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When I try to create cutting technology in my CHMER G32S wire machine using the “Spark Offset”, quite often I do not get any usable code, it is red with yellow background. Any suggestions?

I will setup an example cut that reflects your problem. Refer to the article I wrote for Spring of 2020 if you need help for “Spark Offset” creation. We will be cutting a 2.0” thick tungsten carbide (WC) punch with 0.010” diameter wire and want a good finish, hence, the need for 3-passes. You must have an open file you wish to save the technology to and have “Spark Offset” open. See photo below…

Go to the “MDI” page, then open F2-“DEF.S.BASE” and find WC material for 0.0098” diameter wire with the thickness range that is closest to your desired height. To get the code you need for a 3-pass program, you have to type in a thickness within the range that is given in these pages. See next photo.

Go back to “FILE” page and once you have the correct thickness in the active box, the code will go black from red allowing you to transfer to your .nc program. From here you would follow the normal procedures described in Spring issue of 2020, and as follows…with the “REG.NC PGM.” highlighted, press enter to add the code to the top of your open program.

You will know the code is added to your program when you see the asterisk (*) next to the name. Then scroll left arrow to view the program.

You will see that the code has transferred from the Spark Data Base. Just remember to save your program! The asterisk will disappear once saved. I will continue in following issues on how to build and save your own library of technology under the “USE S. BASE” or “USER” data base.

Alan Barbick, EDM Network Applications Manager

We have a CHMER CNC sinker with software version M (XY 88 M Series) and are having trouble getting a main program to call up a sub-program, the manual is not explaining it very well. Our ultimate goal here is to burn at a table position then move on to the next and so on. Please respond, in detail what to do. Thanks

Sometimes when CHMER updates their software the manual is slower to follow with the changes to coincide. I will show a sample that should work for any main program to call up a sub-program with your software version.

Your main program will have the callout and any position moves. The sub will have the burn technology.

Pictured above is an example of a main program. Start by adding in an E98 to call up the sub. Scroll right to the location by using the arrow (pictured below). Type in the name of the program and always use the letter “O” in front. The name cannot be more than 5 characters long, including the “O”.

Use the above arrow to scroll to the right thru the line of code to type in the name of your sub-program.

Insert a block and add an E75 which is an incremental move to the call out position “A02”. We chose “O5555” as the name of the sub-program, as an example.

The above main program sample will call up the sub and move to the next position and so on. Just remember to save the sub-program the same way you call it up, i.e., “O5555”.

Now, here is the “makes no sense” part. When you go to run your main program, choose mode “0” (zero) which states “NO SUB” to enable the sub to run. We are not certain what CHMER was intending here, but that is how it works to run the main program and calling up the sub.

Alan Barbick, EDM Network Applications Manager

Can you tell us if our AMS AW3 wire machine has the fine finish circuity? We are looking for the finest surface finish possible in A2 steel.

That would be the added optional TFC circuitry (fine finish circuitry). If you go to my article from Spring of 2020 (page 41), you will be able to follow with the technology generation procedures. When you have added in the corresponding materials and conditions (see photos) and you get to “NO. OF CUT”, type in 5. If the tech produces the 5 passes in a clear back drop and not red lettering with yellow back drop, you have the TFC circuitry. EDM Network performed a recent test in A2 steel for a 1.0” cube using 0.010” diameter hard (1100 T/S) brass wire with an AMS AW6X and TFC circuit. To achieve the finest finishes, demands a well running machine with very good, consistent water conditions, i.e. 20oC temperature and an 80-90 K ohm for conductivity. Our results here for the 1.0” cube was a 1.5-hour cycle time and a 3 VDI surface finish.

Above example of a machine without the TFC circuitry.

Alan Barbick, EDM Network, Applications Manager

We have an older model CHMER CW360S wire machine and are having some problems with the AWT feeding thru the bottom nozzle. We have disassembled and cleaned the bottom housing replacing the bearings which seems to help some, but the issue is still there on most cycles. Any ideas on what else we can try?

First, remove the lower head roller assembly (the brass block on the right side held in place by three metric bolts- photo1). This will expose the water jet compartment (see photo2).

Next, activate the manual threading water jet icon on the handset-photo3. Once turned ON there will be high pressurized water releasing from the ports, if not, you may have a clogged jet. The high-pressure water jet acts as a driver for rotating the wire roller assembly forcing the wire to exit to the rear of the machine.

Now, remove the 2 small set screws, pictured in photo4, from the lower head. These screws open the access to the water jet gateway. Photo5 shows the actual jet ports. While holding a rag in place over the open set screw holes, turn ON the water jet again for a few seconds to flush out any dirt. You may need to repeat this process a few times to secure a good cleaning. Replace the set screws, but if the issue persists, use a paper clip or straight pin to pick out any debris in the same threaded hole openings. Lastly, if your problem continues, check for wear inside the housing of the lower head where the brass wire roller assembly rotates, if worn, you may need a new lower assembly. The AWT on CHMER wire machines normally run flawlessly for many hours of operation, we do see this problem only occasionally especially with older machines, heavy production, or poorly maintained equipment.

Alan Barbick, EDM Network Applications Manager and Sergio Altamirano, Service Manager

We have a CHMER G64S wire machine that we are adding a new product/fixture to the machine table.  It has been a while since I’ve utilized the technology development as this is a production machine with seldom changes.  Can you review this procedure for me?  Thank you!

First, open your .nc file and scroll right or left soft key arrow until you reach the page with “SPARK OFFSET” – F8

After “SPARK OFFSET” is pressed the above page will appear. Scroll thru data choices and select what describes your cutting situation. CHMER has a fairly large library of data to choose from but incase all of your choices are not available the data spread sheet (“1 CUTS - 2 CUTS – etc.) will appear yellow in color with red lettering. If this happens, don’t get discouraged, first try changing the THICKNESS (usually safer to go lower), if that doesn’t work try wire diameter (sometimes there are 0.010” but no 0.012” diameter settings, for example, in that case increase your part thickness beyond your actual if using 0.012”) and lastly try changing the number of cuts (or passes). Personally, I use these data pages as a guide and adjust for my situation’s demands, i.e. surface finish, accuracy, or speed, as to cover ALL cutting environments is nearly impossible. Offsets (circled) are automatically generated based on wire diameter and the criteria you have selected.

Once you are satisfied with your selections scroll until “REG. NC PGM.” Is highlighted in green. This gives you the next option of adding the technology you have chosen into your .nc program by pressing “ENTER”. In the upper left corner, you will see your program name and an asterisk (*) in front of it, this tells you that the exercise is complete, and program needs to be saved.

Next, simply use the right or left solid arrow of your machine soft keys to page over to your program to view the technology you just created. The machine generates everything you need to start your cut. The power code is output in S100, S200, etc. increments. “H” is the reference for your offsets, but these can be changed to “D” if you prefer, just be sure to match your cutting code passes (offsets & technology reference) with the header to avoid any mishaps. And, of course SAVE your program when finished.

Alan Barbick, EDM Network Applications Manager

We have a CHMER 360 wire machine from 2005 and have received a large order for multi-cavity die blocks that requires numerous wire threading/cuts, we like your new generation Automatic Wire Threader, can our older model machine be upgraded?

Due to major differences in the mechanics and software between 2^nd and 3^rd generation AWTs it cannot be done without great expense. See the comparison photos.  Therefore, with your situation, and if you can budget it, we have new G32 wire EDMs in stock for under $100K that all offer “wire re-thread at break point” technology that we believe is the industry’s most reliable and no more tracing back to start point for re-threading. Most of which comes from the simplistic design, low cost to maintain, and speed of operation.  There is a video link on our website  https://www.edmnetwork.com/video-gallery.asp titled “Video:  World’s Fastest Threader” for your viewing.

A sample of your CHMER 2nd generation threader that takes an average of 20-30 seconds to thread, depending on work piece thickness.

A sample of the CHMER 3rd generation AWT. On average 6-10 seconds of threading time. Total number of parts is only 60% of 2nd generation lowering maintenance needs.

Alan Barbick, EDM Network Applications Manager

Our location in Florida has many issues with power outage and surges.  We recently purchased one of your G32S wire machines.  We do have an AVR (automatic voltage regulator) to keep the flow of power steady and consistent, but how can we “resume” where the program stopped from an outage?

Referencing my article from the Spring of 2019 issue, this is a similar procedure that works well with or without numbered program lines.  This procedure will give you the exact position your machine was at during the moment of the outage, with confidence, i.e. with a functioning back-up battery.

With a major power cut or surge, it can also be on purpose for maintenance (for example), first, reset your AVR then restart your machine.  Perform a routine “Home” procedure and then follow the pictorial process below.

Touch to light up B.PT “Break Point”

Press to light up “AUTO”

Double tap “RESET” quickly

Double tap “RESTART” quickly

Press “Cycle Start”, but before you do, be sure your wire is cut or out of the way of any obstruction, because, similar to the procedure in the Spring Issue, the wire will take the shortest pathway to the break point location. If you decide to cut the wire, your machine will recognize that it is not threaded once in position and will run an auto-thread procedure, then continue. Alan Barbick, Applications Manager

I supervise a toolroom with 10 of your CHMER G32S wire machines, on occasion, an unqualified operator makes a disastrous change in a program without prior consent. Can I “lockout” the operator from making these modifications?

First of all, thank you, for having a tool room filled with our equipment! Yes, there is a simple way, that is password controlled, to lockout your operators from making program changes. I have included a pictorial to make it easy for you to follow.

For example, we will lockout this “open” program, but in all actuality the procedure will lockout all programs. Here, you will be able to see what happens to the program at the end of this procedure.

Go to the “HELP” tab and put in the password when called out to do so.

Go to the “FLAG PARAM” F3 tab.

You can use the “Page Up” or “Page Down” to get to page 2/6 in the “FLAG PARAM”

Use the arrows on the soft keypad to scroll to “FLAG0687”. Turn “ON” the flag parameter (green highlighted).

Lastly, go back to the “FILE” tab to view that the program is in “lockout” (text will be in all “gray” color)

Alan Barbick, Applications Manager

We have many programs that contain over 10 thousand lines of code with great detail in our CHMER G64S wire machine. When there is a problem and we need to “clean-up” a section with another trim pass we have to “dry run” to this location from the beginning of the program, but this can take 45 minutes or more, is there a better way?!

Yes, as long as you have a generation of machine newer than 2014 or with software version K0 and up,  just follow these pictorial steps.

Press the blue “Reset” button when on the “Auto” page, but DO NOT press the “Auto” button again as this will cancel out the function. Leave the “Reset” button lit up.

Type in the line number with an “MN” in front for “MDI”. For obvious reasons, you will need to have numbered lines in your program with an “N” in front, to achieve the function. Also, the reference line you wish to move to must be a geometry line or a G92, G54, etc. as the function will not recognize a technology reference (N100 S4421 - for example).

Press “ENTER” on the soft key pad to load the line number.

Press “Cycle Start” which will scroll through your program until it reaches the “M” number you entered. Depending on the size of the program, this can still take a minute or two, but it will be much faster than using “Dry Run”. You do not need to have the machine in any particular position on the work table. It will know where to go based on your G92 position. Just don’t forget to cut the wire before proceeding as the machine heads will take the shortest pathway to your chosen location.

Alan Barbick, Applications Manager

Question:  We have a CNC CHMER sinker model CM 434C and are trying to burn in the +Y direction. Our program looks good, but the machine does not burn in the right direction. Please advise

The  “E13” command in your program is not enough for this action.  CHMER created additional commands due to their interface. Go to the “Blue Hot Keys” panel (or page) #3, window #3. It will say either “Z DIR – “ (in older models) or “PLANE XY Z-“.  Following the steps below and reference the photos should give you Y+ axis burning.  The trick is to be certain that you change this command again when burning in another direction.

1) From “EDIT PG” (F2) go to F5 “SEL P.C.” and at “REAL DEEP” change it to your positive depth that you wish to finish burn to in the Y-axis.

2) After producing your lines of code type in “E13” for the spark data and you will see “IN E CODE” highlighted in yellow (directional burn commands:  E11 = Z-axis, E12 = X-axis, E13 = Y-axis).

3) You will be able to change the axis direction of burn from “ Z- “  – the above photo (before change) to “ Y + ” the next photo below (after the change).

4)Photo of change completed.  Then be sure to save the program.

Alan Barbick, EDM Network Applications Manager