RJT,
We do not see many customer's using the Probe on the Wire EDM's. From a technical stance, the Probe system is more accurate/repeatable and the measurements are influenced less by debris/burrs on the part, but it’s also hard to beat a seasoned toolmaker that knows what they are doing!
From my point of view, using the Probe system is not for the lower skilled operator, as most might not appreciate the difference between crashing a $200 Dial Indicator vs. a $10,000 Probe! I do see one application on Wire EDM where a Probe is a MUST HAVE, which is machining of custom Milling cutting tools. In this type of application, a C-Axis is used on the WEDM to rotate and position the cutting tool, and the Probe is a tremendous help in Setup to establish the proper cutting face position and clocking of the C-Axis, and there are special screens on the Hyper-i control dedicated to this type of work (Tool Machining Package).
There is one other attractive feature that a Probe system might provide depending on make/model of your machine, which would be 3D Leveling of the Work Piece. With this process, the Probe is used to capture several points on the top of the work piece to establish a Z-Axis Plane. The machine will then crunch some numbers and calculate a U/V Axis offset that makes the U/V perpendicular with the Work Piece conditions. This is a handy function to have that can save a lot of Setup time, especially for large and heavy parts.
Makino has developed a standard 3D Plane Find function for the Hyper-i control, and this works with the optional Probe system, but also works with a Dial Indicator and Mag-base that every shop will have. Using the Indicator, you will drive the machine manually to (x3) different locations on top of the part and use the [Capture] buttons at the different locations. If the work piece is not flat on top (say a large mold cavity), the 3D Plane Find function has provisions to perform the same type of Setup capturing (x4) points (2 Points on 2 Sides of the part). Below are (x2) video links of the 3D Plane Find function and Probe system…
3D Plane Find Function:
YouTube
3D Probe System:
YouTube
- Brian