How to make a program for Taper cutting with Wire Cut EDM?

1.     Making a drawing with CAXA (CAD), like a circle.

2.     Trajectory generation

2.1 You need to set cut parameter as following picture, and then click OK.

(Note: If you choose Automatic compensation and set Offset value<0.1-0.105mm> here, do not set it at the Code convert any more. Otherwise, please do not set Offset value or Taper angle here, just set them at the Code convert interface.)

2.2 Choose the cutting direction by click any arrow as following:

(Note: the arrow direction you choose is the cutting direction you need).

2.3  Choose the offset direction by clicking any arrow as following:

（Note: Left means the wire at the left of the drawing path, Right means the wire at the right of the drawing path）as following picture. The WDcomp (Wire diameter compensation) = the wire radius +discharging gap (around 0.105mm)

2.4  The Circle Trajectory is generated now.

3.     3B Code generation and save the 3B code file by renaming it.

3.1 Save the 3B code file to your computer by naming it.

3.2 3B code file as following:

(Please choose Compact instruction format for the new machine first time usage as following):

4.     Enter File Manage → Load file, (above renamed 3B code file)

4.1 Choose the file from the computer

5.     Code Convert

Code Convert interface will automatically open. Please choose Cut Mode: Taper cutting and set the taper parameters (Taper Angle, WDcomp, Rotate, Overcutvalue) when you make taper cutting.

(Note: WDcomp means Wire diameter compensation. OvercutVal means over cut value.)

After setting the correct cutting parameters and choosing Cut model, press the key to process the program and press "Exit" to exit.

6.     Set the E code according to your work piece requirement, and click “Change” button.

Note:

PON： its range: 1-256, the unit is uS, and it means the width of pulse discharge (or the discharging time.

You can input PON value here.

POFF：its range: 2-30, multiples of PON, and it means the width between two pulse discharges (Or the rest time between two discharging times). 

Curr (Current)： 1-15, namely open HF amplifier tubes. The more the current, the larger cutting power

WSp( Wire speed)： range 1-20. Normally set with 5,10,15, and 20. (When you install the wire to the wire drum, please set with 5)

Spd( Limited speed of the axis motor)： range 1-1000, the unit um/S, the maximum speed during processing。

Group：1-10, adjust the PON segment width, such as a Group, 3 PON for 1/3 of the original.

Vol： low voltage is used for cutting the workpiece with a smaller height than 100mm, the high voltage is used for cutting the workpiece with a bigger height than 100mm.

Remit( the wire tension)： The wire tension

： after the adjustment of discharge parameters, you need to press this button, to make the adjusted parameters value effectively.
Tracking factor: 1-100, the choice of HF tracking coefficient, the smaller the value of tracking the faster.

   it can be adjusted by input value with keyboard, or through the keyboard of "-" "+" key directly to adjust. (During the multi time cutting, you can use this function to get a stable cutting status.)

7.     Click the button “” to Simulate the programming or cut it.

8.     Remark1: How to set tapper parameter?

The first male mold (wire diameter compensation must be set to positive):

Cutting direction: Clockwise

Right Taper: a negative value (-)

The second male mold (the wire diameter compensation must be set to positive):

Cutting direction: Clockwise

Left Taper: a positive value (+)

9.     Remark2: How to calculate the taper setting parameters?

Step1: Click Machine Adj (R) at the bottom of the windows

Step2: Choose Wimble verify:

There are three ways to calibrate and determine the distance between the upper and lower guide pulleys, the distance between the working table and the lower pulleys to calculate both parameters at the same time.

The results can be calculated by trial cutting a work piece, entering the measured values and clicking on "Calculate".

Automatic modification of the parameters: After the results have been calculated and confirmed, click on "AuToModi param” (It means Automatic modification of the parameters)" to automatically transfer the calculated values to the corresponding parameters in the main interface.

10. Remark 3: How to cut a job with Different graphic between the top and the lower?

Into File Manage → Edit file，open the File editor interface, click the "DiffGraph" menu of combine File,

Open the lower File, choose the lower File firstly,

 then open the top File, choose the top File,

combine them to a new file and then save it.

 

At last, Into File Manage →Load file to open the combined file

The combined file will appear in the following window

Note: Combine of two files must be the same section number, otherwise can't combine.

   2022-3-23