ESPRIT has machining technology that is designed specifically for 2-axis through 5-axis wire EDM, including machines equipped with a rotary axis. This technology is called SolidWire.
SolidWire technology lets you define the physical properties of your wire EDM, create stock models, create specialized EDM features with automatic feature recognition, create wire EDM operations, and perform simulations with either automatic or manual slug removal.
The technology for SolidWire machining cycles is displayed on a tab in the Project Manager. This makes it easy to enter machining parameters and view the part model at the same time. The user can also click on any of the other tabs in the Project Manager to make it easier to select features.
X The technology for a machining cycle will not open unless a valid feature is selected first.
The way that machining parameters are organized for all SolidWire machining cycles is consistent to make it easy to learn and use the technology.
The interface is organized in three main areas:
• Toolbar area
• Vertical tabs
• Parameters area
The Toolbar area contains commands to validate (OK) and close (Cancel) the current technology as well as a Help button to open the help file for the current technology. The drop-down button displays the context menu for the technology. The icon reflects the last command used by the user.
The vertical tabs are arranged to save space. All EDM machine types use the same interface to group machining parameters in a consistent way.
• The General tab contains all the general information about the operation such as the operation name, the machining strategy, information about the workpiece, cut-off moves, and a comment area.
• The Cut Data tab contains the machining parameters for the primary and land cuts
• The Approaches tab contains the parameters that affect the way the wire moves in and out of the part and between skim cuts
• The Advanced tab contains the parameters that give the user more control over the wire path, such as optimized wire path, taper information, and control over machine functions
The Parameters area displays the machining parameters for the current technology. Parameters are grouped by category and each group control can be collapsed or expanded for visualization purposes.
To make the selection of parameters easier, the interface shows the user only what is needed based on the current input. For example, if the selected feature has a land depth, the ‘Land Cut’
parameters display on the Cut Data tab.
If the feature has taper only, the ‘Land Cut’ settings are hidden.
When an arrow button displays next to a parameter, you can click the arrow and select an element in the work area to load a value.
If the value for a parameter is invalid or missing, an error displays next to the parameter. If you hover your mouse over the error icon, a description of the error displays so that it can be corrected.
Saving Machining Technology
Machining technology settings can be easily saved as a separate *.prc (process) file and used over and over for the machining of similar parts. To save the technology for a machining cycle, click Save on the drop-down menu. Enter a name for the file, browse to the location where you want to save the file, and click Save.
After a technology file has been saved, it can be loaded in a technology page. Click ‘Open’ on the drop-down menu, browse to the file, and click Open.
X The type of technology in the file must match the machining cycle. For example, you can only load Pocketing technology into a Pocketing cycle. For this reason, it is important to name the saved technology file with the type of technology in the file.
EDM Machine Types
Before you create SolidWire operations, you must first select the type of EDM you are using. The machine type you choose determines the options that are available on the operation technology pages.
The EDM machine type is selected from the Tools menu.
A dialog displays all the machine types available in ESPRIT. If your machine type is not shown on the list, select ‘Generic’.
X After machining operations are created, the machine type cannot be changed. All existing operations must be deleted before the user is allowed to change the machine type.
Machining strategies for dies and punches
A single EDM operation generates a separate operation for the rough cut, each skim cut, each cut-off, and possibly a skim cut for each cut-off.
ESPRIT offers a collection of machining strategies that provide a quick and easy mechanism to generate highly efficient machining, especially important when you are cutting multiple work pieces or work pieces that require multiple cuts.
The ‘Strategy’ parameter lets you choose the order in which these cutting passes are created.
The following strategies are available:
• [Rough][Skim]: The rough cut for each selected feature is performed first, then all skim cuts for each feature. If a cut-off strategy is selected, the cut-off distance is applied to the rough cut and no retract takes place.
• [Rough][Cut-off][Skim]: This strategy is generally used when the thread point and retract are inside the feature (a die).The rough cut for each selected feature is performed first, then the cut-off, then all skim cuts. The cut-off strategy can insert a stop or optional stop code before the cut-off move for parts that are run unattended.
• [Rough][Skim][Cut-off]: This strategy is generally used when the thread point and retract are outside the feature (a punch). The rough cut for each feature is performed first, then all skim cuts for each feature, then all cut-offs.
Cutting planes
Parameters that control the heights of cutting planes are shown on the General tab. These plane heights are automatically loaded from the feature properties.
If a chain feature is selected as input, the Z-axis position of the feature is used for the location of the work piece bottom and the user must enter the other values.
If an EDM feature is selected as input, these properties are contained in the feature and are loaded automatically in the technology page. For this reason, it is recommended to use EDM features.
• Workpiece Thickness is the total thickness of the workpiece
• Reference Plane is the distance from the work table to where you are holding size for a taper cut. The taper is taken from this position. Land cuts cannot be created when this value is equal to the work piece bottom or the calculated top of the work piece (work piece bottom + work piece thickness).
• Workpiece Bottom is the Z location at the bottom of the workpiece Cut strategies for lands and tapers
The user can choose to create a rough pass only, a rough pass and skim cuts, or skim cuts only.
When a feature contains both a taper and a land, separate strategies can be defined for each type of cut. Up to 9 skim cuts can be created after the rough cut.
X Although a rough cut is included in each strategy, you can use the ‘Suppress Rough’ parameter to output only skim cuts.
ESPRIT also provides the SolidWire Expert System for several types of machines. The Expert System is a database that lets you view and choose cutting data before it is inserted on a SolidWire technology page. The Expert System is launched from a button located on the contouring and pocketing technology pages.
The Expert System has two sets of data: a default (Master) database and a User Custom Database.
You can select data from either database. The Default Database contains
manufacturer-recommended data that cannot be changed. The User Custom Database contains data that is set up by the user.
X Charmilles machines use their own CT-Expert System provided by AgieCharmilles.
Details about how to set up and use data in the Expert System are provided in ESPRIT Help. Press F1 to display the Help window and look for ‘Expert System’ in the index.