2D/3D-Programming and Simulation for Wire EDM Machines

For many years, Desktop Engineering has been developing tailor-made software applications for integration into the CATIA environment covering such niche technologies as wire EDM, 3D laser cutting and laser welding (LaserCUT).

By co-operating with the best manufacturers of wire EDM machines and with the automobile and subcontracting industries, we have developed a software tool which covers the entire CAD/CAM process chain involved in wire EDM. This is a considerable contribution to the creation of customer value, as our products reduce programming and processing times to a minimum. This applies both to customers who are already using a CAM system and also to those who are only just embracing the technology.

CUT4AXES - the programming workplace

Most of our CUT4AXES installations have been implemented in workshop manufacturing where CATIA serves as the CAD/CAM infrastructure. CATIA has very few requirements that have to be fulfilled (COM and WF3), whereas a complete CAD/CAM environment is required for a programming workplace. We provide software tools for an uninterrupted processing chain:

1. Programmingfeatures

• CUT4AXES can program any desired CATIA geometry element, i.e. contours on flat surfaces, top and bottom contours in space, whereby the number of geometry elements may vary, and CATIA exact solids.
• Programming is associative, i.e. as soon as there is a change in a parameter this is immediately incorporated in the program.
• Changes in topology and in the position of the wire-threading point can be taken over without influencing the overall process.
• During programming, inaccuracies in the contour (non-tangential transitions, radii that are too small, contour gaps, undercutting and excessive maximum wire-inclination angles) are checked.
• Freely-definable processing strategies fulfil all requirements of the wire EDM process, such as Day/Night cutting (smoothing in splines), various starting movements (normal, tangential, ...) and full erosion cut in helical mode with any desired starting bore (outside or inside).Standard strategies which can be adapted precisely to the customer's needs are installed. The ease with which the strategy language developed by us can be learned enables the customer to react himself to expanding requirements within his company.

2. Simulation and working plan

• Once the program has been defined, the results of the programming can be directly checked with the simulation function.
• The Script File Simulation of the AGIEVISION control can also be depicted in the simulation function.
• Following simulation, a working plan comprising all important for staff using the machine (starting bore coordinates, program number, maximum travel, etc.) can be worked out and plotted directly from the simulation function. The plot can be produced in either 'hpgl' or 'Postscript' format.3. Geometry processing
• In addition to simple geometry programming, CUT4AXES also offers geometry processing tools:
• Approximation of arcs or splines in lines and circular movements; automatically or "by hand", in which case tolerances can be set separately.
• Rounding out complete geometries at the push of a button. Here "loops" can also be generated to enable dies to cut sharp edges.
• Generation of offsets around the complete contour.
• The geometry processing tools (APPROXIM, CORNER and OFFSET) can also be used without CUT4AXES. In addition to these functions, we can offer our customers other geometry-processing tools. These take over tasks which are not handled by the standard CATIA version.

3. Data reflux

• After calculation of the processing steps, the NC program can be directly converted back into a CATIA model via the replay function. CUT4AXES also offers the possibility of feeding back data changes at the machine as a CATIA model. This permits the existing master data to be taken over and changed.

4. Postprocessors

• We offer postprocessors for virtually every wire EDM process control unit. This is made possible by a generalised 4-axis postprocessor, giving our customers the guarantee that they will be able to go on using CUT4AXES if they purchase a new wire EDM machine with a different control unit. They will not have to invest in an expensive insular solution.

5. Interfaces for CATIA

• DXF, IGES, VDAFX and STEP.

For further information on CUT4AXES, please get in touch with our sales team.