the old dog learns new tricks - edm today article (pdf | 1.6 mb)

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XX EDM Today, Winter 2013 Issue I suspect that some of our readers were wondering when I’d get around to reporting on Sinker training. Well, your wait is over! For my third training session I traveled to the AgieCharmilles headquarters in Lincolnshire, Illinois for a four day introductory Sinker EDM class. I have to admit that prior going into this class, my CNC Sinker experience was quite limited. I have run manual Sinkers since 1965 (gosh, that does date me doesn’t it) and my shop had two CNC Sinkers (which I supervised but did not actually operate), so I was really looking forward to updating my skills. Those shops bringing in a CNC Sinker into a manual machine environment should keep in mind that this is a quantum leap in tech- nology. They should not expect their manual operators to hop onto a newly arrived CNC machine and be productive from the outset without factory training. Class sizes are limited in order to provide each student with individual instructor attention and substantial hands-on opportunities at the machine. In the case of AgieCharmilles, introductory classes are limited to a maximum of six students with two Sinker machines dedicated to training. Our class consisted of four students: Mark Peevy from Martin Tool/Classic Die located in Grand Rapids, Michigan. Martin Tool is plastic and diecast mold builder primarily servicing the automotive industry. Joseph and Justin Jeffs from PlasitFormance Inc. located in Hildale, Utah. PlastiFormance builds high cavitation molds for pipettes for the medical industry Yours truly from EDM Today AgieCharmilles Sinker EDM Training This article is the third in an ongoing series designed to promote the extremely important benefits of attending the training classes provided by the machine builders at no cost when you purchase a new EDM. After my RANT on this subject in the Fall, 2010 issue, I’ve decided to “walk the walk” and will be attending a number of both Wire and Sinker introductory EDM training classes hosted by the machine builders to provide eyewitness accounts of what goes on in these classes. AgieCharmilles Headquarters Building

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XX EDM Today, Winter 2013 Issue

I suspect that some of our readers were wondering when I’d get around to reporting on Sinker training. Well, your wait is over! For my third training session I traveled to the AgieCharmilles headquarters in Lincolnshire, Illinois for a four day introductory Sinker EDM class.

I have to admit that prior going into this class, my CNC Sinker experience was quite limited. I have run manual Sinkers since 1965 (gosh, that does date me doesn’t it) and my shop had two CNC Sinkers (which I supervised but did not actually operate), so I was really looking forward to updating my skills. Those shops bringing in a CNC Sinker into a manual machine environment should keep in mind that this is a quantum leap in tech-nology. They should not expect their manual operators to hop onto a newly arrived CNC machine and be productive from the outset without factory training.

Class sizes are limited in order to provide each student with individual instructor attention and substantial hands-on opportunities at the machine. In the case of AgieCharmilles, introductory classes are limited to a maximum of six students with two Sinker machines dedicated to training.

Our class consisted of four students:

Mark Peevy from Martin Tool/Classic Die located in Grand Rapids, Michigan. Martin Tool is plastic and diecast mold builder primarily servicing the automotive industry.

Joseph and Justin Jeffs from PlasitFormance Inc. located in Hildale, Utah. PlastiFormance builds high cavitation molds for pipettes for the medical industry

Yours truly from EDM Today

AgieCharmilles Sinker EDM TrainingThis article is the third in an ongoing series designed to promote the extremely important benefits of attending the training classes provided by the machine builders at no cost when you purchase a new EDM. After my RANT on this subject in the Fall, 2010 issue, I’ve decided to “walk the walk” and will be attending a number of both Wire and Sinker introductory EDM training classes hosted by the machine builders to provide eyewitness accounts of what goes on in these classes.

AgieCharmilles Headquarters Building

EDM Today, Winter 2013 Issue XX

Vladimir Yudelevich, AgieCharmilles Sinker Appli-cations Engineer, served as our instructor. Vladimir combines a wealth of EDM experience and a passion for teaching EDM to provide a fact filled, informative, and very interesting training experience. Vladimir was born in Saint Petersburg (formerly Leningrad), Russia. He graduated from a six year electronics engineering program at Ship Building University in 1974. He was then employed by the Svetlana Electronics Company that manufactured electronic components. He began his employment as a designer and subsequently transferred to the company’s EDM department which utilized both Wire and Sinker EDM in the production electronic components. His department had more than 100 Wire EDM’s. During the course of his employment, his employer would occasionally collaborate with ENIMS (Experimental Research Institute of Metal Cutting Machines) where he interfaced with Moisey Korenblum the author of our earlier series on EDM in Russia. In 1990, Vladimir was recruited by Charmilles to work as a service and applications engineer for both Wire and Sinker EDM’s in Saint Petersburg. In 1997, Vladimir was transferred to the headquarters of Charmilles USA as a Sinker Application Engineer. Vladimir brings a unique “can do” approach to EDM, since in his mother Russia one often had to devise innovative solutions to work around limited resources to accom-plish spectacular results.

Valdimir utilizes a unique method of describing gap conditions in his classes. He has the ability to accurately mimic the EDM sounds of the various sequences in the cavity erosion process ranging from “Rrrrrrr!” for the cavity roughing down burn to “Shhhhhh” for the final orbit. In a “Tech Tips” article from an earlier issue of EDM Today I proffered the importance of listening to the sounds of the burn in your EDM. Vladimir’s oral technique is remarkably effective at conveying the sounds you’ll hear during the various stages of an orbit burn.

Day 1:

We start off in the classroom with the distribution of training manuals. These books are not only our guide for the training but also an invaluable “go-to” reference for the students when they get back to the shop. The AgieCharmilles Sinker control is a Windows XP based interface to a Fanuc controller called the DP or Dynamic Process system. AgieCharmilles has developed a very handy control simulator that runs on a PC which allows one to simulate most of the functions and operations of the machine control on the PC. In fact, you can pro-gram many aspects of your job off-line on the PC and then transfer the information to the machine control via Ethernet or memory stick. In class we learn about the Machine, Part, and Cavity reference systems, and the basics of defining the Job, the Tools, the Workpiece, the Cavity, the Erosion, the Sequence, and finally making the ISO program.

Then, it’s out to the machines to actually perform the functions we learned in class on a real control. These include picking up the part with the probe and picking up the electrodes with the reference ball to determine electrode offsets. We actually set up and burn a job. Then, we returned to the classroom for a review of all the subjects cov-ered during the day.

Vladimir explains voltage and current discharge wave forms

Joseph Jeffs inputs a program to the control.

Attentive students in the theory class.

XX EDM Today, Winter 2013 Issue

Day 2:

We start the day in the classroom and we discuss the EDM parameters that are used by the control. Knowl-edge of these parameters will allow us to fine tune cutting conditions from suggested technology should it be necessary. These discussions include details of various discharge waveforms and how parameter set-tings affect them. We also learn the nomenclature of 3 digit generator setting technology. We also learn about special techniques and technology for burning subgates.

Then, it’s back to the machines to perform to perform basic setups and burns. We actually burn some subgates using incredibly fragile electrodes brought by the folks from PlastiFormance and learn how to optimize those burns. We end the day back in the classroom to reinforce what we’ve learned throughout the day.

Day 3:

We start the day in the classroom, and we learn how to move job files back and forth from the PC to the machine control. We also learn how to export certain job report files to a memory stick for subsequent printing or storage outside of the machine. We study the Agie-Charmilles technology curves in detail to get a better understanding of the relationship between surface finish, performance, and electrode wear. After lunch, we go back to the machines for more practice burns on different shapes, cavity configurations, and burn directions. We learn how to insert different technology into our programs to optimize cutting performance based upon the technology curves.

Day 4:

The day starts at the machines for more test burns that illustrate the machine capabilities.

Then it’s back to the classroom for some basics of macro programming. Even though macros are written in a special window of the XP interface, since the control itself is based on a Fanuc controller the rules and macro statements will be familiar to anyone with Fanuc Macro B experience.

Finally…graduation and our certificates!

So…why bother with training if you’re an experienced EDM’er and have access to all the machine manuals? First and foremost – Self-training at your shop while

trying to maintain production is a very inefficient way to learn. The opportunity to be trained by a highly skilled and capable professional in an uninterrupted environment is invaluable. Have you ever really sat down and read through the

literally thousands of pages of machine documentation, either hard copy or within the control? Your instructor has “been there, done that”. He’ll

show you the correct way to do things and how to avoid costly mistakes. Your instructor will show you machine specific

shortcuts, techniques, and point out other important items that aren’t always readily apparent.

For example: • Thefinepointsofspecifyingmachiningdirectionusing A and B parameters

• Howtoquicklycallupthecavitypositionscreenwindow while watching the erosion screen

Mark Peevy prepares to set an electrode offset.

My diploma!

EDM Today, Winter 2013 Issue XX

• ThedetailsofusingPilotExpert

• Howtoletthemachinesetselectedsecondaryparameters

• Thecompleteexplanationofthesevendigittechnologycode

• The120amp/squareinchruleforcalculating maximum roughing peak current

• Howapplytooloffsettoasubgateelectrodetoaccurately position a series of radial subgates

• ThedetailsofApproachandPass

• Howtoburnacylindricalcavitywithorbitwithsharpcorners and no body distortion

You will leave with a personal connection to your trainer, someone you can subsequently call to help you out when you have questions back at the shop.

What did I learn?

Plenty! First, no offense intended to you Wire guys, but the level of complexity in CNC Sinker operations exceeds that of a Wire machine.

Today’s modern machines and powerful controls offer the opportunity to do things that couldn’t even be considered with a manual Sinker EDM. However, for

each new capability, there is more potential to “screw up” big time if it’s not applied correctly for that particular machine or control.

I’d like to express my sincere appreciation to the folks at AgieCharmilles: Glynn Fletcher, President; Darin Chartier, Director of Customer Services; and (last but not least) Vladimir Yudelevish for affording me the opportunity to visit their fine facility and attend the class.

Stay tuned for the “Old Dog’s” next training adventure!

– Roger

A group photo of Vladimir and his eager students