angle accuracy

[Bob Mikl]

I am trying to cut a 15-degree angle using a charmilles robofil 510. Before the cut I completed a guide setup at the maximum angle of 10-degrees, switched to large flushing cups, changed out threading diffuser to 1.8mm, changed over to soft brass wire, and had Mastercam double check my part program to make sure it was correct. After all that preparation the part is consistently ¼ degree off. I can manually compensate for this error but I would think I should be able to achieve better accuracy. Any ideas would be greatly appreciated.

[Hardmill]

You may want to have someone come in and service your machine.

How old is it??

 

 

PEACE

[Kannon]

I dont know about charmilles robofil..

but a mits has z heights that need to be entered in. I have seen our wire edm guys battle angles because 1 of their z heights were off.

 

not sure, but that is the first thing that comes to mind.

[John13]

quote:

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not sure, but that is the first thing that comes to mind

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ever?

 

 

[b_daddy]

I would agree with Kannon, double check the height of your guide numbers that you have entered in your machine. My guess is that is where the problem is.

[Bob Mikl]

The machine is 10 years old and maintained pretty good so I belive I can exclude poor maintanance.

 

As far as the z height, that included in the part program.

 

keep the ideas coming, anything helps

[b_daddy]

Ok, now that we ruled out the z height. Even though you swicthed out your flush cups, is the wire hitting them at all?

[Bob Mikl]

I did a dry run of the program off to the side to make sure there was no interferance with the cups.

[HevyMetl]

Have you checked you machine parameters for the guide hts? When I change guides on the Makino I have to reset the machine parameters after I establish guide ht to the table zero. This is not the program numbers. It is actually a number in the machine parameters which tells the machine where in Machine Absolute the upper and lower reside.

[Bob Mikl]

On the Charmilles, when I run a guide setup it automaticaly figures the relationship of the guides to the table.

[Bob Mikl]

I know this is a little off topic, but I sure do appreciate the help!

[HevyMetl]

If it does it automatically I would give it a quick check off of a gauge block to make sure it was correct. ¼° sounds like a lot to me and that is typically set-up error in plane levels.

[Bob Mikl]

That is a great idea! I will give that a try when the machine is not running. Thanks for the responses!

[Guest]

is your wire vertical to begin with?is the piece you are burning square to all planes?is your part setting on the table flat?just a few things to consider.how old are your guides?

[Matt Berube at Ferron Mold]

quote:

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I completed a guide setup at the maximum angle of 10-degrees, switched to large flushing cups, changed out threading diffuser to 1.8mm, changed over to soft brass wire

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If this is the exact sequence you used I think you'd get better results by running "guide setup" AFTER changing to soft wire.

 

This should definitely make a difference.

[Bob Mikl]

Dell,I made sure the block was indicated in before making a cut. The guides are a little old but I have had no problems cutting other parts.

[Bob Mikl]

Matt, yes you are correct, unfortunately I did not list the sequence in the order in which it was performed.

I belive John has a good idea about double checking the guide setup with gage blocks, but I am having problems accurately figuring the dimenision because I need to take into account the guide holder.

[Guest]

bob, check the surfaces that your guides are mounted to with an indicator to make sure that they are parallel with your table along both the x and y.if they have been bumped, this would throw it off.i am just saying this because this

my second shift guy will run into something and not tell me about it.

[Bob Mikl]

del,indicated the bottom head from the table and looks good within .002.

[Guest]

bob, the last thing i know to tell you to do is check the numbers that are constant from your table to your lower guide and upper guide.these must be off, if you have replaced your guides or adjusted your upper or lower head in any way.reducing the tension on your wire will actually improve the accuracy of your angle at 15 deg.,but it would not be off that much at normal tensions.for a fanuc wire edm i also have to remove the upper jet nozzel if the angle exceeds 12 degrees.does your actual angle exceed 15 degrees in dry run in the corners if there are any

or anywhere else along the geometry?

[Bob Mikl]

no interferance with the nozzle, and there are no compound angles in the part.

I think everyone is right in suggesting the guide distances are off but I have to figure out how to accuratley measure to my guides that are up into the holders.

Maybe Charmilles has that dimension.