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Unsubmerged wire edm tips/tricks

nlancaster

Aluminum
Joined
Oct 8, 2018
So my company is quoting a job that will require unsubmerged wire edm.

Sodick AG600L - LN2W control.

I cut a test piece, 2 inches tall steel with 4.5 inches of cut perimeter.

The test cut took 7 hours as customer asked for a .005 inside corner radius, using .006 zinc coated wire.

The radius came out a touch over at .0061.

Anyone have any tips to get the corner radius to .005 or better?

Here are the conditions used.

(CLIMAX 55240_B SINGLE SLOT)
( 5 PASS OPEN-UP );
( ON OFF IP HRP MAO SV V SF C PIK CTRL WK WT WS WP PC SK);
C000 = 007 016 2215 000 260 +050.0 8.0 0060 0 000 0000 015 070 120 040 0000 00;
C001 = 004 040 2215 000 390 +050.0 8.0 0008 0 000 0000 015 070 150 050 0000 00;
C002 = 002 025 2215 000 000 +042.0 5.0 1021 0 000 0000 015 080 130 140 0000 00;
C003 = 001 020 2210 000 000 +037.0 2.0 1038 0 000 0000 015 080 130 240 0000 00;
C004 = 006 014 0515 000 000 +008.0 0.0 1038 0 000 0000 015 080 130 240 0000 00;
C905 = 001 020 1015 000 034 +012.0 3.0 3024 0 009 0000 015 080 130 240 0000 00;
H000 = + 00000.00039 (Approch) ;
H001 = + 00000.00724 ( 1ST ) ;
H002 = + 00000.00449 ( 2ND ) ;
H003 = + 00000.00370 ( 3RD ) ;
H004 = + 00000.00327 ( 4TH ) ;
H005 = + 00000.00311 ( 5TH ) ;
H006 = + 00000.00385 ( 6TH ) ;
H999 = + 00000.00000 ( Taper Offset ) ;
QAIC(2,1,0.00295,003.0,0.00374,0.00157,016.0,0002,0005,15,035);
SFCC10050040;

I am aware the last past C905 H006 didn't make any cut, when I tried setting H006 to .00310 the machine stalled and didnt' cut at all.
 
There is a chance I don't know what Im talking about but my initial thought is, are you accounting for overburn in your wire path? It sounds like the wire is dwelling just a little too long in that particular spot causing the radius to swell. If you scoot it along a little faster, or maybe bring it a hair farther away from the target location, you should come out with a smaller radius. I think. Sort of new to this, so take my advice with a grain of salt lol.
 
Flushing in unsubmerged cutting isn't as efficient, so theres less material removal and less cooling, causing the wire to move a little slower and burn a little hotter, to my understanding. On a taller part like that the flushing is probably particularly "poor" (not horrible, but not great) depending on your flush cups and water flow setting. So that's something to keep in mind as well!
 
So my company is quoting a job that will require unsubmerged wire edm.

Sodick AG600L - LN2W control.

I cut a test piece, 2 inches tall steel with 4.5 inches of cut perimeter.

The test cut took 7 hours as customer asked for a .005 inside corner radius, using .006 zinc coated wire.

The radius came out a touch over at .0061.

Anyone have any tips to get the corner radius to .005 or better?

Here are the conditions used.

(CLIMAX 55240_B SINGLE SLOT)
( 5 PASS OPEN-UP );
( ON OFF IP HRP MAO SV V SF C PIK CTRL WK WT WS WP PC SK);
C000 = 007 016 2215 000 260 +050.0 8.0 0060 0 000 0000 015 070 120 040 0000 00;
C001 = 004 040 2215 000 390 +050.0 8.0 0008 0 000 0000 015 070 150 050 0000 00;
C002 = 002 025 2215 000 000 +042.0 5.0 1021 0 000 0000 015 080 130 140 0000 00;
C003 = 001 020 2210 000 000 +037.0 2.0 1038 0 000 0000 015 080 130 240 0000 00;
C004 = 006 014 0515 000 000 +008.0 0.0 1038 0 000 0000 015 080 130 240 0000 00;
C905 = 001 020 1015 000 034 +012.0 3.0 3024 0 009 0000 015 080 130 240 0000 00;
H000 = + 00000.00039 (Approch) ;
H001 = + 00000.00724 ( 1ST ) ;
H002 = + 00000.00449 ( 2ND ) ;
H003 = + 00000.00370 ( 3RD ) ;
H004 = + 00000.00327 ( 4TH ) ;
H005 = + 00000.00311 ( 5TH ) ;
H006 = + 00000.00385 ( 6TH ) ;
H999 = + 00000.00000 ( Taper Offset ) ;
QAIC(2,1,0.00295,003.0,0.00374,0.00157,016.0,0002,0005,15,035);
SFCC10050040;

I am aware the last past C905 H006 didn't make any cut, when I tried setting H006 to .00310 the machine stalled and didnt' cut at all.

I would try adjusting your first offset, .00724 is alittle big on the first pass in my opinion. Id take .0005 or so off H001 and maybe .00015 - .0002 off H002 especially if I am seeing some of the skim passes kinda jump around.

C003 I might give it 3.0V

If you go that route and still getting the radii large but the burn is good just adjust all your offsets together so the burn will stay consistent.

Just curious, why unsubmerged on a 2in piece? I've only had the luxury of doing that a couple times.
 
2.250in Diameter, 2in thick flat area where cuts are made, and 49 inches long for the first part. Tank is only 41 inches wide.....

Customer may end up bringing 60in and 96in versions of parts to us as well.

The customer stated to our sales engineer they were "happy" with the test part, but my guess is they didn't measure that inside corner.
Engineers wondered why it takes so long, I suggested if we could change the inside corner radius to .008+ we could use .010 wire and speed it up.

I will try those offset changes if we get the order.

Shane, i have not tried it without SFCC corner control, I will have to read up on that and see what it does before removing it.
 








 
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