EDM Wire Cut

EDM Wire Cut

Command using G-codes and M-Codes

HADI KHALID

EDM Wire Cut

Introduction

Electrical discharge machining (EDM), also known as spark
machining, spark eroding, die sinking, wire burning or wire erosion,
is a metal fabrication process whereby a desired shape is obtained
by using electrical discharges (sparks). Material is removed from the

work piece by a series of rapidly recurring current discharges
between two electrodes, separated by a dielectric liquid and subject

to an electric voltage. One of the electrodes is called the tool-
electrode, or simply the tool or electrode, while the other is called
the workpiece-electrode, or work piece. The process depends upon

the tool and work piece not making physical contact.

EDM

EEDDMM wwiirreeccuut t

Chapter 1
Introduction

1

Working environment

http://www.helmancnc.com/wire-edm-programming-example/#Wire_EDM_Programming_Example 2

1

EDM

Wire EDM machine (Electrical Discharge Machining)
or EDM wire cut

• Wire EDM cutting, also known as electrical discharge
machining, is a process that uses an electrically energized thin
wire to slice through metal.

• Wire EDM cutting uses rapid, controlled, repetitive spark
discharges from the wire to the workpiece, thereby eroding the
metal away.

• The workpiece must be electrically conductive.

• Wire EDM cutting can provide high dimensional accuracy for 3
close fitting parts.

• The process can make sharp inside corners.

http://www.helmancnc.com/wire-edm-programming-example/#Wire_EDM_Programming_Example

EDM in industry

4

2

EDM wire cut in industry EDM

• product 5

EDM wire cut machine

6

3

EDM

EDM wire cut machining concept

EDM Programming Example

G92 X0. Y0.

G01 Y1.25 (P1)

G02 X.5 I.25 J0. (P2)

G01 Y.75 (P3)

G03 X1. I.25 J0. (P4)

G01 Y1.25 (P5)

G02 X1.5 I.25 J0. (P6)

G01 Y0. (P7)

X0. (P8)

M02

7

EDM wire cut machining concept

8

4

EDM

EDM wire cut advantages and disadvantages

EDM wire cut discussion 9

• Based on video Machining Practical
task Discussion

10

5

EDM wire cut basic job flow EDM

Machining Practical
task Discussion

11

G codes and M codes

Common preparatory functions for EDM wire cut

12

6

EDM

Sample program of EDM wire cut

13

Sample program

14

7

EDM

THANK YOU VERY MUCH

15

8

EDM

EEDDMM wwiirreeccuut t

Chapter 2
Absolute and Incremental Command

1

G codes and M codes

Common preparatory functions for EDM wire cut

2

1

EDM

ABSOLUTE VALUE COMMAND – G90

3

INCREMENTAL VALUE COMMAND – G91

4

2

EDM

ABSOLUTE VALUE COMMAND – G90

5

PRACTICAL TASK

Wire cut machining product

• Plan view Isometric view

6

3

EDM

Procedure

• Desired Product

7

LINEAR INTERPOLATION (ABSOLUTE) 8

1. Decide value command 4

6
5
4
3
2
1
0

2468

2. Making grid
- wire travel path
- to get measurement

EDM

LINEAR INTERPOLATION (ABSOLUTE)

6

5

4

3

2

1

0 4 6 8
2

3. Wire origin or start point
- wire original position

9

LINEAR INTERPOLATION (ABSOLUTE) 10

6 5
5
4
3
2
1

Wire travel
0 direction

2468

4. Choose wire travel direction or wire path
- wire will travel one way to the end back to the original
position

EDM

LINEAR INTERPOLATION (ABSOLUTE)

6 1. Decide value command
2. Grid , determine measurement

5 3. Wire start point
4. Wire travel direction

4
3
2
1

Wire travel
0 direction

2468

11

LINEAR INTERPOLATION (ABSOLUTE)

5. Writing command

6
5
4
3
2
1

Wire travel
0 direction

2468

12

6

EDM

LINEAR INTERPOLATION (ABSOLUTE)

Button at wire cut “End of
machine Block”
EOB

6 G90 G01 X5.0 Y2.0;
5 X8.0 Y2.0;

X8.0 Y5.0;
4 X2.0 Y5.0;
3 X2.0 Y2.0;

X5.0 Y2.0;
2 X5.0 Y1.0;

1

Wire travel
0 direction

2468

13

LINEAR INTERPOLATION (ABSOLUTE)

Button at wire cut “End of
machine Block”
EOB

6 G90 G01 X5.0 Y2.0; Interface on the wire cut
machine
5 Value X8.0 Y2.0;
command X8.0 Y5.0; G90G01X5.0Y2.0;
4 Linear X2.0 Y5.0;
interpolation X8.0Y2.0;
3 Potong lurus X2.0 Y2.0; X8.0Y5.0;
X5.0 Y2.0; X2.0Y5.0;
2 X5.0 Y1.0; X2.0Y2.0;

1 machining X5.0Y2.0;
profile X5.0Y1.0;
Wire travel bentuk
0 direction

2468

potong

14

7

EDM

LINEAR INTERPOLATION (ABSOLUTE) EXERCISE 1

6 G9__ G__ X___ Y___;
5 X___ Y___;

X___ Y___;
4 X___ Y___;
3 X___ Y___;

X___ Y___;
2 X___ Y___;

1

Wire travel
0 direction

2468

15

LINEAR INTERPOLATION (ABSOLUTE) EXERCISE 2

50 16
45
40
35
30
25
20
15
10

5 Wire travel
0 direction

20 40 60 80

8

EDM

LINEAR INTERPOLATION (ABSOLUTE) EXERCISE 2 &
ANSWER

50 G90 G01 X40.0 Y20.0;
45 X70.0 Y20.0;
40 X70.0 Y45.0;

35

30 X20.0 Y45.0;
25 X20.0 Y20.0;
20 X40.0 Y20.0;
15 X40.0 Y10.0;

10

5 Wire travel
0 direction

20 40 60 80

17

INCREMENTAL VALUE COMMAND – G91

18

9

EDM

PRACTICAL TASK

Wire cut machining product

• Plan view Isometric view

19

Procedure

• Desired Product

20

10

EDM

LINEAR INTERPOLATION (INCREMENTAL –G91)

1. Decide value command

6
3

2. Making dimension 21
- wire travel path
- to get measurement

LINEAR INTERPOLATION (INCREMENTAL)

6
3

3

3. Wire origin or start point
- wire original position

22

11

EDM

LINEAR INTERPOLATION (INCREMENTAL)

6 23

3

3
Wire travel
direction

4. Choose wire travel direction or wire path
- wire will travel one way to the end back to the original
position

LINEAR INTERPOLATION (INCREMENTAL)

6 1. Decide value command
2. Dimension , determine measurement
3 3. Wire start point
4. Wire travel direction
3
Wire travel 24
direction

12

EDM

LINEAR INTERPOLATION (INCREMENTAL)

5. Writing command

6

3

3
Wire travel
direction

25

LINEAR INTERPOLATION (INCREMENTAL)

Button at wire cut “End of
machine Block”
EOB

6 G91 G01 X0.0 Y1.0;
3 X3.0 Y0.0;
X0.0 Y3.0;
3 X-6.0 Y0.0;
X0.0 Y-3.0;
X3.0 Y0.0;
X0.0 Y-1.0;

Wire travel
direction

26

13

EDM

LINEAR INTERPOLATION (INCREMENTAL)

Button at wire cut “End of
machine Block”
EOB

G91 G01 Y1.0; Interface on the wire cut
machine
6 Value X3.0;
3 command Y3.0; G91G01Y1.0;
X3.0;
3 Linear X-6.0; Y3.0;
interpolation X-6.0;
Potong lurus Y-3.0; Y-3.0;

X3.0;

Y-1.0;

Wire travel X3.0;
direction Y-1.0;

machining
profile
bentuk
potong

27

LINEAR INTERPOLATION (INCREMENTAL) EXERCISE 3

6 G9_ G01 Y___ ;
3 X___;
Y___;
3 X___;
Y___;
X___;
Y___;

Wire travel
direction

28

14

EDM

EXERCISE 4

LINEAR INTERPOLATION (INCREMENTAL)

70

30

35 10
Wire travel
direction

29

EXERCISE 4 &

LINEAR INTERPOLATION (INCREMENTAL) ANSWER

70 G91 G01 Y10.0 ;
30 X35.0;
Y30.0;
35 10 X-70.0;
Y-30.0;
X35.0;
Y-10.0;

Wire travel
direction

30

15

EDM

THANK YOU VERY MUCH

31

16

EDM

EDM wire cut

Chapter 3
Linear Interpolation

1

G codes and M codes

Common preparatory functions for EDM wire cut

2

1

EDM

ABSOLUTE VALUE COMMAND – G90

3

PRACTICAL TASK

Wire cut machining product

• Plan view

4

2

EDM

LINEAR INTERPOLATION (ABSOLUTE)

5.5 • For Absolute, coordinate point are
5 required to write a command.

4.5 • For complex profile, it is difficult to
4 determine the coordinate.

3.5 • Need drawing software to identify
3 the exact point of coordinates.

2.5 5
2

1.5
1

0.5 Wire travel
0 direction

2468

Choose wire travel direction or wire path
- wire will travel one way to the end back to the original
position

INCREMENTAL VALUE COMMAND – G91

6

3

EDM

PRACTICAL TASK

Wire cut machining product

• Plan view

7

LINEAR INTERPOLATION (INCREMENTAL) EXERCISE 1

30 15 10
40

10

25 10
Wire travel
direction

8

4

EDM

EXERCISE 1 &

LINEAR INTERPOLATION (INCREMENTAL) ANSWER

G91G01Y10.0;

X25.0;

10 X5.0Y5.0;
40 Y15.0;

10 X-10.0Y10.0;

30 15 X-40.0;

X-10.0Y-10.0;

Y-15.0;

25 10 X5.0Y-5.0;

Wire travel X25.0;
direction Y-10.0;

9

LINEAR INTERPOLATION (INCREMENTAL) EXERCISE 2

40 10
10

30 15

25 10

Wire travel
direction

10

5

Linear interpolation EDM

• Program the following profile EXERCISE 3

Linear interpolation 11

EXERCISE 3

12

6

EDM

THANK YOU VERY MUCH

13

7

EDM

EEDDMM wwiirreeccutut

Chapter 4
Circular Interpolation

1

G codes and M codes

Common preparatory functions for EDM wire cut

2

1

EDM

3

CIRCULAR INTERPOLATION (INCREMENTAL)

END POINT ARC Circular interpolation ;
1. Arc start point
20 2. Arc end point
Wire travel 3. Arc dimension in x,y
direction 4. Arc center in i,j
5. Wire travel direction
20

ARC CENTER WIRE START
POINT

4

2

EDM

CIRCULAR INTERPOLATION (INCREMENTAL)

ARC

20
Wire travel
direction

END POINT 20 G03
ARC CENTER
WIRE START Wire path
POINT CCW

5

CIRCULAR INTERPOLATION (INCREMENTAL)

ARC

20
Wire travel
direction

END POINT 20 G03 X-20.0 Y20.0
ARC CENTER
WIRE START Wire path End from
POINT CCW start point in
the form x,y

6

3

EDM

CIRCULAR INTERPOLATION (INCREMENTAL)

ARC j j
i
20 i- i
Wire travel j- ARC CENTER
direction
START POINT
20
END POINT

G03 X-20.0 Y20.0 I-20.0;

ARC CENTER WIRE START
POINT
Wire path End from
CCW start point in Arc center
the form x,y

7

PRACTICAL TASK

Wire cut machining product

• Plan view

8

4

EDM

CIRCULAR INTERPOLATION (INCREMENTAL) EXERCISE 1

10
40

10

30

20 10
Wire travel
direction

9

EXERCISE 1 &

CIRCULAR INTERPOLATION (INCREMENTAL) ANSWER

G91G01Y10.0;

G01X20.0;

10 G03X10.0Y10.0J10.0;
40 G01Y10.0;

10 G03X-10.0Y10.0I-10.0;

30 G01X-40.0;

G03X-10.0Y-10.0J-10.0;

G01Y-10.0;

20 10 G03X10.0Y-10.0I10.0;

Wire travel G01X20.0;
direction G01Y-10.0;

10

5

EDM

CIRCULAR INTERPOLATION (INCREMENTAL) EXERCISE 2

10
40

10

30

20 10
Wire travel
direction

11

CIRCULAR INTERPOLATION (INCREMENTAL) EXERCISE 2 &
ANSWER

G91G01Y10.0;

G01X20.0;

10 G02X10.0Y10.0I10.0;
40 G01Y10.0;

10 G03X-10.0Y10.0I-10.0;

30 G01X-40.0;

G03X-10.0Y-10.0J-10.0;

G01Y-10.0;

20 10 G02X10.0Y-10.0J-10.0;

Wire travel G01X20.0;
direction G01Y-10.0;

12

6

HALF CIRCLE - VERTICAL EDM

8 G01 Y-8.0; 13
G02 Y-30.0 J-15.0;
G01 Y-10.0;

30

10

HALF CIRCLE - HORIZONTAL

14 G01 X14.0;
42 G02 X42.0 I21.0;
G01 X12.0;

12

14

7

EDM

3/4 - G01 X16.0;
G02 X30.0Y-30.0 I30.0;
16 G01 Y-10.0;

10
D =60

15

3/4 EXERCISE 1

10 16

20 8
D =80

EDM

3/4 EXERCISE 1 &
ANSWER
10
G01 X20.0;
20 G03 X40.0Y40.0 I40.0;
G01 X10.0;

D =80

17

Full circle - punch G01 X-10.0;
G02I-40.0;
10 G01 X10.0;

D =80

18

9

Full circle - punch EDM

EXERCISE 2

30 D =180

19

Full circle - punch EXERCISE 2 &
ANSWER
G01 Y30.0;
G03 J90.0; 20
G01 Y-30.0;
10
30 D =180

EDM

Full circle - die

G01 X50.0;
G02I-50.0;
G01 X-50.0;

D =100

21

EXERCISE 3 &
ANSWER

Full circle - die

D =300

22

11

EDM

EXERCISE 3 &
ANSWER

Full circle - die

G01 Y150.0;
G03J-150.0;
G01 Y-150.0;

D =300

23

THANK YOU VERY MUCH

24

12

EDM

EEDDMM wwiirreeccutut

Chapter 5
Circular Interpolation

1

G codes and M codes

Common preparatory functions for EDM wire cut

2

1

EDM

Wire compensation

Analogy

Wire compensation 3

1. Which part is use, punch or die 4
2. Wire direction
2

EDM

Wire compensation on program

Starting

Ending – return to start point

5

Wire compensation on program EXERCISE 1

6

3

Wire compensation on program EDM

EXERCISE 1 &
ANSWER

7

THANK YOU VERY MUCH

8

4

EDM

Wire compensation

G41 Wire direction
G40
G42

You want this Punch G42
side! Start point

Hack saw G41
1. Put the hack saw outside the
1. Which part is use, punch or die 9
part you want 2. Wire direction

Wire compensation

G41 Wire direction
G40
G42

Punch G42
Start point

G41

1. Which part is use, punch or die 10
2. Wire direction

5