MECHANISM OF ROBOTCUT ( ALPHA-OID )

FANUC ROBOCUT is a latest Generation, High Speed EDM wire cut machine from FANUC, Japan, which can serve your purpose of very precise machining.

Fanuc offers the submerged EDM wire cut machine in three different Sizes and models as follows,

ROBOCUT Alpha-0 iD (Machining stroke 370 mm X 270 mm X 255 mm). Alpha-0iD is with Automatic wire feed mechanism (AWF). ROBOCUT Alpha-1iD (Machining stroke 600 mm X 400 mm X 310 mm). Alpha-1iD is with Automatic wire feed mechanism (AWF), (Optionally 410 mm, Z axis stroke can be provided) These high speed and high precision, submerged, 5 axis EDM Wire cut machines have following features,

Artificial Intelligence Pulse Control (PATENTED)

This feature precisely counts the effective discharge pulses per unit time. The intelligence of the machine counts the pulses, which are actually contributing in the cutting, and the pulses, which are not contributing in the cutting. Accordingly to maximize the efficiency, the feed is controlled in Nanometer. Nano Interpolation This feature controls all the axis movements in Nanometer (1000th part of 1 micron).

NC PROGRAMMING O0159 (DEM12136) G00 G40 G50 ; M60 ; M21 P2 ; G92 X0. Y0. Y-3. ; M21 B7 H6 ; M15 P0 ; M89 ; S1 D1 G04 X0. ; G90 G01 G41 Y0. Y-3. ; X0 Y0 ; X-15. Y0 ; X-15. Y5; X-10. Y15 ; X-20. Y15 ; X-20. Y25 ; X-10. Y25 ; X-10. Y30 ; X-15, Y30 ; X-10. Y30 ; X-15 Y35.5 ; X-10. Y35.5 ;

X-10 Y35 ; X-5. Y35 ; X-5. Y40 ; X5. Y40 ; X5. Y35 ; X10. Y35 ; X10. Y35.5 ; X15. Y35.5 ; X15. Y30 ; X10. Y30 ; X10. Y25 ; X20. Y25 ; X20. Y15 ; X10. Y15 ; X15. Y5 ; X15. Y0 ; X0. Y0 ; M50 ; M30 ;

MACHINING PROCESS Compressor 1. Turn on the compressor main switch 2. Release the emergency switch 3. Turn on the compressor 4. Open the valve

EDM Machine 1. Turn on the EDM machine main switch 2. Turn on the EDM MCU machine 3. Open the valve 4. Release emergency switch 5. Turn on the EDM controller panel

Product Process 1. Open the menu Programming 2. Click the open file icon 3. Search for unused file number 4. Create new file DEM12132 5. Open edit mode 6. Key in the file name by using Input button 7. Key in the product coordinate data in programming by using Insert button 8. Put the work piece 90 perpendicular to the table using L- square ruler 9. Click position icon 10. Set the stroke limit for X,Y,Z and make sure when using panel jog button is on and if use remote press Pending (PEND) button 11. Set the distance between the nozzle and the work piece is 0.2mm 12. Click Limit On at Z axis 0.02 mm 13. Move the nozzle near the work piece 14. Click setting icon , on the setting screen has wire , work , rot and scale

15. At Wire block set the diameter of wire 0.2mm and type of wire hard brass * HBZ (N)20 ] 16. At Work block set the type of work piece aluminium 17. At Scale block set rotation from = 0 to = 90 18. Open graphic menu then click erase auto play and check the design 19. Make sure the wire in the vertical condition then trip wire 20. Use suitable speed and move the wire near to the work piece 21. If the short icon is pop-up so move the wire away from the work piece by using the smallest scale until the pop-up is gone 22. Start the cutting process

Cutting Process

1. Open the program menu 2. Click on the program name 3. Click reset button 4. Choose memory mode then click Fill button 5. Open graphic menu then click erase auto play and check the design 6. Then click 4 condition (4 COND.) or EDM POWER , WIRE FEED , WATER and TENSION 7. Lastly , click cycle start button

CONCLUSION ADVANTAGES OF EDM WIRE CUT EDM-Wire Cut is much faster than EDM. It can cuts intricate shapes, narrow slots, etc. No burrs generated during the process. The wire electrodes used are much cheaper than shaped electrodes in EDM. EDM-Wire Cut cables to cut tapered shape products. Electrical Discharge Machining or EDM is a highly accurate method of part production. Wire EDM technology is essential for higher tolerance parts and repeatable tooling. Achieving high accuracy and tighter tolerances is essential for many industries such as aerospace, medical, injection molding and tool and die. With Electrical Discharge Machining we can produce and repeat the required specifications with ease DISADVANTAGES OF EDM WIRE CUT The edm-wire cut machine more expansive than other machine. High skills are required to handle the machine. The work piece only conductors can be machine. Edm-wire cut have slow material removal rate (MRR) and less flexible compared others machine. How Wire EDM Works Wire EDM machining (also known as "spark EDM") works by creating an electrical discharge between the wire or electrode, & the workpiece. As the spark jumps across the gap, material is removed from both the workpiece & the electrode.

REFERENCES

1. http://ezinearticles.com/?An-Introduction-To-Wire-EDM&id=407706 2. http://en.wikipedia.org/wiki/Electrical_discharge_machining#Sinker_EDM 3. http://www.scribd.com/doc/117222757/safety-precautions-of-EDM 4. http://en.wikipedia.org/wiki/Electrical_discharge_machining 5. http://www.indiamart.com/fanuc-india/products.html 6. http://www.slideshare.net/NurShafikahAhmadMaulana/report-bengkel-edm-wirecut 7. http://mienasukasuki.blogspot.com/2011/09/report-bengkel-cnc-edm-wire-cut.html 8. Electrical Discharge Machining Elman C. Jameson 9. Complete Edm Handbook Carl Sommer, Steve Sommer 10. Advanced MacHining Technology Handbook James Brown