CNC EDM WIRECUT WORKBOOK FOR MECHANICAL WORKSHOP PRACTICE by PolisasLib3

CNC EDM WIRECUT WORKBOOK FOR MECHANICAL WORKSHOP PRACTICE

MAZLAN BIN OMAR NORAZLINA BINTI ABDUL RAHMAN

Politeknik Sultan Haji Ahmad Shah

Published by POLITEKNIK SULTAN HAJI AHMAD SHAH SEMAMBU 25350 KUANTAN

Copyright ©2022, by Politeknik Sultan Haji Ahmad Shah Materials published in this book under the copyright of Politeknik Sultan Haji Ahmad Shah. All rights reserved. No part of this publication may be reproduced or distributed in any form or by means, electronic, mechanical, photocopying, recording, or otherwise or stored in a database or retrieval system without the prior written permission of the publishers.

TABLE OF CONTENT Page Table of content

Preface

Mechanical Workshop Practice Information

Course Name

Course Synopsis

Course Learning Outcomes

Course Content

Introduction of CNC EDM Wirecut

Characteristic of the Machine

Major Components

Equipmets

Types of Wire

Advantages

Disadvantages

CNC Programming

Safety Precautions

Personal Safeguards

Machine and tool handling safeguards

Safe machining practices

Shop environment safeguards

Standard Operation Procedure

The CNC EDM Wirecut Machine Control Panel

CNC Programming

1. Diagnostics (Select Language)

2. Illumination (On Lamp)

3. Program Setting (Insert Manually CNC Programming)

Tutorial Questions and Answers

Practical Task CNC EDM Wirecut and Rubric

Report CNC EDM Wirecut and Rubric

Reference

59 i

PREFACE CNC EDM Wirecut workbook is created for a learning purpose in Diploma of Mechanical Engineering level. This eBook is intended to be a guideline for a student to learn and gain input of knowledge of practical in CNC EDM Wirecut operation. This eBook contains with theoretical knowledge and standard operation procedure of the CNC EDM Wirecut processes, tutorial question, practical task drawing and the marking rubrics for the practical task and reports. During the practical session, students were given briefing and demonstration first. The theoretical knowledge included in the eBook, acts as an early briefing to start the practical task. Theoretical knowledge is important as an early exposure and preparation for starting the practical task. Several textbooks and articles are used to provides references sources for theoretical knowledge of the CNC EDM Wirecut processes.

Mazlan bin Omar Norazlina binti Abdul Rahman

Cnc Edm Wirecut For Mechanical Workshop Practice

MECHANICAL WORKSHOP PRACTICE INFORMATION

Cnc Edm Wirecut For Mechanical Workshop Practice

COURSE NAME Mechanical Workshop Practice 4

COURSE SYNOPSIS MECHANICAL WORKSHOP PRACTICES 4 course allows the students to operate machine tools, precision grinding, CNC machine and able to work in a clean and safe workshop environment.

COURSE LEARNING OUTCOMES Upon completion of this course, students should be able to: 1. CLO1 - Perform high precision machining processes for the surface or cylindrical grinding machine. (P4, PLO5) 2. CLO2 - Construct programs for EDM and CNC machining process using ISO codes or any related machining software. (P5, PLO3) 3. CLO3 - Demonstrate safety procedures in the workshop according to the workshop safety regulation correctly to create a secured environment in an organization while doing practical work and ability to work in team to complete assigned tasks during practical work sessions. (A3, PLO7)

COURSE CONTENT

TOPIC

CNC EDM WIRECUT

COURSE CONTENT Computer Numerical Control Machines (CNC) And Machining Software 1. Operate the CNC Machines and using any related Machining Software 2. Follow Standard Operation Procedure (SOP) to keep working area clean and safe

CLO

ASSESSMENT

PRACTICAL TASK

REPORT

Cnc Edm Wirecut For Mechanical Workshop Practice

INTRODUCTION OF CNC EDM WIRECUT

Cnc Edm Wirecut For Mechanical Workshop Practice

1. INTRODUCTION OF EDM WIRECUT

Figure 1 : CNC EDM Wirecut

In CNC wirecut electrical discharge machining (WCEDM), also know as CNC EDM wirecut and wire cutting as shown in figure 1, a thin single-strand metal wire, usually brass, is fed through the work piece, submerged in a tank of dielectric fluid typically deionized water. EDM wirecut is typically used to cut plates as thick as 300mm and to make punches, tools and dies from hard metals that are difficult to machine with other methods. The wire, which is constantly fed from a spool, is held between upper and lower diamond guides. The guides, usually CNC-controlled, move in the x-y plane. On most machines, the upper guide can also move indenpently in the z-u-v- axis, giving rise to the ability to cut tapered and transitioning shapes (circle on the bottom square at the top for example). The upper guide can control axis

Cnc Edm Wirecut For Mechanical Workshop Practice

movements in x-y-u-v-i-j-k-l. This allows the EDM wirecut to be programmed to cut very intricate and delicate shapes. In wirecut cutting process, a thin metallic wire is fed on to the piece, which is submerged in a tank of dielectric fluid, such as deionized water. The wire, which is constantly fed from a spool, is held between upper and lower diamond guides. The guides are usually CNC controlled. In the EDM wirecut process, water is commonly used as the dielectric fluid. Filters and de-ionizing units are used for controlling the resistivity and other electrical properties. Wires made of brass are generally preferred. The area where in discharge takes place gets heated to very high temperature such that the surface gets melted and removed. The cut particles (debris) get flushed away by the continuously flowing dielectric fluid and keep the wire and workpiece cool. The wire and workpiece must be electrically conductive.

2. CHARACTERISTICS OF THE MACHINE

MODEL ONA PRIMA E250 X – Y axes stroke (mm)

350 x 250

Z axis stroke (mm)

200

U – V axes stroke (mm)

80 x 80

Maximum workpiece size (X,Y,Z) (mm)

910 x 680 x 200

Maximum workpiece weight (kg)

500

Taper cutting maximum angle

300

Wire spool

DIN125 – DIN160

Wire guide

Closed diamond guide

Cnc Edm Wirecut For Mechanical Workshop Practice

3. MAJOR COMPONENTS

A wire EDM system is comprised of four major components

Computerized Numerical Control (CNC) Process is controlled by CNC.

Power Supply Provides energy to the spark.

Mechanical Section Worktable, workstand, taper unit and wire drive mechanism

Dielectric System

The water reservoir where filtration, condition of water (resistivity/conductivity) and temperature of water is provided and maintained.

Cnc Edm Wirecut For Mechanical Workshop Practice

4. EQUIPMENTS a)

POWER SUPPLY

It transforms the AC to DC

DIELECTRIC SYSTEM

Dielectric fluid

Delivery devices

Pumps

Filters

ELECTRODES

SERVO SYSTEMS

5. TYPES OF WIRE a)

COPPER First material used in EDM wire cut but today it is used to machines with power supply designed for copper wire.

BRASS First logical alternative to copper. It is a combination of copper and zinc, typically alloyed in the range of 63-65% copper and 35-37% zinc.

COATED It is called “stratified wire” having a core of brass or copper for conductivity and tensile strength, electroplated with coating of pure or diffused zinc for enhanced spark formation and flush characteristics.

FINE WIRES (MOLY & TUNGSTEN) High precision work on EDM wire cut machines and advantage for small diameter work with range of 0.001-0.004. It is used as substitute to low load carrying capacity of brass and coated wire.

Cnc Edm Wirecut For Mechanical Workshop Practice

6. ADVANTAGES

a) Machining time is less than the conventional machining process. b) Any completed shape that can be made on the tool can be reproduced on the work piece. c) The process can be employed for extremely hardened work piece. d) The process can be applied to all electrically conducting metals and alloys irrespective of their melting points. e) Brittle and slender work pieces can be machined with out distortion. f)

Considerably easier and more economical polishing can be done on the catering type surface developed by EDM.

g) Fine holes can be easily drilled. h) Enables high accuracy on tools and dies, because they can be machined in as hard condition.

7. DISADVANTAGES a) It can not be applied to non conducting materials. b) Power required is very high compared to conventional machining processes. c) In some material surface cracking may take place. d) Sharp corners can not be produced. e) Material removal rate is slow. f)

Surface tends to be rough for larger removal rates.

Cnc Edm Wirecut For Mechanical Workshop Practice

8. CNC PROGRAMMING There are three basic CNC machine programming methods 1. manual 2. conversational 3. CAM system

Manual •With manual programming, the operator inputs code manually, which can be time-consuming and somewhat tedious. It also requires intimate knowledge of the programming language. However, manual programming is a valuable foundational skill set to have on hand, and it’s an effective way to make quick modifications to CAM outputs and optimize code.

Conversational •Conversational or “shop-floor” programming is an increasingly popular method that involves graphic and menu-driven functions. Operators input commands directly into the CNC machine, just like in manual programming, which alleviates potential issues that may arise from poor post processors in CAM.

CAM system •CAM system programming is similar to the conversational method, but more advanced. With a CAM system, the software provides an advanced GUI with tool path strategies to help the operator prepare and generate the program — eliminating the need for any manual programming — and transfer it directly to the CNC machine.

All these CNC machine programming methods involve G-code and M-code. G-code is the programming language that instructs the CNC machine what to do, facilitating accurate and repeatable parts. Mcode controls all the miscellaneous CNC machine functions, such as spindle rotation start and stop. M-codes are customizable and vary by machine, so operators and programmers must double-check they’re inputting the right functions before they start machining.

Cnc Edm Wirecut For Mechanical Workshop Practice

Machine functions for immediate execution or for programming 1. END :

End of program

2. SETT : Setting of COOR (new coordinates), DECA (decalaje-offset), CTOL (contact tolerance for centering), OFFN (wire offset number), TPAN (taper cutting angle), ANG (angle increment degrees). 3. INTP : Interpolation LINE (linear), CIR+ (circular anti-clockwise), CIR- (circular clockwise) 4. ABS :

Absolute

5. INCR : Incremental 6. TRAV : Rapid traverse to X, Y, U, V, PNT (point) 7. GSET : Generator setting parameters by means of workpiece Thickness, Criterion, Technology 8. SET :

Set generator parameters

9. DWE : Dwel time (off-time), INP (until the input number is activated/deactivated), ULTD (unlimited) 10. EXMD : Execution mode (normal or dry run) 11. ATHR : Auto wire threading (optional) 12. WCUT : Wire cut (optional) 13. OFFC : Cancel offset 14. OFFR : Offset by the right 15. OFFL : Offset by the left 16. TPRC : Cancel taper cutting 17. TPRR : Taper cutting by the right 18. TPRL : Taper cutting by the left 19. METR : Metric 20. INCH : Inches 21. VECT : Vector of length, ANG (angle), FEDD, OFFN (wire radius offset), TPAN (taper cutting angle) 22. VERT : Automatic wire verticality adjustment (optional) 23. MPRT : Memorize actual position (in working coordinates) to reverse point 24. MOFF : Memorize actual position (machine coordinates) in offset

Cnc Edm Wirecut For Mechanical Workshop Practice

G-FUNCTIONS ISO-CODE

DESCRIPTION

G00

Rapid traverse

G01

Linear interpolation

G02

Clockwise circular interpolation

G03

Anticlockwise circular interpolation

G04

Dwell

G05

Input wait

G10

Vector

G26

Jump

G27

Assigment

G28

Constant angle taper cutting mode

G29

Sharp angle taper cutting mode

G30

Constant radius taper cutting mode

G39

Rotation

G40

Compensation cancelled

G41

Left compensation

G42

Right compensation

G45

X axis reversal

G46

Y axis reversal

G47

Activate chamferings

G48

Activate roundings

G49

Deactivate roundings/chamferings

G50

Cancel taper cutting

G51

Taper cutting by the left

G52

Taper cutting by the right

G54

Offset setting

G61

Setting of angle increment

G62

Setting of offset

G63

Setting of contacts tolerance

G64

Setting taper angle

G65

Setting of rounding radius 11

Cnc Edm Wirecut For Mechanical Workshop Practice G66

Setting of chamfers length

G69

Generator setting

G70

Inches

G71

Metric

G74

Automatic return to start

G82

Memorize actual position in working coordinates to traverse point

G83

Memorize actual position in machine coordinates to traverse point

G84

Memorize actual position in machine coordinates in offset

G90

Absolute

G91

Incremental

G92

Coordinate setting

G95

Scale

G96

Axes change Y X

G97

Axes change X Y

G98

Programmed coordinates origin

M-FUNCTIONS ISO-CODE

DESCRIPTION

M00

Unlimited dwell (programmed stop)

M01

End of program

M25

Contact workpiece on X axis

M26

Contact workpiece on Y axis

M27

Contact workpiece on U axis

M28

Contact workpiece on V axis

M31

Program generator parameter : dielectric

M32

Program generator parameter : offtime

M33

Program generator parameter : power

M34

Program generator parameter : flocculant OFF

M35

Program generator parameter : feedrate

M38

Program generator parameter : gap

M44

Start generator

M47

Activate output

M48

Automatically adjust wire verticality 12

Cnc Edm Wirecut For Mechanical Workshop Practice M50

Wire cutting

M51

Program generator parameter : voltage

M52

Program generator parameter : wire stress

M53

Program generator parameter : wire feedrate

M54

Program generator parameter : corner correct

M60

Auto wire threading

M65

Inner centering on X

M66

Inner centering on Y

M67

Inner centering on U

M68

Inner centering on V

M72

Dry run mode

M73

Normal mode

M75

Center piece in axis X

M76

Center piece in axis Y

M77

Center piece in axis U

M78

Center piece in axis V

M84

Program generator parameter : Inversion ON

M85

Program generator parameter : Inversion OFF

M87

Deactivate output

M94

Program generator parameter : Finishing ON

M95

Program generator parameter : Finishing OFF

M96

Macro

M98

Subroutine

M99

Subroutine return

The absolute and incremental commands ( G90, G91 ) Movements can be specified in two ways: i)

Absolute (G90) – The absolute command specifies the coordinates of the point at which movement terminates.

ii)

Incremental (G91) – The incremental command specifies the distance moved relative to the current position.

Cnc Edm Wirecut For Mechanical Workshop Practice

SAFETY PRECAUTIONS

Cnc Edm Wirecut For Mechanical Workshop Practice

SAFETY PRECAUTIONS A. Personal Safeguards 1.

Wear approved safety glasses with side shields at all times in designated areas.

Wear safety shoes when working with heavy tools and equipment.

Wear hearing protection for noise.

Wear an approved face mask for dusk.

Keep long hair covered when operating or standing near machines.

Do not wear jewelry or loose clothing while operating or standing near machines.

Lift with the legs, not the back.

Avoid skin contact with any cutting fluids or oils.

Do not operate any machines or equipment while under the influence of drugs (prescribed or otherwise).

10. Always report any injury and apply first-aid treatment.

B. Machine and tool handling safeguards 1.

Store tools in their appropriate tool trays and racks.

Keep tools sharp and in good working condition.

Ensure that safety guards and devices are in place and working before operating any machine.

Keep all electrical and mechanical panels secures in place.

Do not handle loose wires or electrical components.

Check that all oil levels are maintained.

Check that all compressed air equipment is in good working condition.

Do not use compressed air to clean machine slides.

Keep tools, parts and any other items off the machine and part.

10. Use gloves when handling tools by their cutting edges. 11. Never use gloves when operating a machine. 12. Check that the machine is electrically sound and use lock-out tag-out practices. 13. Check that all lights in the machine work area are in good working condition. 14. Keep clear from obstructions and sharp tools when leaning into the machine area.

Cnc Edm Wirecut For Mechanical Workshop Practice

C. Safe machining practices. 1.

In case of any emergency while operating a machine, immediately press the Emergency Stop button.

Keep hands away from the spindle while it rotating.

Do not open the electrical panel or control doors.

Keeps hand clear of all moving machine components.

Check each tool for possible collisions with the part or machine components before starting any operation.

Do not operate controls unless you have been properly instructed about the Emergency Stop button, Feed Hold button, Spindle Stop button and the various other operation functions.

Use caution to avoid inadvertently bumping any CNC control buttons.

Prove out new programs in Dry Run mode before actual cutting.

Setup the work holding device and cutting tools as rigidly as possible.

10. Do not remove chips or debris by hand or while the spindle is on or in operation. 11. Check that all feeds and speeds do not exceed recommended values. 12. Maintain continuous flow of coolant to the cutting tool when it is required. 13. Always consult with an authorized person if you are uncertain or unfamiliar with any operation.

D. Shop environment safeguards. 1. Remove chips from the floor 2. Clean all liquid, oil and grease spills immediately. 3. Keep floors and walk aisles clean 4. Report any fumes or odors.

Cnc Edm Wirecut For Mechanical Workshop Practice

STANDARD OPERATION PROCEDURE

Cnc Edm Wirecut For Mechanical Workshop Practice

FLOW OF STANDARD OPERATION PROCEDURE (S.O.P)

A. THE EDM WIRECUT MACHINE CONTROL PANEL To turn on the EDM Wirecut Machine, we must know about the EDM Wirecut Machine control panel

EMERGENCY STOP – It disconnects the equipment

OPEN ARCH VOLTAGE INDICATOR

SHORT CIRCUIT INDICATOR

LOW VOLTAGE INDICATOR MAIN LIGHT – Indicates if the electrical switch is active (ON) or not (OFF)

GENERAL OFF BUTTON – By means of this switch protected to avoid wrong manipulations, power supply to the equipment is turned off

GENERAL ON BUTTON – This is the button for supplying power to all equipment. It remains illuminated while power allows the initiation of any operation 18

Cnc Edm Wirecut For Mechanical Workshop Practice

Ammeter

This device shows the average work current in the wire.

Volmeter

It shows the average voltage between the wire and the work piece.

B. CNC PROGRAMMING

As mentioned before, there are three basic CNC machine programming methods; manual, conversational and CAM system. In this workbook, we focus on manual programming method only.

Cnc Edm Wirecut For Mechanical Workshop Practice

1. DIAGNOSTICS (select language) The language used in programming on the ONAPRIMA machine is an assisted language for block formation, and its representation in ISO format. Follow steps below to select English language: 1.1 When the CNC EDM Wirecut is turn on, the Cathode Ray Tube (C.R.T) screen display as shown in Figure 1.1

Figure 1.1: C.R.T Screen Display at the starting

1.2 Press F8 at the control panel to choose DIAGNOSTIC (F8 DIAG). The control panel display as shown in figure 1.2

Figure 1.2: Control Panel Display

Cnc Edm Wirecut For Mechanical Workshop Practice

1.3 The C.R.T display after pressing F8 is shown in figure 1.3

Figure 1.3: C.R.T Screen Display after choose DIAGNOSTIC

1.4 Press page selector

and the C.R.T Screen display is shown in figure 1.4

Figure 1.4: C.R.T Screen Display after press page selector

1.5 Press cursor movement keys selector keys

to move cursor up and down. Press option

to choose the language and press ENTER. The C.R.T Screen

display after finish choosing English language as shown in figure 1.5

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 1.5: C.R.T Screen Display after finish select English language

ILLUMINATION (on lamp) Follow steps below to on the machine lamps: 2.1 When the CNC EDM Wirecut is turn on, the lamp is turn off as shown in figure 2.1

Figure 2.1: CNC Wirecut EDM machine when lamps are still off

Cnc Edm Wirecut For Mechanical Workshop Practice

2.2 Press F1 to make sure we start from BASE as shown in figure 2.2

Figure 2.2: C.R.T Screen base display

2.3 Press F5 to choose MACH. The C.R.T Screen display after pressing F5 as shown in figure 2.3

Figure 2.3: C.R.T Screen MACH display

Cnc Edm Wirecut For Mechanical Workshop Practice

2.4 Press page selector

and the C.R.T Screen display is shown in figure 2.4

Figure 2.4: C.R.T Screen Display after press page selector

2.5 Press cursor movement keys selector keys

to move cursor up and down. Press option

to change the MACHINE ILLUMINATION from OFF to ON.

The C.R.T Screen display after on the machine lamps as shown in figure 2.5

Figure 2.5: C.R.T Screen Display after on the machine lamps

Cnc Edm Wirecut For Mechanical Workshop Practice

2.6 Figure 2.6 shown the CNC EDM Wirecut machine when the machine lamps is ON

Figure 2.6: Wirecut EDM machine when the machine lamps is ON

PROGRAM SETTING (insert manually CNC programming) As example, we will insert manually CNC programming for cutting our workpiece to the shape in figure 3 below. In this example, we will using absolute coordinate system.

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3: Absolute Coordinate System

3.1 PROGRAMMING NUMBER SETTING: Press F3 at the control panel to choose PROGRAM (F3 PROG). Press cursor movement keys

for reset the field PRG. NR

to another new program number. For this example, we insert PRG. NR with 11 and press ENTER to confirm. Press F2 at the control panel to choose EDIT (F2 EDIT). The C.R.T. Screen display as shown in figure 3.1.

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.1: C.R.T Screen Display after choose PROGRAM

3.2 SETTING OF ABSOLUTE (G90): At the control panel, press F8 to choose ETC (F8 ETC). Then press F4 to choose ABS (F4 ABS) and Press F4 to choose ETC (F4 ETC) before press ENTER. The C.R.T. Screen display as shown in figure 3.2.

Figure 3.2: C.R.T Screen Display for G90 (Absolute)

3.3 OFFSET SETTING (G54): At the control panel, press F8 to choose ETC (F8 ETC). Then, press F2 to choose SETTING (F2 SETT) and press F2 to choose DECA (F2 DECA). DECA is meant change of origin of the work coordinates. The DECA that will be used by number in the program from 0 to 255. Example Insert the value 12 and press ENTER. The C.R.T. Screen display as shown in figure 3.3.

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.3: C.R.T Screen Display for G54 (Offset Setting)

3.4 SETTING OF RAPID TRAVERSE (G00): At the control panel, press F8 to choose ETC (F8 ETC) and press F6 to choose TRAVERSE (F6 TRAV). Then, press F2 and insert value of X (insert 0). After that, press F3 and insert value of Y (insert 0). Lastly press F6, insert value of Z (insert 0) and press ENTER. The C.R.T. Screen display as shown in figure 3.4.

Figure 3.4: C.R.T Screen Display for G00 (Rapid Traverse)

3.5 GENERATOR SETTING (G69): At the control panel, press F8 2 times to choose ETC (F8 ETC) and press F1 to choose GENERATOR SETTING (F1 GSET). Insert 10 for generator setting with thickness. Then, press F2 to choose CRITERION (F2 CRIT) and insert 0 for the value of criterion. After that, press F2 to choose TECHNOLOGY (F2 TEC) and insert 4 for value of technology (see table). Press ENTER and the C.R.T. Screen display as shown in figure 3.5.

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.5: C.R.T Screen Display for G69 (Generator Setting)

3.6 SETTING OF PROGRAM GENERATOR PARAMETER- OFFTIME (M32): At the control panel, press F8 2 times to choose ETC (F8 ETC) and press F2 to choose SETTING (F2 SET). Then, press F2 to choose OFFTIME (F2 OFFTIME) and insert 28 for value of offtime. Press ENTER and the C.R.T. Screen display as shown in figure 3.6.

Figure 3.6: C.R.T Screen Display for M32 (Program Generator Parameter: OFFTIME)

3.7 SETTING OF LEFT COMPENSATION (G41): At the control panel, press F8 6 times to choose ETC (F8 ETC) and press F3 to choose OFFSET LEFT (F3 OFFL). Press ENTER and the C.R.T. Screen display as shown in figure 3.7.

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.7: C.R.T Screen Display for G41 (Left Compensation)

3.8 SETTING OF RAPID TRAVERSE (G00): At the control panel, press F8 to choose ETC (F8 ETC) and press F6 to choose TRAVERSE (F6 TRAV). Then, press F2 and insert value of X (insert 5). After that, press F3 and insert value of Y (insert 2). Press ENTER and the C.R.T. Screen display as shown in figure 3.8.

Figure 3.8: C.R.T Screen Display for G00 (Rapid Traverse)

3.9 SETTING OF LINEAR INTERPOLATION (G01): At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 5). After that, press F3 and insert value of Y (insert -10). Press ENTER and the C.R.T. Screen display as shown in figure 3.9.

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.9: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (5,-10)

3.10 At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 15). After that, press F3 and insert value of Y (insert -10). Press ENTER and the C.R.T. Screen display as shown in figure 3.10.

Figure 3.10: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (15,-10)

3.11 SETTING OF CLOCKWISE CIRCULAR INTERPOLATION (G02): At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F2 to choose CLOCKWISE CIRCULAR (F2 CIR_). Press F2 and insert value of X (insert 25). After that, press F3 and insert value of Y (insert -10). Press F7 to choose CENTER (F7 CENT). Press F2 and insert value of X (insert 5). After that, press F3 and insert value of Y (insert 0). Press ENTER and the C.R.T. Screen display as shown in figure 3.11 31

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.11: C.R.T Screen Display for G02 (Clockwise Circular Interpolation); second coordinate of circular (25,-10) with center (5,0) from the first coordinate of circular

3.12 SETTING OF LINEAR INTERPOLATION (G01): At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 35). After that, press F3 and insert value of Y (insert -10). Press ENTER and the C.R.T. Screen display as shown in figure 3.12.

Figure 3.12: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (35,-10)

3.13 At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 35). After that, press F3 and insert value of Y (insert -20). Press ENTER and the C.R.T. Screen display as shown in figure 3.13.

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.13: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (35,-20)

3.14 SETTING OF COUNTERCLOCKWISE CIRCULAR INTERPOLATION (G03): At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F3 to choose COUNERCLOCKWISE CIRCULAR (F2 CIR+). Press F2 and insert value of X (insert 35). After that, press F3 and insert value of Y (insert -30). Press F7 to choose CENTER (F7 CENT). Press F2 and insert value of X (insert 0). After that, press F3 and insert value of Y (insert -5). Press ENTER and the C.R.T. Screen display as shown in figure 3.14.

Figure 3.14: C.R.T Screen Display for G03 (Counterclockwise Circular Interpolation); second coordinate of circular (35,-30) with center (0,-5) from the first coordinate of circular

Cnc Edm Wirecut For Mechanical Workshop Practice

3.15 SETTING OF LINEAR INTERPOLATION (G01): At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 35). After that, press F3 and insert value of Y (insert -40). Press ENTER and the C.R.T. Screen display as shown in figure 3.15.

Figure 3.15: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (35,-40)

3.16 At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 22.5). After that, press F3 and insert value of Y (insert -40). Press ENTER and the C.R.T. Screen display as shown in figure 3.16.

Figure 3.16: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (22.5,-40)

Cnc Edm Wirecut For Mechanical Workshop Practice

3.17 SETTING OF COUNTERCLOCKWISE CIRCULAR INTERPOLATION (G03): At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F3 to choose COUNTERCLOCKWISE CIRCULAR (F3 CIR+). Press F2 and insert value of X (insert 17.5). After that, press F3 and insert value of Y (insert 35). Press F7 to choose CENTER (F7 CENT). Press F2 and insert value of X (insert -5). After that, press F3 and insert value of Y (insert 0). Press ENTER and the C.R.T. Screen display as shown in figure 3.17.

Figure 3.17: C.R.T Screen Display for G03 (Counterclockwise Circular Interpolation); second coordinate of circular (17.5,-35) with center (-5,0) from the first coordinate of circular

3.18 SETTING OF LINEAR INTERPOLATION (G01): At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 17.5). After that, press F3 and insert value of Y (insert -40). Press ENTER and the C.R.T. Screen display as shown in figure 3.18

Cnc Edm Wirecut For Mechanical Workshop Practice

Figure 3.18: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (17.5,-40)

3.19 At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 5). After that, press F3 and insert value of Y (insert -40). Press ENTER and the C.R.T. Screen display as shown in figure 3.19.

Figure 3.19: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (5,-40)

Cnc Edm Wirecut For Mechanical Workshop Practice

3.20 At the control panel, press F8 to choose ETC (F8 ETC) and press F3 to choose INTERPOLATION (F3 INTP). Then, press F1 to choose LINEAR (F1 LINE). Press F2 and insert value of X (insert 5). After that, press F3 and insert value of Y (insert 2). Press ENTER and the C.R.T. Screen display as shown in figure 3.20.

Figure 3.20: C.R.T Screen Display for G01 (Linear Interpolation) for coordinate (5,2), out of the workpiece

3.21 COMPENSATION CANCELLED (G40): At the control panel, press F8 6 times to choose ETC (F8 ETC). Then press F2 to choose OFFSET CANCELLED (F2 OFFC) and press ENTER. The C.R.T. Screen display as shown in figure 3.21.

Figure 3.21: C.R.T Screen Display for G40 (Compensation Cancelled)

Cnc Edm Wirecut For Mechanical Workshop Practice

3.22 END OF PROGRAM (M02): At the control panel, press F8 6 times to choose ETC (F8 ETC). Then press F1 to choose END (F1 END) and press ENTER. The C.R.T. Screen display as shown in figure 3.22.

Figure 3.22: C.R.T Screen Display for M02 (End of Program)

3.23 SIMULATION: At the control panel, press F1 to choose FEDI (F1 FEDI), make C.R.T Screen Display return to BASE. Then press F4 to choose EXEC (F4 EXEC) and press F5 to choose GRAPH (F5 GRPH). After that, press F8 to choose DELT (F8 DELT), press F7 to choose AXIS (F7 AXIS), press F6 to choose SCALE (F6 SCAL) and press F4 to choose SIMULATION (F4 SIMU). The C.R.T. Screen display as shown in figure 3.23.

Figure 3.23: Simulation of the CNC programming

Cnc Edm Wirecut For Mechanical Workshop Practice

CNC PROGRAMMING (G AND M CODE)

Figure 4: Example of CNC EDM Wirecut practical task

G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

G00 RAPID TRAVERSE X = 5, Y = 2

N0007 G00

X5 Y2

A. G01 X = 5, Y = -10

N0008 G01

X5 Y-10

B. G01 X = 15, Y = -10

N0009 G01

X15 Y-10

N0010 G02

X25 Y-10 I5 J0

D. G01 X = 35, Y = -10

N0011 G01

X35 Y-10

E. G01 X = 35, Y = -20

N0012 G01

X35 Y-20

N0013 G03

X35 Y-30 I0 J-5

G. G01 X = 35, Y = -40

N0014 G01

X35 Y-40

H. G01 X = 22.5, Y = -40

N0015 G01

X22.5 Y-40

N0016 G03

X17.5 Y-35 I-5 J0

G01 INTERPOLATION

C. G02 X = 25, Y = -10

F. G03 X = 35, Y = -30

G03 X = 17.5, Y = -35

I = 5, J = 0

I = 0, J = -5

I = -5, J = 0

Cnc Edm Wirecut For Mechanical Workshop Practice

G01 X = 17.5, Y = -40

N0017 G01

X17.5 Y-40

K. G01 X = 5, Y = -40

N0018 G01

X5 Y-40

L. G01 X = 5, Y = 2

N0019 G01

X5 Y2

G40 CANCEL OFFSET

N0020 G40

M02 END PROGRAM

N0021 M02

QUICK TIPS: ROUNDING RADIUS There are two interpolation circular setting: i)

F2 CIR_

– Interpolation circular clockwise

ii)

F3 CIR+

– Interpolation circular counterclockwise

Cnc Edm Wirecut For Mechanical Workshop Practice

QUICK TIPS: MAIN PROGRAM SETTING 1. G90/ABSOLUTE F8 ETC

F4 ABS

F8 ETC

ENTER

2. G54/SETTING OF DECA F8 ETC

F2 SETT

INSERT VALUE

F2 DECA

ENTER

3. G00/RAPID TRAVERSE F8 ETC

F6 TRAV

F2 INSERT

F3 INSERT

VALUE X

VALUE Y

ENTER

4. G69/GENERATOR SETTING F8 ETC 2X

F1 GSET

F2 CRIT

F2 TEC

ENTER

5. M32/PROGRAM GENERATOR SETTING F8 ETC 2X

F2 OFFTIME

F2 SET

ENTER

6. G41/OFFSET BY LEFT F8 ETC 6X

ENTER

F3 OFFL

7. G01/INTERPOLATION (DEPENDS ON THE DRAWING) F8 ETC

F3 INTP

F1 LINE

F2 INSERT

F3 INSERT

VALUE X

VALUE Y

ENTER

8. GO2/G03 F8 ETC

F3 INTP

F2 CIR_ @ F3 CIR+

F2 INSERT VALUE X

F3 INSERT VALUE Y

F7 CENT

F2 INSERT VALUE X

F3 INSERT VALUE Y

ENTER

9. G40/CANCEL OFFSET F8 ETC 6X

F1 OFFC

ENTER

10. M02/END OF PROGRAM F8 ETC

F1 END

ENTER

Cnc Edm Wirecut For Mechanical Workshop Practice

TUTORIAL QUESTIONS AND ANSWERS

Cnc Edm Wirecut For Mechanical Workshop Practice

1. Construct the CNC EDM Wirecut programming for Figure 1 below.

Figure 1: Tutorial 1

2. Construct the CNC EDM Wirecut programming for Figure 2 below.

Figure 2: Tutorial 2

Cnc Edm Wirecut For Mechanical Workshop Practice

3. Construct the CNC EDM Wirecut programming for Figure 3 below.

Figure 3: Tutorial 3

4. Construct the CNC EDM Wirecut programming for Figure 4 below.

Figure 4 : Tutorial 4

Cnc Edm Wirecut For Mechanical Workshop Practice

5. Construct the CNC EDM Wirecut programming for Figure 5 below.

Figure 5: Tutorial 5

6. Construct the CNC EDM Wirecut programming for Figure 6 below.

Figure 6: Tutorial 6

Cnc Edm Wirecut For Mechanical Workshop Practice

7. Construct the CNC EDM Wirecut programming for Figure 7 below.

Figure 7: Tutorial 7

Cnc Edm Wirecut For Mechanical Workshop Practice

ANSWER : TUTORIAL 1 G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

A. G00 X = 5, Y = 2

N0007 G00

X5 Y2

B. G01 X = 5, Y = -5

N0008 G01

X5 Y-5

C. G01 X = 15, Y = -5

N0009 G01

X15 Y-5

N0010 G03

X25 Y-5 I5 J0

E. G01 X = 45, Y = -5

N0011 G01

X45 Y-5

F. G03 X = 55, Y = -5 I = 5, J = 0

N0012 G03

X55 Y-5 I5 J0

G. G01 X = 70, Y = -5

N0013 G01

X70 Y-5

H. G01 X = 75, Y = -8

N0014 G01

X75 Y-8

G01 X = 75, Y = -10

N0015 G01

X75 Y-10

G01 X = 70, Y = -13

N0016 G01

X70 Y-13

K. G01 X = 50, Y = -15

N0017 G01

X50 Y-15

L. G01 X = 42, Y = -23

N0018 G01

X42 Y-23

M. G01 X = 26, Y = -23

N0019 G01

X26 Y-23

N. G01 X = 20, Y = -15

N0020 G01

X20 Y-15

O. G01 X = 5, Y = -15

N0021 G01

X5 Y-15

P. G01 X = 5, Y = 2

N0022 G01

X5 Y2

G40 CANCEL OFFSET

N0023 G40

M02 END PROGRAM

N0024 M02

D. G03 X = 25, Y = -5

I = 5, J = 0

Cnc Edm Wirecut For Mechanical Workshop Practice

TUTORIAL 2 G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

A. G00 X = 5, Y = 2

N0007 G00

X5 Y2

B. G01 X = 5, Y = -40

N0008 G01

X5 Y-40

C. G01 X = 10, Y = -40

N0009 G01

X10 Y-40

D. G01 X = 10, Y = -10

N0010 G01

X10 Y-10

E. G01 X = 15, Y = -5

N0011 G01

X15 Y-5

F. G01 X = 20, Y = -10

N0012 G01

X20 Y-10

G. G01 X = 20, Y = -20

N0013 G01

X20 Y-20

H. G01 X = 40, Y = -20

N0014 G01

X40 Y-20

G01 X = 40, Y = -10

N0015 G01

X40 Y-10

G01 X = 45, Y = -5

N0016 G01

X45 Y-5

K. G01 X = 50, Y = -10

N0017 G01

X50 Y-10

L. G01 X = 50, Y = -40

N0018 G01

X50 Y-40

M. G01 X = 55, Y = -40

N0019 G01

X55 Y-40

N. G01 X = 55, Y = -45

N0020 G01

X55 Y-45

O. G01 X = 35, Y = -45

N0021 G01

X35 Y-45

P. G01 X = 35, Y = -40

N0022 G01

X35 Y-40

Q. G01 X = 40, Y = -40

N0023 G01

X40 Y-40

R. G01 X = 40, Y = -25

N0024 G01

X40 Y-25

S. G01 X = 20, Y = -25

N0025 G01

X20 Y-25

T. G01 X = 20, Y = -40

N0026 G01

X20 Y-40

U. G01 X = 25, Y = -40

N0027 G01

X25 Y-40

V. G01 X = 25, Y = -45

N0028 G01

X25 Y-45

W. G01 X = 5, Y = -45

N0029 G01

X5 Y-45

X. G01 X = 5, Y = 2

N0030 G01

X5 Y2

G40 CANCEL OFFSET

N0031 G40

M02 END PROGRAM

N0032 M02 48

Cnc Edm Wirecut For Mechanical Workshop Practice

TUTORIAL 3 G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

A. G00 X = 5, Y = 2

N0007 G00

X5 Y2

B. G01 X = 5, Y = -20

N0008 G01

X5 Y-20

N0009 G03

X15 Y-20 I5 J0

D. G01 X = 25, Y = -20

N0010 G01

X25 Y-20

E. G01 X = 25, Y = -30

N0011 G01

X25 Y-30

F. G01 X = 17.5, Y = -40

N0012 G01

X17.5 Y-40

N0013 G03

X37.5 Y-40 I10 J0

H. G01 X = 30, Y = -30

N0014 G01

X30 Y-30

G01 X = 30, Y = -20

N0015 G01

X30 Y-20

G01 X = 40, Y = -20

N0016 G01

X40 Y-20

N0017 G03

X50 Y-20 I5 J0

N0018 G01

X50 Y-10

N0019 G03

X40 Y-10 I-5 J0

N0020 G01

X32.5 Y-10

N0021 G02

X22.5 Y-10 I-5 J0

N0022 G01

X15 Y-10

N0023 G03

X5 Y-10

R. G01 X = 5, Y = 2

N0024 G01

X5 Y2

G40 CANCEL OFFSET

N0025 G40

M02 END PROGRAM

N0026 M02

C. G03 X = 15, Y = -20

G. G03 X = 37.5, Y = -40

K. G03 X = 50, Y = -20

I = 5, J = 0

I = 10, J = 0

I = 5, J = 0

L. G01 X = 50, Y = -10 M. G03 X = 40, Y = -10

I = -5, J = 0

N. G01 X = 32.5, Y = -10 O. G02 X = 22.5, Y = -10

I = -5, J = 0

P. G01 X = 15, Y = -10 Q. G03 X = 5, Y = -10

I = -5, J = 0

Cnc Edm Wirecut For Mechanical Workshop Practice

TUTORIAL 4 G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

A. G00 X = 10, Y = 2

N0007 G00

X10 Y2

B. G01 X = 10, Y = -5

N0008 G01

X10 Y-5

N0009 G03

X20 Y-5 I5 J0

D. G01 X = 30, Y = -20

N0010 G01

X30 Y-20

E. G01 X = 50, Y = -20

N0011 G01

X50 Y-20

F. G01 X = 55, Y = -25

N0012 G01

X55 Y-25

G. G01 X = 50, Y = -30

N0013 G01

X50 Y-30

H. G01 X = 30, Y = -30

N0014 G01

X30 Y-30

G01 X = 20, Y = -45

N0015 G01

X20 Y-45

G03 X = 10, Y = -45

N0016 G03

X10 Y-45 I5 J0

N0017 G01

X10 Y-40

N0018 G02

X10 Y-30 I0 J5

N0019 G01

X10 Y-20

N0020 G02

X10 Y-10 I0 J5

O. G01 X = 10, Y = 2

N0021 G01

X10 Y2

G40 CANCEL OFFSET

N0022 G40

M02 END PROGRAM

N0023 M02

C. G03 X = 20, Y = -5

I = 5, J = 0

I = -5, J = 0

K. G01 X = 10, Y = -40 L. G02 X = 10, Y = -30

I = 0, J = 5

M. G01 X = 10, Y = -20 N. G02 X = 10, Y = -10

I = 0, J = 5

Cnc Edm Wirecut For Mechanical Workshop Practice

TUTORIAL 5 G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

A. G00 X = 5, Y = 2

N0007 G00

X5 Y2

B. G01 X = 5, Y = -20

N0008 G01

X5 Y-20

C. G01 X = 10, Y = -20

N0009 G01

X10 Y-20

D. G01 X = 20, Y = -10

N0010 G01

X20 Y-10

E. G01 X = 25, Y = -10

N0011 G01

X25 Y-10

N0012 G02

X35 Y-10 I5 J0

G. G01 X = 40, Y = -10

N0013 G01

X40 Y-10

H. G01 X = 50, Y = -20

N0014 G01

X50 Y-20

G01 X = 55, Y = -20

N0015 G01

X55 Y-20

G01 X = 55, Y = -25

N0016 G01

X55 Y-25

N0017 G03

X55 Y-35 I0 J-5

L. G01 X = 55, Y = -40

N0018 G01

X55 Y-40

M. G01 X = 45, Y = -40

N0019 G01

X45 Y-40

N0020 G02

X25 Y-40 I-10 J0

N0021 G01

X5 Y-40

N0022 G03

X5 Y-30 I0 J5

Q. G01 X = 5, Y = 2

N0023 G01

X5 Y2

G40 CANCEL OFFSET

N0024 G40

M02 END PROGRAM

N0025 M02

F. G02 X = 35, Y = -10

K. G03 X = 55, Y = -35

N. G02 X = 25, Y = -40

I = 5, J = 0

I = 0, J = -5

I = -10, J = 0

O. G01 X = 5, Y = -40 P. G03 X = 5, Y = -25

I = 0, J = 5

Cnc Edm Wirecut For Mechanical Workshop Practice

TUTORIAL 6 G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

A. G00 X = 5, Y = 2

N0007 G00

X5 Y2

B. G01 X = 5, Y = -20

N0008 G01

X5 Y-20

C. G01 X = 15, Y = -20

N0009 G01

X15 Y-20

D. G01 X = 20, Y = -10

N0010 G01

X20 Y-10

E. G01 X = 25, Y = -10

N0011 G01

X25 Y-10

N0012 G02

X35 Y-10 I5 J0

G. G01 X = 40, Y = -10

N0013 G01

X40 Y-10

H. G01 X = 50, Y = -20

N0014 G01

X50 Y-20

G01 X = 60, Y = -20

N0015 G01

X60 Y-20

G01 X = 60, Y = -15

N0016 G01

X60 Y-15

K. G01 X = 65, Y = -15

N0017 G01

X65 Y-15

L. G01 X = 65, Y = -20

N0018 G01

X65 Y-20

M. G01 X = 70, Y = -20

N0019 G01

X70 Y-20

N. G01 X = 60, Y = -30

N0020 G01

X60 Y-30

O. G01 X = 15, Y = -30

N0021 G01

X15 Y-30

P. G01 X = 5, Y = -25

N0022 G01

X5 Y-25

Q. G01 X = 5, Y = 2

N0023 G01

X5 Y2

G40 CANCEL OFFSET

N0024 G40

M02 END PROGRAM

N0025 M02

F. G02 X = 35, Y = -10

I = 5, J = 0

Cnc Edm Wirecut For Mechanical Workshop Practice

TUTORIAL 7 G90 ABSOLUTE

N0001 G90

G54 SETTING DECA 12

N0002 G54

X12

G00 RAPID TRAVERSE X = 0, Y = 0, Z = 0

N0003 G00

X0 Y0 Z0

G69 GENERATOR SETTING

N0004 G69

X10 U0 W4

M32 OFFTIME 28

N0005 M32

X28

G41 OFFSET BY LEFT

N0006 G41

A. G00 X = 25, Y = 2

N0007 G00

X25 Y2

B. G01 X = 25, Y = -15

N0008 G01

X25 Y-15

N0009 G02

X45 Y-15 I10 J0

D. G01 X = 40, Y = -15

N0010 G01

X40 Y-15

E. G01 X = 40, Y = -25

N0011 G01

X40 Y-25

F. G01 X = 50, Y = -25

N0012 G01

X50 Y-25

G. G01 X = 50, Y = -20

N0013 G01

X50 Y-20

N0014 G02

X50 Y-40 I0 J-10

C. G02 X = 45, Y = -15

H. G02 X = 50, Y = -40

I = 10, J = 0

I = 0, J = -10

G01 X = 50, Y = -35

N0015 G01

X50 Y-35

G01 X = 40, Y = -35

N0016 G01

X40 Y-35

K. G01 X = 40, Y = -45

N0017 G01

X40 Y-45

L. G01 X = 45, Y = -45

N0018 G01

X45 Y-45

N0019 G02

X25 Y-45 I-10 J0

N. G01 X = 30, Y = -45

N0020 G01

X30 Y-45

O. G01 X = 30, Y = -35

N0021 G01

X30 Y-35

P. G01 X = 20, Y = -35

N0022 G01

X20 Y-35

Q. G01 X = 20, Y = -40

N0023 G01

X20 Y-40

N0024 G02

X20 Y-20 I0 J10

S. G01 X = 20, Y = -25

N0025 G01

X20 Y-25

T. G01 X = 30, Y = -25

N0026 G01

X30 Y-25

U. G01 X = 30, Y = -15

N0027 G01

X30 Y-15

V. G01 X = 25, Y = -15

N0028 G01

X25 Y-15

W. G01 X = 25, Y = 2

N0029 G01

X25 Y2

G40 CANCEL OFFSET

N0030 G40

M02 END PROGRAM

N0031 M02

M. G02 X = 25, Y = -45

R. G02 X = 20, Y = -20

I = -10, J = 0

I = 0, J = 10

Cnc Edm Wirecut For Mechanical Workshop Practice

PRACTICAL TASK AND RUBRIC

Cnc Edm Wirecut For Mechanical Workshop Practice

CNC EDM WIRECUT PRACTICAL TASK NAME MATRIC NO. CLASS LECTURER DATE

: _____________________________________________ : _____________________________________________ : _____________________________________________ : _____________________________________________ : _____________________________________________

A. Practical Task Outcomes At the end of the lab session students should be able: i) Construct programs for EDM and CNC machining process using ISO codes or

any related machining software B. Description of Practical Task 1. 2. 3. 4. 5. 6.

Start and setup CNC EDM Wirecut Machine Write the CNC Programming (G and M Code) Positioning Coordinate system Prepare and display Geometric Drawing. Cutting operation Write a report

CNC EDM WIRECUT PRACTICAL TASK RUBRIC Excellent (5-4)

Good (3-2)

Unsatisfactory (1-0)

Able to setup the basic machine operation partially Able to apply the G and M code partially correct Able to establish the position of the coordinate system partially correct

Unable to setup the basic machine operation

Unable to apply the G and M code

Positioning coordinate system

Able to setup the basic machine operation correctly Able to apply the G and M code correctly Able to establish the position of the coordinate system correctly

Unable to establish the position of the coordinate system

(10-7)

(6-4)

(3-0)

Geometric Drawing

Able to draw a geometric drawing correctly

Able to draw a geometric drawing partially correct

Unable to draw a geometric drawing

TASK Machine Setup CNC Programming

Total Marks

Total

/ 10 / 25

Cnc Edm Wirecut For Mechanical Workshop Practice

REPORT AND RUBRIC

Cnc Edm Wirecut For Mechanical Workshop Practice

CNC EDM WIRECUT REPORT NAME MATRIC NO. CLASS LECTURER DATE

1. INTRODUCTION (4 Marks) ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

2. EQUIPMENT (4 Marks) ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

Cnc Edm Wirecut For Mechanical Workshop Practice

3. SAFETY PRECAUTIONS (4 Marks) ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 4. PROCEDURES (8 Marks) ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

Cnc Edm Wirecut For Mechanical Workshop Practice

5. DISCUSSION (8 Marks) ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 6. CONCLUSION (8 Marks) ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 7. REFERENCE (4 Marks) ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________

Cnc Edm Wirecut For Mechanical Workshop Practice

CNC EDM WIRECUT REPORT RUBRIC Skill / Aspect

Introduction

Marks

Very Good

Good

Fair

Unsatisfactory

MARK

Weight

Excellent and detail

Good information

Satisfactory

Incomplete / out of

information about

about the topics

information about

topics

the topics

Equipment

the topics

Excellent and detail

Good information

Satisfactory

Incomplete / out of

information about

about equipment

information about

topics

equipment used in

used in workshop

equipment used in

workshop

Safety Precaution

Procedure

workshop

Excellent and detail

Good information

Satisfactory

Incomplete / out of

information about

about safety

information about

topics

safety

Excellent and detail

Good information

Satisfactory

Incomplete / out of

information about

about procedures

information about

topics

procedures taken

taken

procedures

with diagram

diagram but loss

with

taken

without diagram

some point Excellent explanation

Discussion

discussion

and

course

theory

and

learning

course

learning

Out of topic and not related

theory

and

related with course learning outcomes

learning

outcomes

Excellent and detail

Good analyse and

Satisfactory analyse

Hardly analyse and

analyse

and

integrate

and

integrate acquired

acquired

information

information with

information

own ideas

Retrieve relevant

Retrieve

information from

information

three sources

two sources

with

relevant

information four

and

from above

outcomes

Retrieve

Satisfactory

and

related to theory

own ideas

Reference

Good explanation

discussions related

course

Conclusion

and

integrate

information with

relevant from

with

own ideas

Retrieve

relevant

information

from

only one sources

sources

TOTAL MARKS

/ 40

Cnc Edm Wirecut For Mechanical Workshop Practice

REFERENCE 1. Kalpakjian S. & Schmid S. R. (2003) Manufacturing Engineering Technology (6th Edition) In Si Units [Photograph]. Prentice Hall. 2. Groover P. Mikell (2010) Fundamental of Modern Manufacturing: Material, Processes and System (4th Edition) [Photograph]. John Wiley &Sons. Inc 3. Krar, Stephen F. and Gill, Arthut R. (2003) Exploring Advanced Manufacturing Technologies, 4. Industrial Press Inc. Jameson, E. C. (2002) Electrical Discharge Machining

Cnc Edm Wirecut For Mechanical Workshop Practice

CNC EDM WIRECUT WORKBOOK FOR MECHANICAL WORKSHOP PRACTICE

Articles inside

Introduction of CNC EDM Wirecut

The CNC EDM Wirecut Machine Control Panel