Figure 1: NC EDM menu

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1 Click To See: How to Use Online Documents SURFCAM Online Documents 685)&$0Ã5HIHUHQFHÃ0DQXDO 6 :,5(('0 6.1 INTRODUCTION SURFCAM s Wire EDM mode is used to produce toolpaths for 2 Axis and 4 Axis EDM machines. This chapter describes three Wire EDM operations that are available in SURFCAM: 2 Axis XY, 4 Axis and 4 Axis UV. 2 Axis XY (Contour) The 2 Axis XY operation is described in Section 6.2: 2 Axis XY (EDM Contour) on page Axis The 4 Axis operation is described in Section 6.3: 4 Axis on page Axis UV Trim The 4 Axis UV operation produces toolpaths that let you perform trimming operations with a 4 Axis EDM machine. Refer to Section 6.4: 4 Axis UV Trim on page 363. Cutting operations described here are all performed in the top view (plan view). Part geometry should be drawn with the profile of the part in a plan view at Z0. If there are different top and bottom profiles, they should also be drawn at Z0. When creating geometry, the CView (construction view) should be set to 1 (Top View) AXIS XY (EDM CONTOUR) Figure 1: NC EDM menu An example of a typical SURFCAM Wire EDM job is to use 2 Axis XY to cut a closed contour. You will set the width of a Tab on the contour. You can pre-select and color code the Thread Point (in green) and the Start Point (in red) on the contour. With the color code, SURFCAM can automatically select the Thread and Start Points and chain the contour. You will indicate the side of the contour to cut. SURFCAM will create the toolpath starting with the initial burn from the Thread Point to the entry Retract Point. The initial pass begins with a Straight Line leadin move from the entry Retract Point to an offset from the Start Point on the contour. The initial pass ends with a Straight Line leadout from the offset of the End point on the contour to the exit Retract Point. SURFCAM Reference Manual, Chapter 6 Wire EDM

2 342 SURFCAM Reference Manual, Chapter 6 Wire EDM There, a Stop command is inserted in the code to allow the operator to apply appropriate clamps on the part. The Tab is then cut with a pass that ends at the entry Retract Point. Another Stop command is inserted so the waste material can be removed. Next a number of Skim passes are executed beginning and ending at the entry Retract Point. The Leadin and Leadout moves for Skim passes can be one of three types: Straight Line, Teardrop, or Offset Curve Overlap. After the final Skim pass the wire can be set to stop at the Retract Point or the Thread Point. Figure 2: Initial Pass Before Tab is Cut Figure 3: Skim Passes with Teardrop Lead moves You can also use 2 Axis XY to cut multiple contours. Three strategies are available for the order in which you perform initial passes, Tab cuts, and Skim passes. Click NC > EDM > 2 Axis XY to display the 2 Axis EDM Contour dialog box. Refer to 1. Section 6.2.1: Tool Information Tab on page 343, 3. Section 6.2.3: Skim Cut Tab on page Section 6.2.2: Cut Control Tab on page 345, 4. Section 6.2.4: EDM Options Tab on page 351. After you click OK on the 2 Axis EDM Contour dialog box, SURFCAM will display the NC > EDM > Select Chain menu. Figure 4: NC > EDM > 2 Axis XY > Select Chain There are two ways to create the toolpath. If you have already created and color coded the Thread (green) and Start Points (red), click Auto on the Select Chain menu. Click Visible on the Select menu, then click Done. Click Done on the Select Chain menu. Note: If you do not select a Start Point, SURFCAM will start at the point on the contour nearest the Thread Point. With the Auto > Visible method, red Start Points must be on the contour, not just near it. Be sure to consider the width of the Tab when you select a Start Point. Gouges are possible if either a Start Point or an End Point is too close to a sharp corner. If you did not color code the Thread and Start Points, perform the following steps. 1. Chain the contour(s) to be cut, but do not click Done on the Select Chain menu until you have selected the Thread and Start Points. 2. Click Thread. SURFCAM will display the Select Point menu. Select the Thread point(s) and click Done.

3 SURFCAM Reference Manual, Chapter 6 Wire EDM Click Start Point. The Select Point Menu will be displayed. Select the Start Point(s) on or near each contour and click Done. Selected points not on the contour will be projected onto the contour as the Start Points. Click Done on the Select Chain menu. You will be prompted to select the side to contour. After you click on the correct side of a contour, SURFCAM will create the 2 Axis XY toolpath and display the tool motion on the screen. It will then display the Keep Operation dialog box. Click Accept to keep the operation. Note: To permanently save these toolpaths, you must use the Save command on the File menu to re-save the DSN file and the ICD file Tool Information Tab Figure 5: 2 Axis EDM Contour Tool Information tab

4 344 SURFCAM Reference Manual, Chapter 6 Wire EDM Tool The name of the currently selected tool is displayed. The corresponding tool reference number is displayed on the button. To select a different tool, edit a tool record, or add a new tool, click the button to display a Select EDM Tool dialog box. Refer to Section : Select an EDM Tool on page 357 and Section : Edit or Add an EDM Tool on page 359. Material The name of the currently selected material is displayed. The corresponding material reference number is displayed on the button. To select a different material, edit a material record, or add a new material, click the button to display the Select Material dialog box. Refer to the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2.2: The Material Library on page 76. Wire Diameter This is the diameter of the EDM wire. Thread Wire Check this box to cause the EDM machine to automatically thread the wire. Spark Gap The distance to offset the tool path for spark compensation. Submerge Tank Check this box to cause the EDM machine to automatically fill the tank with fluid so the material will be submerged. Offset Register Enter the number of the register used to store the offset value for the initial cut. Initial Power Setting Specify the power setting for the initial burn into the material. Power Setting Specify the power setting for the remainder of the burn along the contour. Initial Feed Rate Specify the XY axis feed rate, in inches per minute, for the initial burn into the material. Feed Rate Specify the XY axis feed rate, in inches per minute, for the remainder of the burn along the contour. Work Offset Enter the work offset for the operation. This value is used by the post processor to define the desired fixture offset register. Flushing Specify the force that will be used to propel the flushing fluid down the wire. Your choices are High, Medium, Low and None.

5 SURFCAM Reference Manual, Chapter 6 Wire EDM 345 Program Number Specify the program number that the EDM machine will use for the program. On some controls, this is the O number at the top of the program. The largest number accepted is 32,767. Comments You can place a comment into the tool change output during post processing as a message to the operator. Insert Post Processor Commands... Refer to the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2.3: Inline Text on page Cut Control Tab Figure 6: 2 Axis EDM Contour Cut Control tab

6 346 SURFCAM Reference Manual, Chapter 6 Wire EDM Wire Compensation This is the wire compensation type. The actual value used for wire compensation is the value for Spark Gap on the Tool Information tab. None This method outputs the coordinates of the chained geometry. The output will not include G41/G42 codes. SURFCAM This method outputs the compensated coordinates of the chained geometry. The coordinates are adjusted by the value for Spark Gap. The output will not include G41/G42 codes. Control This method outputs the coordinates of the chained geometry. The output will include G41/G42 codes. Both This method outputs the compensated coordinates of the chained geometry. The coordinates are adjusted by the value for Spark Gap. The output will include G41/ G42 codes. Compensation Side Choose Right or Left as the side on which to cut the contour. The compensation will apply to this side. Taper Taper is the value of the angle between the wire and the normal to the part. A positive value will create an edge that is beveled toward the top of the part. A negative angle will create an edge that is beveled toward the bottom of the part. A value of zero will create a part edge that is perpendicular to the surface of the part. Retract Distance Figure 7: Positive Taper angle Figure 8: Negative Taper angle This is the distance from the contour of a point that is the beginning of a leadin move or the end of a leadout move. Sharp Corner Type A sharp corner occurs when two sides of a part intersect at a point and create an interior angle that is less than 180. The toolpath around a sharp corner can be one of three shapes.

7 SURFCAM Reference Manual, Chapter 6 Wire EDM 347 Sharp Choose Sharp to force two consecutive parts of the toolpath to intersect at a point. Round Choose Round to force an arc to be inserted between two parts of the tool path. Figure 9: Sharp Corner Loop Choose Loop to force a loop to be inserted between two parts of the tool path. Figure 10: Round Corner Figure 11: Loop Corner Overlap Overlap is not currently active. Lead In Out Type This parameter controls the lead moves from a Retract Point to a Start Point or from an End point to a Retract Point for Skim passes. SURFCAM will display the EDM Leadin and Out Information dialog box. Figure 12: EDM Leadin and Out Information dialog box

8 348 SURFCAM Reference Manual, Chapter 6 Wire EDM Lead Type Straight Line The lead moves are along a line normal to the contour. The wire makes a 90 turn to travel along the contour. Teardrop The lead moves consist of a line from the Retract Point to one end of an arc whose measure can be from 120 to 180. Figure 13: Straight Line The other end of the arc is located at the intersection of the normal to the contour and the toolpath along the contour. The arc is tangent to the toolpath. You will enter the radius and angular measure of this arc. Offset Curve Overlap This parameter is not currently active. Figure 14: Teardrop Length Length is not currently active. Angle Angle becomes active when Lead Type is Teardrop. This is the angular measure of the arc in the teardrop lead move. It can have a value between 120 and 180. Radius Radius becomes active when the Lead Type is Teardrop or Offset Curve Overlap. This is the radius of the arc in each of these moves. This value must be less than one fourth of the Tab width. Feed Rate Feed Rate is not currently active. Stock To Leave This is the stock to leave after the first pass. Pre-drill Thread Points Check this box to have the EDM machine pre-drill the thread points, if it has that capability. Burn To Thread Point On Exit Check this box to burn from the retract point to the thread point at the end of the last skim cut. Tab Width Enter the length of the Tab or enter zero for no Tab.

9 SURFCAM Reference Manual, Chapter 6 Wire EDM 349 Tab Stop Code A tab stop code is placed at the end of the first cutting pass after the wire has reached the Retract Point. Another stop code is placed at the end of the pass that cuts the Tab but before the move to the other Retract Point. OPSTOP OPSTOP will cause a reading of the stop switch on the controller. STOP STOP will force an automatic stop. Cut Strategy When you cut multiple contours, you have three options for the order in which Rough (or initial) passes, Tab cuts, and Skim passes are performed. Rough, Tab, Skim each profile The Tab is cut after the Rough pass. Then the Skim passes are performed before SURFCAM moves to the next profile. Rough, Skim, Tab each profile The Skim passes are performed after the Rough pass. Then the Tab is cut before SURFCAM moves to the next profile. Rough and Skim each, then All Tabs The Rough and Skim passes are performed, but not the Tab cut, before SURFCAM moves to the next profile. All passes on all profiles are performed before SURFCAM cuts the Tabs on each profile. Part Thickness It is optional to enter the thickness of the material being cut. Upper Guide Distance This is the distance from the top of the work piece to the upper guide. Lower Guide Distance This is the distance from the bottom of the work piece to the lower guide.

10 350 SURFCAM Reference Manual, Chapter 6 Wire EDM Skim Cut Tab Figure 15: 2 Axis EDM Skim Cut tab Number of Skim Passes Enter the number of skim passes to be made after the first pass. Offset Register Enter the number of the register to be used to store the offset value for each of the skim passes. Stock To Leave This is the stock to leave at the end of each skim pass. Power Setting This is the power setting for each skim pass.

11 SURFCAM Reference Manual, Chapter 6 Wire EDM 351 Flushing Enter the Flushing force (None, Low, Medium or High) to use for each of the skim passes EDM Options Tab Figure 16: 2 Axis EDM Options tab Maximum Feed Between When the wire finishes one pass and must move to the start of the next pass, it can either rapid or feed across the part at the current feed rate setting. If the distance from the end of one pass to the start of the next is smaller than the value specified here, the wire will feed across. Note: Too large a value could cause the tool to overcut the part by feeding through a narrow area. To avoid this, reduce the Maximum Feed Between size to less than the distance to the start of the next pass.

12 352 SURFCAM Reference Manual, Chapter 6 Wire EDM Constant / Cutter Radius This controls how the value you enter in the accompanying box (on the left) will be used. Constant The value you enter will be used for this parameter. Cutter Radius The value you enter will be multiplied by the radius of the cutter selected to determine this parameter. Corner Angle (30º 150º) This is not currently available in Wire EDM. Corner Clearance This is not currently available in Wire EDM. Side Clearance This is the side clearance for the infeed and outfeed movements at the start and end of each pass. Refer to Constant / Cutter Radius (p. 352). Side Finishing Step Size This is the default distance between finishing passes. This is the distance for the wire to cut into the work on each finish pass. The default overlap is 80% of the wire radius. Refer to Constant / Cutter Radius (p. 352). Gouge Check There are two options when developing toolpaths that affect the gouge checking. Full This is the default. SURFCAM will evaluate the entire profile before generating tool paths. This guarantees that the tool path will not gouge the profile. Single When creating a tool path that drives the center of the tool on the profile, select this option. Otherwise the system will not machine all of the chained elements when they intersect others. Sort Type Refer to the online SURFCAM Getting Started Manual, Chapter 6: 2 Axis, Sort Type on page 187. Display Thread Point Changes Yes SURFCAM will notify you when a thread (plunge) point is changed, and the reason why the point was changed. No SURFCAM may change the thread point without notification.

13 SURFCAM Reference Manual, Chapter 6 Wire EDM 353 Sharp Corner Angle SURFCAM creates toolpaths by creating offsets from the contour or sides of a part. The offsets around a corner angle will be two lines that may or may not intersect. The Sharp Corner Angle parameter tells SURFCAM how to fill the offset gap when a sharp corner angle is between 5 and < Corner Angle < 160 If a corner angle is in the range of 5 to 160 and is greater than the value you enter for Sharp Corner Angle, SURFCAM will extend the offsets so they intersect at a point. If a corner angle in this range is less than or equal to the value you enter for Sharp Corner Angle, SURFCAM will close the offset gap with two lines, an arc, or a loop depending on your selection of Sharp, Round, or Loop for the Sharp Corner Type parameter on the Cut Control tab. Notes: Corner Angle > 180 The lines will intersect. The wire path continue at the intersection. 160 < Corner Angle < 180 Offsets of corner angles between 160 and 180 will not intersect, but SURFCAM will automatically extend them so they do. The toolpath will then change direction at this intersection. Corner Angle < 5 SURFCAM will close the gap between the two offsets by inserting an arc. Curve Tolerance SURFCAM will break all contour moves along a spline into linear moves along chords connecting two points on the spline. When driving the tool along a spline curve, SURFCAM will adjust the length of the chordal moves to make sure that the contour is never a greater distance from the chord than the value of the Curve Tolerance. Restore Defaults Restore the SURFCAM default values for EDM options.

14 354 SURFCAM Reference Manual, Chapter 6 Wire EDM AXIS The 4 Axis operation is used to make a single pass with the EDM wire in swarf cut mode. This operation is available to end users with the SURFCAM 2 Axis PLUS system and above. Before you use the 4 Axis operation you must: 1. Create a top profile; 2. Create a bottom profile; 3. Connect the two profiles with a surface; 4. Edit the surface so the arrow is A. attached along the bottom profile; B. pointed to the outside of the surface; C. pointing in the direction of the cut; 5. Create a Thread Point; 6. Create a Cut Point (the location Figure 17: 4 Axis EDM Example where the wire will be cut). Note: The Thread and Cut points must be on the side of the surface to be cut. They must be located so the wire will not gouge the part as it moves from the Thread Point to the Start Point and from the End Point to the Cut Point. The Start Point of the cut will be the location on the bottom profile where the surface arrow is attached. When you click 4 Axis on the NC > Wire EDM menu you will be prompted to Select a surface. Select the surface by clicking its surface arrow. (Make sure the arrow is pointed in the right direction. The 4 Axis EDM dialog box will be displayed. Refer to 1. Section 6.2.1: Tool Information Tab on page 343, 2. Section 6.3.2: Cut Control Tab on page 361, and 3. Section 6.2.4: EDM Options Tab on page 351. Note: Since gouge checking is not currently implemented in 4 Axis EDM, it is recommended that you enter a value of 0 for the Tool Diameter parameter on the Tool Information tab. It is best to use the cutter compensation on the machine controller to control potential gouges in narrow interior angles.

15 SURFCAM Reference Manual, Chapter 6 Wire EDM 355 It is also recommended that you enter a value of 0 for the Curve Tolerance on the Cut Control tab. This will prevent a tool move that is within the allowable chordal deviation from cutting off the tip of a sharp exterior corner. After you click OK on the 4 Axis EDM dialog box, the Select Point menu will be displayed and you will be prompted to Select the thread point of the wire. Click on the Thread Point. You will then be prompted to Select cut point. Click the Cut Point. SURFCAM will create the 4 Axis toolpath and display the tool motion on the screen. It will then display the Keep Operation dialog box. Click Accept to keep the operation. Note: To permanently save these toolpaths, you must use the Save command on the File menu to re-save the DSN file and the ICD file Tool Information Tab Figure 18: 4 Axis EDM dialog box

16 356 SURFCAM Reference Manual, Chapter 6 Wire EDM Tool The name of the currently selected tool is displayed. The corresponding tool reference number is displayed on the button. To select a different tool, edit a tool record, or add a new tool, click the button to display a Select EDM Tool dialog box. Refer to Section : Select an EDM Tool on page 357 and Section : Edit or Add an EDM Tool on page 359. Material The name of the currently selected material is displayed. The corresponding material reference number is displayed on the button. To select a different material, edit a material record, or add a new material, click the button to display the Select Material dialog box. Refer to the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2.2: The Material Library on page 76. Tool Number Specifies the tool number for the upcoming cutting cycle. Diameter Offset The diameter offset number not a diameter measurement to be used with this tool. On most NC machines a D or an H number appears in the code to identify which offset number to activate not the distance to offset the tool. Initial Power Setting This value is used by the machine for the initial burn into the material. Power Setting Power Setting is sometimes called EPAC. This value is used by the machine for the length of the contour. Feed Rate Feed Rate is sometimes called velocity. Specify the XY axis feed rate in inches per minute. Taper Angle The angle of the wire as it moves along the contour. Spark Gap The distance to offset the tool path for spark compensation. The system does not include this offset in the tool path, rather it is used by the control. Wire Feed If the machine has the ability to automatically feed the wire through the material, set this to Yes. Program Number Specifies the program number that the NC machine will use for the program being generated. On some controls, this is the O number at the top of the program. The largest number accepted is 32,767.

17 SURFCAM Reference Manual, Chapter 6 Wire EDM 357 Comments You can place a comment into the tool change output during post processing as a message to the operator. Insert Post Processor Commands... Refer to the SURFCAM Getting Started Manual, Chapter 3: Common NC Parameters, Section 3.2.3: Inline Text on page Select an EDM Tool To select an EDM tool, click the button after the description of the current tool. Figure 19: Tool and Material Buttons on Tool Information Tab Figure 20: Select EDM Tool dialog box. Go to first record. Go to previous record. Go to next record. Add EDM tool to library. Edit / Save the current tool information. Delete the current tool record. Go to last record. Figure 21: Select EDM Tool dialog box Toolbar

18 358 SURFCAM Reference Manual, Chapter 6 Wire EDM Tables This box is available so you can select from different tool tables that you might have. Available Tools This list box will display the available EDM tools. The tool reference number and description appear in the list. Selecting a tool from the list selects its parameters as the ones that will be used in the next NC EDM operation. You can change the value of the tool parameters in the text fields, but the changes affect only the current operation and are not saved in the EDM tool library. EDM Tool Parameters List Box The EDM tool parameters that can be changed are displayed in the EDM Tool Parameters list box next to the Available Tools list box. Figure 22: EDM tool parameter list box Spark Gap This value defines the distance to offset the tool path for spark compensation. The system does not include this offset in the tool path, rather it is used by the control. Diameter The diameter of the wire. Initial Power This value is used by the machine for the initial burn into the material. Power Setting This value is used by the machine for the length of the contour. Wire Feed If the machine has the ability to automatically feed the wire through the material, set this to Yes.

19 SURFCAM Reference Manual, Chapter 6 Wire EDM Edit or Add an EDM Tool New tools can be added to the EDM tool library. Features of an existing tool can be edited. Click the Edit/Save button or the Add EDM Tool button to display the EDM Tool Information dialog box. Figure 23: Edit/ Save Tool Figure 24: Add EDM Tool Figure 25: Use this dialog box to edit an EDM tool or add a new EDM tool to the EDM tool library. Reference Number The tool reference number. This number is used to look up the tool in the EDM tool library and must be unique. (Hint: Choose a reference number before selecting the add tool button. There are usually unused reference numbers following each group of tools. Use one of these numbers when adding new tools to the list.) Tool Description The description of the tool as it is to appear in the EDM tool list box on the Select EDM Tool dialog box. This is limited to 40 characters. (The default descriptions provided include information such as the size and tool material type.) Tool Number An integer value that indicates the station in the machine s tool carousel that will hold the current tool. If the machine being used has no tool carousel, the post processor for that machine will ignore any entry for Tool Number.

20 360 SURFCAM Reference Manual, Chapter 6 Wire EDM Length Offset Not applicable to Wire EDM. Diameter Offset Diameter Offset is an integer value that tells the post processor the number of the controller register in which the diameter offset value will be stored. For many controllers this is the D number. Tool Material The material from which the tool is made. Default Coolant The default flushing to be used with the wire. This can be Off, Flood or Mist. Drawing Files Specify the files used to draw the tool and the tool holder. When tool paths are being drawn, you can press the tab key to toggle through displaying just the tool, the tool and the tool holder, or neither the tool nor the holder. The file in the Tool list box contains the design for the tool. Click the... button to display the Select Tool Drawing File dialog box which is used to select an existing tool file. Figure 26: Select Tool Drawing File dialog box These tool files are design files in the same format as a DSN file except they are given the TLE file extension. The default directory for storing TLE files is C:\ SURFCAM\Tool. Spark Gap, Diameter, Initial Power, Power Setting, Wire Feed Refer to Section : Select an EDM Tool on page 357. Chip Load Per Flute Not applicable to Wire EDM.

21 SURFCAM Reference Manual, Chapter 6 Wire EDM Cut Control Tab This section describes the parameters that appear on the 4 Axis and the 4 Axis UV EDM Cut Control tabs. Figure 27: Cut Control tab for Wire EDM Cutting Method On This is used to drive the center line of the wire directly along the path of the chained elements. Right SURFCAM drives the tool to the right side of the contour, based on the chaining direction. Left SURFCAM drives the tool to the left side of the contour, based on the chaining direction.

22 362 SURFCAM Reference Manual, Chapter 6 Wire EDM Curve Tolerance SURFCAM will break all contour moves along a spline into linear moves along a chord between two points on the spline. When driving the tool around a spline curve, SURFCAM will adjust the length of the chordal moves to make sure that the edge of the contour is never a greater distance from the chord than the value of the curve tolerance. Side Clearance (type) A side clearance move is a linear move that is perpendicular to the beginning of a leadin move or the end of a leadout move. If lead moves have not been defined (if Lead Type is None), a side clearance move will be perpendicular to the part contour. Side clearance moves are commonly used for applying cutter compensation. They are also often used to position the tool away from the profile to avoid leaving a dwell mark. The Side Clearance (type) parameter indicates the cutting situation in which a side clearance move will be applied. None No side clearance moves are applied. On All Apply side clearance moves to all lead moves. With Cutter Comp This will force the post processor to add diameter compensation codes to the infeed and outfeed moves in the final NCC program G41, G42 and G40 on most machines. Side Clearance Amount This is the length of the perpendicular side clearance moves (infeed and outfeed moves to and from lead moves). When no leadout move has been defined this is the value of the leadout move, away from the part, along a perpendicular to the part. When you set the Side Clearance (type) to be With Cutter Comp, the Side Clearance (value) must be larger than the value stored in the corresponding diameter offset register on the machine, otherwise the machine may not be able to correctly cut the contour. Cutter or diameter compensation involves making an adjustment for the difference between the programmed tool diameter and the diameter of the actual tool that is used. Finish Passes SURFCAM automatically incorporates finish passes into the cycle if you enter a nonzero number. For a single pass around the contour, set this value to 1 or zero. You can, however, have as many finish passes as desired. Each pass will remove the amount of stock entered in the Finish Spacing parameter. Finish Spacing Specify the amount of stock to be removed in each finish pass.

23 SURFCAM Reference Manual, Chapter 6 Wire EDM 363 Stock To Leave This cutting operation will leave the stock in the amount of the value entered on the sides of the contour. Leadin Move / Leadout Move SURFCAM can add linear motion or arc motion that causes the tool to approach and depart the workpiece with a tangent move. Click the Leadin Move / Leadout Move buttons to display the Leadin Information / Leadout Information dialog boxes. These dialog boxes are the same as those used in 2 Axis cutting. Refer to the SURFCAM Getting Started Manual, Chapter 6: 2 Axis, Section : Leadin/Leadout Parameters 2 Axis on page EDM Options Tab Refer to Section 6.2.4: EDM Options Tab on page AXIS UV TRIM The 4 Axis UV operation is used to trim excess material from the edge or periphery of a part. One application is to trim the edges of a part that has been formed from a relatively thin sheet of material by some process such as vacuum forming or stamping. The The toolpath is directed by a trimming curve that coincides with the final edge of the part. During the 4 Axis UV operation, the outside edge of the tool is tangent to the trimming curve. The center of the tool is offset to one side or the other of the trimming curve. This makes it possible to trim material from the edges of a hole in the interior of a part as well as material from the outer edges. Doing both on the same part requires two separate 4 Axis UV operations. The angle between the top surface of the part and the edge that is cut by the side of the tool is determined by direction lines that Figure 28: A trimming curve you attach to the trimming curve at appropriate locations. The angle at which the direction lines intersect the surface is the angle at which the tool will cut. If a direction line is normal to the surface at a given location, the angle between the surface and the edge will be 90. The size of the cutting angle, as the tool moves from the location of one direction line to the next, will change in a smooth transition. Direction lines must be attached to the trimming curve at end points of elements that make up that curve. If you must put a direction line between the end points of an element (such as a spline, an arc or a line), you must use the Break 1 command on the Edit > Trim/Break menu to break that element where it intersects the direction line. Figure 29: Trimming curve with direction lines

24 364 SURFCAM Reference Manual, Chapter 6 Wire EDM Figure 30: Views showing tool tilted to follow direction lines To access the 4 Axis UV operation, click 4 Axis UV on the NC > Wire EDM menu. The Trim Curve chaining menu will be displayed and you will be prompted to Select beginning element of trimming curve. After you complete the chaining of the trimming curve, the EDM 4 Axis UV Trim dialog box will be displayed. Figure 31: EDM 4 Axis UV Trim Tool Information dialog box

25 SURFCAM Reference Manual, Chapter 6 Wire EDM 365 Refer to 1. Section 6.3.1: Tool Information Tab on page 355, 2. Section 6.3.2: Cut Control Tab on page 361, and 3. Section 6.2.4: EDM Options Tab on page 351. After you click OK on the EDM 4 Axis UV Trim dialog box, the Select menu will be displayed. You will be prompted to Select tool direction lines or vectors. Select the lines or vectors and click Done. You will then be prompted to Select offset side. Click on the appropriate side of the trimming curve. SURFCAM will create the trim toolpath and display the tool motion on the screen. The Keep Operation dialog box will be displayed. Click Ok to keep the operation. Note: To permanently save these toolpaths, you must use the Save command on the File menu to re-save the DSN file and the ICD file. 6.5 OPTIONS The Options command displays the NC Option dialog box which contains all the NC mode Options tabs. It provides a convenient way to view and/or edit the EDM Options tab and the tabs of the other NC modes at the same time. The EDM Options tab parameters are described in Section 6.3.3: EDM Options Tab on page 363.

26 366 SURFCAM Reference Manual, Chapter 6 Wire EDM