Move
If the arrow is pointing in both X and Y, you will have both an I and a J in the circular command and the pluses and minuses must also be considered. The sketches in figure 5-3 and figure 5-4 illustrate this technique: Copyright November, 98 Page 5-3 Sodick Inc.
Page 52 1 G01Y1.25 2 G02 X.5 I.25 J0. 3 G01 Y.75 4 G03 X1. I.25 J0. 5 G01 Y1.25 1.25" 6 G02 X1.5 I.25 J0. 0.75" 7 G01 Y0. 8 X0. Program Zero Figure 5-4 Copyright November, 98 Page 5-4 Sodick Inc.
Page 53: Circular Motion Using Ther Word ( Constant Radius )
When taper cutting, if you use the R word to create a circular movement, the control will form the same radius at the top and bottom of the part. If you are machining form tools, the radius generated by an R word is desirable. Copyright November, 98 Page 5-5 Sodick Inc.
Page 54 For more details, see figure 5-6 or “Automatic Corner Rounding” on page 10-14. Taper With G02 - 3 Corners Taper With "R" Word Corners Figure 5-6 G00, G01, G03 XAMPLE ROGRAM HOWING HREE OTION YPES Figure 5-7 Copyright November, 98 Page 5-6 Sodick Inc.
Page 55 Careful study of the program will reveal how the part (figure 5-7) is formed using the movement commands just described. In the following chapters you will learn more of the techniques used in the above program (Offset use). Copyright November, 98 Page 5-7 Sodick Inc.
Page 56 Wire EDM Machine Operation Chapter 5 Copyright November, 98 Page 5-8 Sodick Inc.
Page 57: Chapter 6 Description Of Programming Codes And Words
Y.2 or Y2000 when in 4-place inch. ( notice where decimal point would be). Used to specify position movement in the Z-axis when the machine has a power Z-axis. A value of 3 inches would be written as Z3. 5 or Z35000 Copyright November, 98 Page 6-1 Sodick Inc.
Page 58 .The three digits may be any existing combination from 000 to 999. A Non EF II machine uses 1-199 for the operator to create their own. An EF II machine uses 1-99. Copyright November, 98 Page 6-2 Sodick Inc.
Page 59 Used when you want to program the machine to cut taper, holding size at different heights for different openings. Example: G92XY TP2.000 (Sets Table To Program At 2.000) TN0000(Sets Table To Next At 0) Copyright November, 98 Page 6-3 Sodick Inc.
Page 60: List O F G Codes
Work Coordinate System Number 2 pg.3-4 Work Coordinate System Number 3 pg.3-4 Work Coordinate System Number 4 pg.3-4 Work Coordinate System Number 5 pg.3-4 4 Axis On 4 Axis Off Sensor touch pg.14-5 Move To Limits pg.14-1 Copyright November, 98 Page 6-4 Sodick Inc.
Page 61: List O F T Codes
Thread Wire By Auto Wire Threader Sequence Two Switch To Submersed Machining Worktank Fill Pump On Worktank Fill Pump Off Note: Out of the above T codes, the only codes that are usually used in an NC program Copyright November, 98 Page 6-5 Sodick Inc.
Page 62: List O F M Codes
M03 code before the T90 codes. Example: G92X0 Y0 M98P0000 (This first M03 here is not really needed, but is OK ) G00X1.500 Y2.500 If wire tread fails, then skip to next M03 code M98P0001 G00X2.500 Y2.500 Copyright November, 98 Page 6-6 Sodick Inc.
Page 63: Additional Information For Post Processor Creation
Chapter 6 M98P0002 DISK FORMAT: The floppy drive on the Sodick EX21 and Mark 21 control is capable of using 720KB type 3.5-inch floppies – “2DD” type. Disks formatted for IBM use will be fine, just be sure to format at 720Kb (not 1.44Mb). If the floppy is a “2HD” type...
Page 64: Nc Program Examples
N0012 G02 X.15 Y-.25 I-.1 J0. N0013 G01 X-.15 N0014 G02 X-.25 Y-.15 I0. J.1 N0015 G01 Y.15 N0016 G02 X-.15 Y.25 I.1 J0. N0017 G01 X-.1 N0018 X0. N0019 G50 A0. G40 Y0. (Cancel Offset and Taper) Copyright November, 98 Page 6-8 Sodick Inc.
Page 65 N0009 G02 X0. Y.25 I.1 J0. N0010 G01 X.15 N0011 G02 X.25 Y.15 I0. J-.1 N0012 G01 Y-.15 N0013 G02 X.15 Y-.25 I-.1 J0. N0014 G01 X-.15 N0015 G02 X-.25 Y-.15 I0. J.1 N0016 G01 Y.15 Copyright November, 98 Page 6-9 Sodick Inc.
Page 66 N0032 G03 X.25 Y-.15 I0. J.1 N0033 G01 Y.15 N0034 G03 X.15 Y.25 I-.1 J0. N0035 G01 X0. N0036 G03 X-.1 Y.15 I0. J-.1 N0037 G50 A0. G01 G40 X0. Y0. N0038 M02 Copyright November, 98 Page 6-10 Sodick Inc.
Page 67: Chapter 7 Wire Offset Description
Wire offsetting requires three steps in the program: 1) Instate wire offset (G41 or G42 codes) 2) Drive the wire through its motions 3) When finished, you MUST cancel offset (G40 code) Copyright November, 98 Page 7-1 Sodick Inc.
Page 68 (plus the amount of overburn) of the wire is flush with the surface you wish to be on size. Copyright November, 98 Page 7-2 Sodick Inc.
Page 69 "Approach Pattern" And Wire Offset Initialization Approach Pattern = 1 Approach Pattern = 0 G41 H062 G41 H062 G01 Y-.250 G01 Y-.250 Figure 7-2 Copyright November, 98 Page 7-3 Sodick Inc.
Page 70 N070 G40 Y-.02 (MOVE TO POINT 10 AND CANCEL COMP.) N075 M00 (PROGRAM STOP TO APPLY MAGNETS) N080 G01 X1. (MOVE TO POINT 11 TO CUT OFF) N085 Y-.15 (MOVE BACK TO START POINT) N090 M02 (END OF PROGRAM) Copyright November, 98 Page 7-4 Sodick Inc.
Page 71 If you find that the finish and size of the part is unacceptable, the set of conditions and offsets must be modified. For beginners, it would be wise to contact Sodick for help. If the finish is OK but the size of the part is incorrect, you will have to modify ALL offsets by the amount of error.
Page 72 H number. In this case the H number can be called up as a negative value EX: G41 H-050 (negative .005 inch Copyright November, 98 Page 7-6 Sodick Inc.
Page 73 Wire EDM Machine Operation Chapter 7 value). This negative call out is new for Sodick, starting with the Mark21 and EX21 controls. But this is a good time to point out that there is another way of setting offsets (positive or negative) using what we call a HEADER. Cutting conditions can also be entered into the header using C registers.
Page 74 Below is an example of how to do this. NC Program Example: G92X0Y0 G41H-015 (This calls out the value of H015 and switches it negative) G01X.5 G40Y0 G41H-044 (This calls out the value of H044 and switches it negative) G01X.5 Copyright November, 98 Page 7-8 Sodick Inc.
Page 75 G41H1 (Calls the H1 register, which was set to -.0044” above) G01X.5 G40Y0 H1=-.0047 (Sets H1 register content to -.0047”) G41H1 (Calls the H1 register, which was set to -.0047” above) G01X.5 G40Y0 Copyright November, 98 Page 7-9 Sodick Inc.
Page 76 Wire EDM Machine Operation Chapter 7 This Page Left Blank Copyright November, 98 Page 7-10 Sodick Inc.
Page 77 Generally, you will want the taper angle to be at its smallest acceptable angle to keep the die strong. The desired taper angle will also affect the best and easiest way to machine the die. More on this later. Copyright November, 98 Page 8-1 Sodick Inc.
Page 78 Max Angle = TAN [U axis travel per side / [part thickness + .800]] The models A320D or A530D have .980” of U axis travel per side. The models AP350 or AP500 have 1.380” of U axis travel per side.
Page 79 1) Initialize taper (G51 for left, G52 for right) 2) Make machining motions 3) Cancel taper cutting mode (with G50) (Notice the similarities to wire radius compensation. These commands should be easy to remember!) Copyright November, 98 Page 8-3 Sodick Inc.
Page 80 If you want to machine a half-degree taper (per side), the program needs A.5 in it. You also need to know that there is a limitation of the Copyright November, 98 Page 8-4 Sodick Inc.
Page 81 X and or Y movement. Figure 8-2 NC program for figure 8-2 N005 G54 (SELECT COORDINATE SYSTEM) N010 G92 X.5 Y.2 (SET PROGRAM ZERO) N015 G90 (ABSOLUTE MODE) N020 G41 H061 (LEFT OFFSET OF .0061) Copyright November, 98 Page 8-5 Sodick Inc.
Page 82 These techniques are also explained during the program formatting section of the course. Copyright November, 98 Page 8-6 Sodick Inc.
Page 83 Table To Limit is handled differently for a manual Z-axis and a power Z-axis. In both cases, Table To Limit is a CONSTANT that will usually not change for the life of the machine. Like Table to lower, you will find it documented in the mechanical file printout Copyright November, 98 Page 8-7 Sodick Inc.
Page 84 This is the distance from the worktable to the lower wire guide. This is a constant that will usually not change. Sodick documents this value in the list of parameters (the mechanical file) that comes with your machine. You should write this value down and keep it near the machine.
Page 85 Note: When 4 axis cutting, it must be used. This sets the position of the u-v axis plane in your part, so set this value to the amount that the top of the part is above the table. Copyright November, 98 Page 8-9 Sodick Inc.
Page 86 “Limit Switch” error. This is a normal condition do to the speed of the Dry Run. It is required by the operator to monitor the axis position on the “SET” “DISPLAY” Copyright November, 98 Page 8-10 Sodick Inc.
Page 87 Wire EDM Machine Operation Chapter 8 screen, to be sure this doesn’t occur. Otherwise the machine may stop while machining with the error. “Limit check” in graphics can also be used to check for overtravel. Copyright November, 98 Page 8-11 Sodick Inc.
Page 88 T-Program = .0500” Z Vernier = .8750” T-Next = 1.000 Figure 8-5 Known Values Operator input T-Limit = .6990” T-Upper = 1.6740” T-Lower = .3535” T-Program = .9500” Z Vernier = .9750” T-Next = 0.000 Copyright November, 98 Page 8-12 Sodick Inc.
Page 89 All other settings are machine constants and should already be set. Note: Now Table To Next is actually being used in 4-axis cutting. Its value should represent the workpiece thickness + fixturing thickness if one is being used. Copyright November, 98 Page 8-13 Sodick Inc.
Page 90: Flush Nozzles
When drawing or viewing the graphic picture of a program with taper, the screen will show 2 colors. While running a taper program, there will also be 2 asterisks following the graphics drawing. Copyright November, 98 Page 8-14 Sodick Inc.
Page 91 Wire EDM Machine Operation Chapter 8 Blue = Top of workpiece Green = Bottom of workpiece USE THESE PAGES FOR NOTES Copyright November, 98 Page 8-15 Sodick Inc.
Page 92 Wire EDM Machine Operation Chapter 8 Copyright November, 98 Page 8-16 Sodick Inc.
Page 93 Also the location of the tab area should be planned in a way to allow easy grinding of the tab that will be left after the punch is cut off. The figure 9-1 is a drawing that shows the programmed movements for a typical punch BEFORE THE CUT OFF. Copyright November, 98 Page 9-1 Sodick Inc.
Page 94 However, reverse trim passes are a little more difficult to program (manually) and many manual programmers will simply program trim passes in the same direction as the rough pass. Copyright November, 98 Page 9-2 Sodick Inc.
Page 95 (G codes) to drive the wire around the shape. The subroutine (beginning with the N word, which is specified by the P word) will ALWAYS be included AFTER the end of the main program (after the M02 of the main program). Copyright November, 98 Page 9-3 Sodick Inc.
Page 96 Say you were machining a punch that required three total passes (rough and two trims). Based on the Material Type, Material Thickness, Wire Diameter and Flushing condition you looked in the Sodick condition manual and below are the set of conditions and offsets the manual recommended:...
Page 97 N2000 G01 Y0 (MOVE TO POINT 15) N2005 X.1 (MOVE TO POINT 14) 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) Copyright November, 98 Page 9-5 Sodick Inc.
Page 98 See if you can figure out what is happening. NOTE: We are using a 1 cut on size offset for the taper cut, since no trims will be done on the tapered area. Copyright November, 98 Page 9-6 Sodick Inc.
Page 99 Trim pass (straight portion) - C620 and H053 Figure 9-3 NC Program for figure 9-3 N005 G54 (SELECT COORDINATE SYSTEM) N010 G92 X.5 Y.2 (SET PROGRAM ZERO) N015 G90 (SELECT ABSOLUTE MODE) N020 C411 (SELECT CONDITION FOR ROUGH PASS) Copyright November, 98 Page 9-7 Sodick Inc.
Page 100 N1105 G03 X.515 Y.015 J.015 (ARC OUT TO POINT 18) N1110 G01 Y.2 (MOVE TO POINT 19) N1115 G40 G50 X.5 (CANCEL COMP ,TAPER & MOVE TO POINT 1) N1120 M99 (END OF SUB ROUTINE) Notes about the die program: Copyright November, 98 Page 9-8 Sodick Inc.
Page 101 APT system will do it. The only changes are that the APT system will NOT use the optional block skip technique. It will create THREE subroutines. Also, the APT system will create reverse direction trim passes for you (the better way to do it). Copyright November, 98 Page 9-9 Sodick Inc.
Page 102 Wire EDM Machine Operation Chapter 9 Copyright November, 98 Page 9-10 Sodick Inc.
Page 103 As you know, a sub- routine is included in the same file as the main program but is placed after the M02 of the main program. A sub-routine is totally Copyright November, 98 Page 10-1 Sodick Inc.
Page 104 STARTUP on your user disk or hardrive, it makes machine homing easier. ARIABLES OUTINES So far, we have just scratched the surface of what can be done with Q routines. You also Copyright November, 98 Page 10-2 Sodick Inc.
Page 105 Q routine named EXAMPLE. (Q routine named example) H000 = +00000000 H001 = +00000000 H002 = +00000000 H003 = +00000000 H004 = +00000000 H005 = +00000000 (Continued on next page) Copyright November, 98 Page 10-3 Sodick Inc.
Page 106 In the above command, first the value of H001 (10000) would be divided by two (result = Copyright November, 98 Page 10-4 Sodick Inc.
Page 107 Wouldn’t it be nice if all you had to do to machine this die button is make the command: QOVAL(5000,10000) Believe it or not, this is possible. However, let’s also add the condition and offset to be used to the call statement so the revised version looks like this: Copyright November, 98 Page 10-5 Sodick Inc.
Page 108 N045 G01 X[[H001/2]-[H000/2]] (MOVE TO POINT 5) N050 G03 Y[H000/2] J[H000/2] (MOVE TO POINT 6) N055 G01 X-[[H001/2]-[H000/2]] (MOVE TO POINT 7) N060 G03 Y-[H000/2] J-[H000/2] (MOVE TO POINT 8) N065 G01 X0 (MOVE BACK TO POINT 4) Copyright November, 98 Page 10-6 Sodick Inc.
Page 109 ODES OUTINES Along with the features shown to this point, Sodick has also designed some special G codes that have application with Q routine techniques. G80 - Sensor Touch This command can be used to pick up the edge of a workpiece. But to this point, you have only used the G80 in MAL, MDI mode.
Page 110 The command G83 X005 would load the current X position of the wire into the H005 register. You know by now that Sodick allows up to sixty different coordinate systems to be used. These coordinate systems are helpful when you need to run multiple parts in a setup (like multiple die openings in a progressive die.).
Page 111 N056 G54 N060 QDIE3 (THIS RUNS ENTIRE DIE3 PROGRAM) ’ SING A OORDINATE YSTEM TO RACK OF THE ACHINE OSITION One VERY helpful technique for Coordinate System Shifting is to keep track of the Copyright November, 98 Page 10-9 Sodick Inc.
Page 112 This can be a little confusing so always dry run the program prior to actually cutting your part to be sure it will come out correctly. Copyright November, 98 Page 10-10 Sodick Inc.
Page 113 The axis under the influence turns red on the CRT. Copyright November, 98 Page 10-11 Sodick Inc.
Page 114 X + Y Mirror (G05 G06) XY Exchange + Y Mirror XY Exchange (G08) (G08 G06) XY Exchange + X&Y Mirror XY Exchange + X Mirror (G08 G05 G06) (G08 G05) Figure 10-4 Copyright November, 98 Page 10-12 Sodick Inc.
Page 115 Once the scale factor is set, the control will modify all movements by the amount of the scale factor. Note: scaling does not effect the offset value. Also, an icon appears in the run screen if set to a value other than 1000 which is full scale. Copyright November, 98 Page 10-13 Sodick Inc.
Page 116 NOTE: Offset code G41 (or G42) is required in the program for the R word to work. If you want to cut without offset, simply include the G41 (or G42) code and use H000 for the offset value. Copyright November, 98 Page 10-14 Sodick Inc.
Page 117 Wire EDM Machine Operation Chapter 10 Copyright November, 98 Page 10-15 Sodick Inc.
Page 118 Sodick machine respond to commands that are used in your other machines. You can think of the string file as a translation table. It lets the Sodick machine read and execute commands that it would not normally recognize. It can also convert single codes to mean more than one code.
Page 119 T89:T89T83T97 DRN:T83T97 FIL:T82T96 G254:G254 G255:G255 G256:G256 G257:G257 G258:G258 G259:G259 G454:G454 G455:G455 G456:G456 G457:G457 G458:G458 G459:G459 G25:G92 G43:G41 G44:G41 G45:G40 G60:G28 G96:G09 M20:T91 M21:T90 M22:M06 M30:M02 M40: M80:T84 T86 M81:T85 T87 M82:T80 M83:T81 M84: Copyright November, 98 Page 10-17 Sodick Inc.
Page 120 Wire EDM Machine Operation Chapter 10 M85: M90: (Continued on next page) M91: T01:C000 D000 T02:C001 D001 Copyright November, 98 Page 10-18 Sodick Inc.
Page 121 ________________________________________________________________________ ________________________________________________________________________ D) Wire Tension: ________________________________________________________________________ ________________________________________________________________________ E) Water Resistivity: ________________________________________________________________________ ________________________________________________________________________ F) Workpiece Material Hardness: ________________________________________________________________________ ________________________________________________________________________ 3) How do you determine the proper wire diameter to use for any one workpiece? Copyright November, 98 Page 11-1 Sodick Inc.
Page 122 8) Which kind of tool steel cuts faster, the material in its soft state or the material in its hardened state? ________________________________________________________________________ Parameters Specific To Sodick: 9) Name the parameters that have the tendency to “add power” to the wire during cutting. ________________________________________________________________________ 10) Name the parameters that have the tendency to “take power away”...
Page 123 14) Where do you go to find the specific Condition Numbers to machine a specific material, thickness, with a particular wire diameter and number of trim passes? ________________________________________________________________________ 15) What programming word (letter address) specifies the condition? ________________________________________________________________________ Copyright November, 98 Page 11-3 Sodick Inc.
Page 124 ________________________________________________________________________ C) Acknowledges the fact that you have read a warning or alarm. ________________________________________________________________________ D) Permanently stops the activation of a program. ________________________________________________________________________ 3) What does the “KYB / REM” switch do? ________________________________________________________________________ Copyright November, 98 Page 11-4 Sodick Inc.
Page 125 ________________________________________________________________________ ________________________________________________________________________ 8) For the drawing to follow, fill in the corresponding coordinate sheet. Then, mark up a location on the drawing that would be an acceptable start point for the punch program Copyright November, 98 Page 11-5 Sodick Inc.
Page 126 And last, tell what wire diameter would be best to machine this part. Best wire start point for a die? X_____________ Y_____________ Best wire start point for a punch? X_____________ Y_____________ Copyright November, 98 Page 11-6 Sodick Inc.
Page 127 1) ___________________________________________ 2) ___________________________________________ 3) ___________________________________________ 4) ___________________________________________ 3) How do you choose the correct wire size for your job? ________________________________________________________________________ 4) How do you choose the starting point of your cut? ________________________________________________________________________ Copyright November, 98 Page 11-7 Sodick Inc.
Page 128 5) What are the two ways to specify circular motions? ________________________________________________________________________ ________________________________________________________________________ Which is the way we recommend and why? ________________________________________________________________________ ________________________________________________________________________ 6) For the following drawing and program (on the following page), fill in the “blanks” to complete the program. Copyright November, 98 Page 11-8 Sodick Inc.
Page 129 N095 G03 X________ Y________ J-.05 (14) N100 G01 Y________ (15) N105 G40 X________ (16) N110 M00 (GLUE STOP) N115 G01 Y.5 (CUT OFF) N120 X-.3 (MOVE BACK TO START POINT) N125 M02 (END OF PROGRAM) Copyright November, 98 Page 11-9 Sodick Inc.
Page 130 G word ________________________________________________________________________ X and Y ________________________________________________________________________ U and V ________________________________________________________________________ T word ________________________________________________________________________ H word ________________________________________________________________________ C word ________________________________________________________________________ M word ________________________________________________________________________ R word ________________________________________________________________________ 2) What is the “slash” code used for? Copyright November, 98 Page 11-10 Sodick Inc.
Page 131 A) H055 = __________ B) H087 = __________ C) H065 = __________ 4) What are the three steps to using wire radius compensation? ________________________________________________________________________ ________________________________________________________________________ 5) For the following examples, circle the correct G code. Copyright November, 98 Page 11-11 Sodick Inc.
Page 132 6) Say you had to machine a punch and die. Based on the workpiece material, wire diameter, workpiece thickness, and finish requirements, you looked in the SODICK condition manual and found that you needed three total passes (rough and two trims) to machine the parts to the desired size and finish.
Page 133 Wire EDM Machine Operation Chapter 11 13) When the required die clearance is greater than the smallest offset to be used in the program, what may be used to incorporate the die clearance? ________________________________________________________________________ Copyright November, 98 Page 11-13 Sodick Inc.
Page 134 ________________________________________________________________________ 5) Define the following parameters (in relation to the worktable): Table To Limit : Table To Upper : Table To Lower : Table To Program : Table To Next : Copyright November, 98 Page 11-14 Sodick Inc.
Page 135 9) Name the G codes related and their corresponding system numbers: ________________________________________________________________________ Subroutine Techniques: 10) What are the four words related to subroutines? ________________________________________________________________________ ________________________________________________________________________ 11) When is it most helpful to use subroutine techniques? (based on our discussions). Copyright November, 98 Page 11-15 Sodick Inc.
Page 136 18) What is the purpose of having these features (mirror image and axis exchange)? ________________________________________________________________________ Axis Rotation: 19) What are the programming words related to axis rotation? ________________________________________________________________________ What are their functions? ________________________________________________________________________ Copyright November, 98 Page 11-16 Sodick Inc.
Page 137 Wire EDM Machine Operation Chapter 11 String File 20) What is the purpose of the string file? ________________________________________________________________________ Copyright November, 98 Page 11-17 Sodick Inc.
Page 138 Wire EDM Machine Operation Chapter 11 Copyright November, 98 Page 11-18 Sodick Inc.
Page 139 Wire EDM Machine Operation Chapter 12 Sodick Wire EDM’s are precision machine tools and should be treated as such. Preventative maintenance will eliminate unnecessary problems, downtime, and aggravation and should be performed on a regular basis religiously. Sodick Wire EDM’s had a reputation in the industry to run longer and in dirtier conditions between maintenance intervals than their competitors.
Page 140 4)AWT machines: Check oil level in air hydro unit for upper guide (on side of machine). Refill with AWT oil from Sodick Parts dept. or Mobil DTE 24,SIO grade 32, sold by Grainger (p.n. 4ZF33). This is a spindle oil. Both resevoirs floats should be between the lines when full.
Page 141 Also make sure the hoses don’t get kinked, thus blocking the flow. The meter should return to your setting value in an hour or so. Copyright November, 98 Page 12-3 Sodick Inc.
Page 142 They need to be indexed when the witness line is about .010"-.015" deep or about every 70 or 80 hours. Sodick provides an indexing tool with the machine or a 6" scale could be used to track location of the power feeder. Loosen the set screw (3mm allen wrench) located inside the head of the cap screw that holds the short power cable to the front of the upper head and push the feeder about .040"...
Page 143: Wire Guides
WIRE GUIDES: Sodick provides a round tool for removing the screw on style guides. The tool (die driver) has 2 lugs that fit into 2 slots ground on the guide. The hole drilled through the tool is to put an allen wrench through to loosen and tighten the guide.
Page 144: Way Lubrication
The upper pulley is driven by an electric motor. The pipe travels down until it contacts the stop block. This block is at a fixed location on the A320D. The water jet then turns on and acts as a guide for the wire to follow. The drive rollers located above the pipe feed the wire until it reaches the ejection rollers.
Page 145: Wire Cutter
RPM of the flush pump when in high or low flushing mode. Use this readout to track flushing pressure since the numbers change as the knobs are rotated. LOW set to 20Hz (should get 1 Liter / minute flow). HIGH set to 60Hz Copyright November, 98 Page 12-7 Sodick Inc.
Page 146: Rst Button
Wire EDM Machine Operation Chapter 12 RST BUTTON: The RST button is located below the resistivity meter. If the circulation pump shuts off, press the RST button to restart the pump. Copyright November, 98 Page 12-8 Sodick Inc.
Page 147: Wire Guide Assembly Drawings
Wire EDM Machine Operation Chapter 12 IGURE HOWING OWER SSEMBLY Copyright November, 98 Page 12-9 Sodick Inc.
Page 148 Wire EDM Machine Operation Chapter 12 AWT H IGURE HOWING PPER SSEMBLY Copyright November, 98 Page 12-10 Sodick Inc.
Page 149: Lower Head Alignment Procedure
SET, MACHINE screen. There are also a few adjustments available in the electrical cabinet located behind the machine tool on the A320D and A530D types, and on the left side of the machine tool on A350, A500, A600, A750 and A1000 types. The wire should be square before performing the following procedure.
Page 150: Awt U And V Alignment Procedure
2) Set the upper head to the cutting position, then move the AWT pipe all the way down (A320D) and to about .5" above the lower wire guide on all other machines. 3) Go to “MAL”, “MDI” and flip the switch on the control to W. (turns on water jet).
Page 151 AWT 2 cycle. On an A320D set this to 30. On A530D’s it is only needed with parts 5.0” or thicker. 0: Do not drain worktank.
Page 152 WATER TO OIL TIME (SEC) This parameter is used to set the time duration in seconds, for which to drain the dielectric when switching from water to oil. Used on machines equipped with both a water and oil dielectric system (not used on A320, A530, A350, A500). Copyright November, 98 Page 12-14 Sodick Inc.
Page 153 Wire EDM Machine Operation Chapter 12 ELECTRICAL CABINET SETTINGS A320D,A530D There 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 80 When the wire breaks, the AWT unit must rewind the broken wire above the upper guide.
Page 154: Wire Spool Settings A350Wp,A500Wp, A600Wp
Normal setting tension range = 600 to 2500 grams. Knob setting 8 will = 1200 grams Thin setting tension range = 400 to 800 grams. Knob setting 8 will = 550 grams Copyright November, 98 Page 12-16 Sodick Inc.
Page 155: Awt Electrical Cabinet Settings 350,500 ,600
Setting it further clockwise makes the drive rollers feed the wire faster when it is threading the wire. This unit is recognizable by its orange knob. If you adjust the speed of this unit, adjust the parameter AWT 2 FEED TIME (SEC) Copyright November, 98 Page 12-17 Sodick Inc.
Page 156 Wire EDM Machine Operation Chapter 12 Copyright November, 98 Page 12-18 Sodick Inc.
Page 157 Press “Arrow Up” then “Home Clear” keys to start at the top of the file. c) Change the “DRY” horizontal soft-key to “1 or2”. d) Press the “Enter” key. e) Check for crash zones, axis limits, proper conditions & offsets. (Continued) Copyright November, 98 Page 13-1 Sodick Inc.
Page 158 Wire EDM Machine Operation Chapter 13 Note: (A320D & A530D only) If the plotting table is up and the side door is shut, DO NOT put the plotting pen arm on or it will hit the cover!!!!!! 10) Move machine back to the start point location and check machine numbers.
Page 159: Power Up The Machine
7) Go to the “SET”, “TRAVEL” screen and turn on “AUTO T UPPER”. Now it is OK to jog the Z-axis. This parameter allows the machine to track the location of the upper head as it is jogged, and automatically set the “Table To Upper” parameter. Copyright November, 98 Page 14-1 Sodick Inc.
Page 160: Move Axis By "Mdi
“ ” ” The Sodick control allows you to move any axis (one or more) by “MDI” in a similar way to how it is done in a program. Any rules you know related to programming will still apply to “MDI”...
Page 161: Awt Special Note
This is 1 of 2 procedures used to locate the edge of a workpiece. It leaves the wire flush with the edge of the part. However, this procedure is not the most accurate. Remember Copyright November, 98 Page 14-3 Sodick Inc.
Page 162 5) Press the “ACK” key. 6) The edge of the wire is now flush with the edge of the part. Press down the wire run switch to turn the wire run off. Copyright November, 98 Page 14-4 Sodick Inc.
Page 163: Edge Find (Using G80)
NOTE: Be sure the wire run turns on. If it doesn’t, enter G80:T80G80 in the string file, or turn the wire run on manually. NOTE: Wire run will not turn off automatically when the cycle is done. G80 X- X0 Edge G92 X.0049 (Or 1/2 the wire diameter) Copyright November, 98 Page 14-5 Sodick Inc.
Page 164: Changing The Axis Display Read Any Number
3) Type G92 and the values you want for X, Y, U, V, and press “ENTER” . “G92X.500 Z0” Note that all axis (X,Y, U,V,Z.) need not be included. If you are only interested in setting one axis (X for example), you would type “G92X” and press enter. Copyright November, 98 Page 14-6 Sodick Inc.
Page 165: Vertically Align The Wire
15) When satisfied, press the “OFF” and “ACK” key. 16) Type G90 to go to absolute mode. 17) Type G97UV and press “ENTER” to zero out the U and V readout in all screens. Copyright November, 98 Page 14-7 Sodick Inc.
Page 166 Wire EDM Machine Operation Chapter 14 AdjustingVaxis AdjustingUaxis Copyright November, 98 Page 14-8 Sodick Inc.
Page 167 Wire EDM Machine Operation Chapter 14 There are Q Assist routines named 0145,0146 and 0155 designed by Sodick to make operation easier. Use these programs to pickup the center of a hole or shape. Be sure DRY = 0, WS=2and WT=8 and the pickup surface is burr-free, clean and dry and scale is 1000 1) Thread the wire through the opening and confirm that it is not touching the workpiece.
Page 168: Corner Find Routine
Wire EDM Machine Operation Chapter 14 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 your program zero point, for example), this routine will automatically pick up both edges of the corner and make the X and Y axis position values of that corner be any numbers you want.
Page 169: Clearing The Memory
2) Press the soft key next to “FILE”. 3) Make sure the Load/Save key is highlighting the word Save in blue. 4) Using the arrow keys bring the cursor to the filename you want to save. 5) Press “ENTER”. Copyright November, 98 Page 14-11 Sodick Inc.
Page 170: Saving Programs From Memory To User Disk (With Hard Drive)
6) If you pressed “ENTER” and the control has a hard drive, the changes are saved onto the hard drive. If there is no hard drive, they are saved to the user disk. Copyright November, 98 Page 14-12 Sodick Inc.
Page 171: Saving Programs From Memory To Hard Drive
4) Make sure the Load/Save button is highlighting the word “Load”. 6) Using the arrow keys, cursor to the file you wish to load and press “ENTER”. 7) The program is now in memory. Copyright November, 98 Page 14-13 Sodick Inc.
Page 172: Loading Programs From User Disk To Memory (Without Hard Drive)
9) If you want only specific files to be saved to disk, highlight specific files to the right of NC program file choice and press “ENTER”. 10) Files on hard drive will appear on the screen numbered in red, 16 maximum per Copyright November, 98 Page 14-14 Sodick Inc.
Page 173: Saving Programs From User Disk To Hard Drive
6) Press “ENTER” for yes or “ESC” for no. 7) If you want to delete all the programs in memory, highlight Memory Clear. 8) The prompt, will you clear memory?, appears in the lower left corner of the screen. Copyright November, 98 Page 14-15 Sodick Inc.
Page 174: Deleting Programs From User Disk (Without Hard Drive)
“ENTER”. 5) The prompt, will you delete?, appears in the lower left corner of the screen. 6) Press “ENTER” for yes or “ESC” for no. Copyright November, 98 Page 14-16 Sodick Inc.
Page 175: Copying A User Disk To Another Disk (Without Hard Drive)
11) There is a maximum of 10 files you can copy at a time. 12) To copy the chosen files, press “ENTER”. Once you load a program into memory, you have complete control of the program. Many Copyright November, 98 Page 14-17 Sodick Inc.
Page 176 1) Search to the first character to be deleted. 2) Press the soft key under “AREASET”. 3) Bring the cursor to the last character to be deleted (characters to be deleted will be highlighted). 4) Press the soft key under “DELETE”. Copyright November, 98 Page 14-18 Sodick Inc.
Page 177: Copying A System Disk (Without Hard Drive)
1) Press the soft key next to “SET”. 2) Press the soft key next to “DISK”. 3) Press the soft key under “SYSTEM BACKUP”. 4) Place the BLANK, NON- FORMATTED disk in drive 2. Copyright November, 98 Page 14-19 Sodick Inc.
Page 178: Initializing A New User Diskette
If you want to boot up the machine with the pre-formatted disk, be sure to copy the following files onto this disk. If you initialize a disk with the procedure above ,the files below are automatically saved onto the disk. COND.DAT OFFSET.DAT STRING.DAT Copyright November, 98 Page 14-20 Sodick Inc.
Page 179: Running Programs From The Active Memory
If on a line by themselves , they will appear. See page 15-7 for more info. Example: (may not appear in graphics) N0123 G01X12.354 M00 (will appear in graphics) N0123 G01X12.354 N0124 M00 Copyright November, 98 Page 14-21 Sodick Inc.
Page 180: Changing Power Settings While Machining
2) Replace the SYSTEM DISK in drive one when prompted to and then press return. press “ESC” if you have a hard drive. 3) Press the F10 key when prompted to return to the CNC side. Copyright November, 98 Page 14-22 Sodick Inc.
Page 181 For all macro programs use *.apt, instead of *.pro in step 4 above. (c:*.apt _b) For all G code programs use *.nc, instead of *.pro in step 4 above (c:*.nc_ b) For all part programs use *.pro, instead of *.pro in step 4 above (c:*.pro_ b) Copyright November, 98 Page 14-23 Sodick Inc.
Page 182 2) Put the floppy disk for the “APT” files into drive #1 3) Type: copy b:*.pro _c: and press return. All files will be copied to the hard drive. 4) Press f1 to go to APT or f10 to return to the machine system. Copyright November, 98 Page 14-24 Sodick Inc.
Page 183: Chapter 15 Crt Screens
When the control is sourced on, it will boot up with the parameter settings set the way they were when the machine was sourced off. Copyright November, 98 Page 15-1 Sodick Inc.
Page 184 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-2 Sodick Inc.
Page 185: Mal-Mdi Screen
Choose “MAL” and choose “MDI” to UN-highlight MDI mode. This screen displays the functions available in manual (MAL) mode in the middle. It is another way to do the things you usually do in the “MAL”,” MDI” screen. For example: To get the machine to Copyright November, 98 Page 15-3 Sodick Inc.
Page 186 “FILENAME:” and type the name of the file you want to run. Press “RETURN”. Now press “ENT” to execute the program. The machine will search for the program in memory first. If it doesn’t find the program in memory, it will search the hard drive. Copyright November, 98 Page 15-4 Sodick Inc.
Page 187 “RETURN” and it turns blue. Choose which axis you want to move, enter the value and press “RETURN”. Move the cursor to positioning move and press “RETURN” and “ENTER” and the machine will move even if the wire touches something. Copyright November, 98 Page 15-5 Sodick Inc.
Page 188 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-6 Sodick Inc.
Page 189: Edit, Graph Screen
LIMIT CHECK: When ON, it will tell you if the machine will hit a limit switch, when running the program. This does not replace dry run. Remember to be at the start point before graphing the program. Copyright November, 98 Page 15-7 Sodick Inc.
Page 190 MANUAL SCALE: When OFF, the control automatically scales the size of the picture to fit on the screen, usually OFF. When ON, you must define the size of picture you want on the screen using the XY MIN, MAX parameters below this parameter. Copyright November, 98 Page 15-8 Sodick Inc.
Page 191: Edit, Graph, Scrn Flag Input Screen
A CIRCLE POINT - When using G2 & G3, it compares the radius at the start and end points. If within the value specified in this parameter, the program will graph. Copyright November, 98 Page 15-9 Sodick Inc.
Page 192 0 - Leads in at an angle, and leads out at an angle. GRAPHIC SINGLE RUN - When turned on, it draws one line of NC code at a time in graphics. Press the Return key to continue drawing. Copyright November, 98 Page 15-10 Sodick Inc.
Page 193: Display Screen
Now press the time reset key .To restart the clock, press the key below time stop and then again to start the clock. Copyright November, 98 Page 15-11 Sodick Inc.
Page 194 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-12 Sodick Inc.
Page 195: Set Screen #1
SINGLE - When ON, the machine executes one line of NC code and stops. X-Y CHANGE - When ON, the X Axis becomes Y and the Y Axis becomes X: MIRROR X - When ON, it flips the program in the X-axis. Copyright November, 98 Page 15-13 Sodick Inc.
Page 196 0 (G14)= Wire break recovery turned off (T90-T91 codes still active). 1 (G13)= Returns with C888 power. 2 (G15)= Returns without power, but uses feedrate set by C888. TABLE TO LIMIT - See Chapter 8 Copyright November, 98 Page 15-14 Sodick Inc.
Page 197 TAPER IGNORE - Turns ON or OFF taper capability when G51 or G52 are in your program. If you want to cut straight, turn it ON. If you want to cut taper, turn it OFF. Copyright November, 98 Page 15-15 Sodick Inc.
Page 198 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-16 Sodick Inc.
Page 199: Set Screen #2 ( Roll Up Key )
OFF key will turn the CRT screen back on. If M00, M01 are read or the wire breaks during cutting, the screen turns on and stays on. When M02 is read the screen turns on and then back off. Copyright November, 98 Page 15-17 Sodick Inc.
Page 200 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-18 Sodick Inc.
Page 201: Set, Travel Screen #1
Table To Upper in the SET Screen. TWO LEVEL OFF - Only available on certain versions of software. When turned on and the machine is executing a program, you can press off and it will allow you to edit Copyright November, 98 Page 15-19 Sodick Inc.
Page 202 TWO LEVEL RESTART - When on and the “HALT” key is pressed or a stop is in the program the machine stops. If Z is moved and “RST” is pressed, Z returns and the machine stops again; you must press “RST” again to continue cutting. Copyright November, 98 Page 15-20 Sodick Inc.
Page 203: Set, Travel Screen #2
G22 and press “ENT”. To turn software limits off, type G23 and press “ENT”. SOFTWARE LIMITS IN/OUT - ON - Keeps you from entering a predetermined cube when outside of it. OFF - Keeps you from exiting a predetermined cube when inside of it. Copyright November, 98 Page 15-21 Sodick Inc.
Page 204 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-22 Sodick Inc.
Page 205: Set, Sir/Ptr Screen #2
Wire EDM Machine Operation Chapter 15 This is the RS232 parameter screen. This is the calendar screen. Please set up the correct parameters on your machine. Year Month Date Hour (military time) Minute Copyright November, 98 Page 15-23 Sodick Inc.
Page 206 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-24 Sodick Inc.
Page 207: Run Screen
When the picture of the program is on the screen, you can have the NC program on or off the screen by using the GRA.NC key. There is also other data that can be turned on or off with the GRA.DT key. Copyright November, 98 Page 15-25 Sodick Inc.
Page 208 Wire EDM Machine Operation Chapter 15 Copyright November, 98 Page 15-26 Sodick Inc.
Page 209: Selectinga Jog Speed
Note: The KYB/REM switch chooses between the remote or keyboard “ MFR” settings. If the switch is at KYB the remote still works, but it moves at the “MFR” speed set on the keyboard. Copyright November, 98 Page 16-1 Sodick Inc.
Page 210: T O Jog Xory
CRT and you will see the bottom of the CRT flicker and the axis will now be zero. LIGNMENT To align the wire set your alignment block on the work table. 1) Go to “MAL”, “MDI”. Copyright November, 98 Page 16-2 Sodick Inc.
Page 211 8) After the U & V Axis are aligned go to “MAL”, “MDI” and type G90 and press ENTER to go back to Absolute. 9) Type G97UV and press ENTER to zero out the U & V Axis in all 59 work coordinate screens. Copyright November, 98 Page 16-3 Sodick Inc.
Page 212 Wire EDM Machine Operation Chapter 16 Copyright November, 98 Page 16-4 Sodick Inc.
Page 213 An axis is showing a negative number. The machine is too close to a limit switch. PUT 0 AT FOURTH DECIMAL POINT OF U,V AXIS The U or V axis is not truly zeroed out. Go to MAL, MDI and type G92 UV and press enter. Copyright November, 98 Page 17-1 Sodick Inc.
Page 214 UV AXIS PRESENTLY RUNNING IS NOT ZERO - The wire is not square. Move the U and V axis to zero to square the wire and retry the procedure you’re attempting. Copyright November, 98 Page 17-2 Sodick Inc.

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SODICK A320D Manual

Chapter 1 Description of the Edm Process

Chapter 2 Machine Layout Description

Chapter 3 Program Zero Description

Chapter 4 Program Makeup

Chapter 5 The Four Kinds of Wire Motion

Chapter 6 Description of Programming Codes and Words

Chapter 7 Wire Offset Description

Chapter 15 Crt Screens

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