5 959 840 e PDF

ROBOFORM 35• 2400•54/55•84
Training Manual
205 959 840/E/07.2001 ver. E
205 962 080/E/10.07.2001

0. Introduction
1. Description
2. The generator and the technology
Training Manual
3. Machine language and machining

ROBOFORM
35•2400•
54/55•84
4. Automation and machining
IMPRESSUM
This document was conceived and written by O. Mallet, E.Iannalfo and P.Vaucher
(RédaTECH)
Typesetting and production by Edipresse Imprimeries Réunies Lausanne s.a. /Renens
Technical data originate from our SDS product line, managed by J.- J. Paccaud,
CTSA-Geneva.
Our thanks for their collaboration go to : A. Favre, J.- M. Bosson,

Table of
L. Pereira and C. Chapatte
5. Alphabetical index contents
Printed by Edipresse Imprimeries Réunies Lausanne s.a. /Renens
CHARMILLES TECHNOLOGIES 205 962 130/E/24.02.2000 0.1

Table of
contents
0.2 CHARMILLES TECHNOLOGIES 205 962 130/E/24.02.2000

Introduction
Definition of electrical discharge machining (EDM) 3

Definition of the process 3
Historical background 3
Physical principle of EDM 5
Types of machining by EDM 7
Public health and safety regulations 9

Introduction 9
Training 9
Premises 9
Connection to electrical mains 9
Fumes 9
Dielectric 9
Hygiene instructions
Fire 10
Preventive measures
Danger of electricity 10
Protections 10
Safety 11
Description of safety devices
Control of protectors
Safety selector switch
Maintenance 12
Storage of diskettes 12
Modifications 12
Waste disposal 12
General nature of waste
General recommendations
Flow chart for elimination of
EDM machine waste (Switzerland) 13
Documents available 14
General 14
Training manual 15
Numerical control manual 17
Technologies manual 18
Maintenance manual 19
CHARMILLES 205 962 180/E/10.07.2001

1
2 CHARMILLES 205 962 180/E/10.07.2001
Definition of electrical discharge
machining (EDM)
Definition of the process

EDM is characterized by the removal of material by a succession of non-stationary electrical
discharges separated from each other in time, i.e. only one spark is created at a time.
The phenomenon is thus unitary and periodical. The discharges are produced by voltage
sources (no-load voltage) over 20 volts, and always take place in a dielectric machining fluid.
The EDM process is also sometimes called spark erosion.
Historical
background
It was as far back as 1770 that the English scientist Priestly observed the erosive effect of
electrical discharges.
The soviet scientists B.R. and N.I. Lazarenko, while carrying out research to eliminate this
erosion effect on electrical contacts, hit on the idea of exploiting the destructive effect of an
electrical discharge and developing a process of controlled machining of metals.
In 1943, they perfected a process of spark machining, so called because of the fact that a
succession of sparks (electrical discharges) operates between two current conductors
immersed in a dielectric liquid.
The principle of the discharge generator then used, called Lazarenko circuit, was used for
many years in the construction of generators for EDM machines. In an improved form this
type of generator is still used today for certain applications.
The spectacular development of EDM is also due to the perseverance of many other
researchers who contributed to demonstrating the fundamental characteristics of this machining
method and making maximum use of its advantages today.
Charmilles became interested in EDM in 1952 and the first machine using this
system was shown for the first time at the 1955 European Machine Tools Exhibition in Milan.
CHARMILLES 205 962 180/E/10.07.2001

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4 CHARMILLES 205 962 180/E/10.07.2001
Physical principle of EDM
The electrical discharge
To generate a discharge between the two Under the effect of this field, electrons and
electrodes, a voltage greater than the break- positive free ions will be accelerated to high
down voltage of the Gap (space between velocities and very rapidly form an ionized
the wire and workpiece) must be applied. channel that conducts electricity.
This breakdown voltage depends on :

– The distance between the wire and the
workpiece.
– The insulating properties of the dielectric.
– The degree of pollution in the Gap (ero-
sion residues).
22.*
At this stage, current can flow and the spark

takes place between the electrodes, causing
an infinite number of collisions between the
particles.
20.*
A plasma zone is formed, which very quickly
reaches extremely high temperatures, in the
At the place where the electric field is strongest region of 8 000 to 12 000° C, and which
a discharge will be initiated. builds up under the effect of an ever-increas-
ing number of collisions to cause instantaneous
This is in fact the culmination of the whole local melting of a certain amount of material
process. at the surface of the two conductors.
At the same time a bubble of gas due to

vaporization of the electrodes and dielectric
develops with its pressure rising steadily until
it becomes very high.
21.*
23.*
CHARMILLES 205 962 180/E/10.07.2001

5
When the current is cut off, the sudden drop The erosion on the electrode and workpiece
in temperature causes implosion of the bub- is dissymmetrical and depends notably on
ble, giving rise to dynamic forces that have polarity, thermal conductivity, melting points
the effect of projecting the melted material of the materials, and the duration and inten-
out of the crater. sity of the discharges.
The erosion is called wear when it takes

place on the electrode, and material removal
when it takes place on the workpiece.
24.*
The eroded material then re-solidifies in the

dielectric in the form of small spheres and is 25.*
removed by the dielectric.
6 CHARMILLES 205 962 180/E/10.07.2001

Types of machining by EDM
Die sinking Wire cutting
Used for making injection molds, molds of Used for making cutting dies and punches,
special shapes and all cavities or volumes extrusion dies, and any other complex through
of complex shape. The cavity is produced profile. The profiles are obtained by means
by means of an electrode having the reverse of a wire/electrode of small diameter that can
shape to the desired result. move simultaneously along X, Y and U, V.
Wire
26.*
Part Electrode Part

28.*
Part
Wire
Part
0,6 mm
100 mm
29.*
Electrode
27.*
CHARMILLES 205 962 180/E/10.07.2001

7
EDM milling
Used for making small molds for electrical This process enables complex mold shapes
connectors, machining of large areas with to be produced by means of inexpensive
homogeneous surface finish, and any machin- electrodes.
ing of irregular shapes. Machining is done
by removing fine layers of material by means
of cylindrical electrodes.
Electrode
Electrode
31.*
Part
Part
30.*
8 CHARMILLES 205 962 180/E/10.07.2001

Public health and safety regulations
Introduction Fumes
In order to guarantee healthy and agree- Essentially, emanations from the dielectric
able working conditions both for persons consist of gases and fumes produced by the
working on EDM machines and for those thermal decomposition of the oil during the
present in the same premises, it is essential spark erosion process.
to respect some elementary hygiene and
safety rules related to this machining process. These emanations are of different kinds and
Operators, foremen and also company include :
heads are called upon to respect the rules
listed below. • Polycyclic aromatic hydrocarbons (PAH)
Charmilles Technologies disclaims all in the solid or vapor state.
responsibility if these rules are not • Aromatic hydrocarbon and paraffin
respected. vapors.
• Metallic particles.
• Various substances which may result from
the breakdown of additives.
Training
Only persons trained on machines of this The following instructions must be
type and their equipment are authorized to respected :
use them.
Training sessions concerning hygiene and • The fume extraction device must be con-
safety problems must be held annually. nected to a sufficiently powerful exhaust
system capable of providing a suction
rate, measured at the edge of the work
tank, of at least 1 m/s.
Premises • The fume suction conduit must be non-
Renewal of the ambient air of the premises inflammable.
must be guaranteed so as to avoid formation • If the fume suction conduit has a metal
of a noxious and dangerous atmosphere, framework, the latter must be connected
without forgetting the volume of air evacu- to ground.
ated through fume suction, which must be
replaced. The electrical installations in these Note
premises must comply with the requirements The machines are equipped with a
of the safety standards in force. detector in the fume extraction device ;
For Germany : standard VDE 0100 T 720. if suction is insufficient, it is impossible
For technical details please refer to to start machining.
“Installation and commissioning” in the
maintenance manual.
Dielectric
Connection to electrical The dielectric used on EDM machines must
mains be identifiable by its designation.
For electrical mains with isolated neutral, a A plate affixed to the front of the work tank
differential circuit-breaker must be built into is used to inscribe the following :
the generator connection circuit.
• Type of dielectric.
For technical details please refer to • Its flash point.
“Installation and commissioning” in the • Dermatological risks.
maintenance manual. • Safety instructions.
Note
The use of dielectrics having a flash
point below 60° C is prohibited.
CHARMILLES 205 962 180/E/10.07.2001

9
Hygiene instructions • In the case of machining without supervi-
• To prevent long contact of the skin with sion, an installation for detecting and
the dielectric, gloves must be worn. automatically extinguishing by CO2 is
• Wash your hands after any contact with compulsory.
the dielectric. • When machining, the workpiece must be
• Protect the eyes against possible dielec- covered with a minimum of 40 mm of
tric splashes. dielectric fluid, while avoiding immersion
• Do not ingest dielectric. of the electrode holder.
• Gases generated by the machining pro-
cess must not be allowed to collect in the
hollow sections of the machined part or
the electrode (risk of explosion).
• Use a dielectric recommended by CT
and having a flash point temperature
higher than 60° C.
Danger of electricity
When using an EDM process, the electrode
is energized and constitutes a risk of electri-
cal discharges by direct contact. Consequently,
the electrode must not be touched, and any
32.*
contact with the frame of the machine must
be avoided (risk of short circuit). The protec-
tive units initially fitted (shield to prevent unin-
tentional contact) prevent all dangerous
contacts.
It is therefore mandatory to avoid touching
the electrode during machining operation.
Protections
All covers and protective panelling must be
kept in place when working with the equip-
ment.
The protection systems must not be rendered
inoperative.
After an intervention, all protective devices
33.*
must be put back in place before machining.
In the event of an accident, and if the safety
instruction have not been respected, Charmilles
Technologies may disclaim all responsibility.
Use of the machine does not require personal
Fire protective equipment to be worn.
Preventive measures
• To avoid any overheating of the dielectric,
the cooling system must be permanently
in operation.
• Two safety thermostats control the dielec-
tric temperature in the work tank, and
will cause machining to stop if the tem-
perature becomes too high.
• Within a radius of 5 meters around the
machine, the presence of flames and
naked light bulbs is prohibited.
Similarly, smoking is prohibited (NO
SMOKING signs).
• A CO2 extinguisher must be located in
the immediate proximity of the machine.
10 CHARMILLES 205 962 180/E/10.07.2001

Safety Safety selector
A safety selector using a key is mounted on
ROBOFORM machines are built to meet the the front panel. It permits a qualified and
essential safety and health requirements responsible person to have a certain freedom
described in the European “Machines” of action for preparing machining jobs,
Directive of 14 June 1989 (89/392/EEC) measuring cycles, dry runs, etc., with the
and the CEN and CENELEC standards tank door open. The selector allows move-
derived therefrom. There is therefore no dan- ments requiring continuous action on the
ger for the operator when using the remote control. Automatic mode is not possi-
machine. ble with the door open.
This selector informs the software of its posi-
ROBOFORM machines for the European tion (maintenance). In normal operation
market are comply with the “Electromagnetic (automatic) the key must be taken out.
Compatibility” directive of 3 May 1989
(89/336/EEC).
Anti-fire unit
A fire detection installation must be fitted on
Description of safety devices. the machine for unsupervised machining. The
Overall electrical protection machine supplies the two-phase 380 V AC
The machine is protected by a main magnetic supply for the anti-fire unit. In the event of fire
circuit-breaker of 25A (QS1) with a break- the unit sends out the two following alarm
ing capacity of 10 kA. signals :
Emergency stop circuit

There are two emergency stop buttons, one 1st signal
on the electrical cabinet and one on the Complete stopping of the machine through
remote control. They function by cutting the opening of the emergency stop circuit.
power (three phase 380/400 V supply) to
the machine through a redundant and self-
monitoring wired logic circuit. The machin- 2nd signal
ing power and movements are immediately External alarm for switching on extinguishing,
halted without fail. cutting off of air suction, remote fire alarms,
etc.
Monitoring of dielectric
The temperature and level of the dielectric User safety
are monitored. No tank movement can be performed with
The temperature is monitored by two ther- the manual protection not closed. The latter
mostats, ST1, ST2, 43°, which stop the must be raised with the handles provided for
machining if these values are exceeded. this purpose. Non-compliance with these
One of the two sensors works in wired logic instructions can be dangerous for the user.
(ST2).
The level of the liquid covering the workpiece
is monitored by two float switches. If the set
level drops too low, machining is stopped.
One of the two floats works in wired logic
(SL2). In both cases there is redundancy of
monitoring.
Tank door
The tank door is monitored by a safety switch
with positive opening operation. As soon as
the door opens, there is redundant wired logic
cut-off of the machining power. An order is
given to stop movements. The tool changer
is disabled. With the tank door open, move-
ments are done in manual mode.
CHARMILLES 205 962 180/E/10.07.2001

11
Maintenance Storage of diskettes
Respect the safety warning signs (color pic- Do not store diskettes close to magnetic field
tograms), and consult the relevant chapter sources such as transformers, power supply
in the manual before every maintenance cables, etc.
operation. Precautions must be taken when
handling and packing electronic compo- Refer to the instructions of the diskette manu-
nents and modules to protect them from the facturers regarding storage.
destructive effects of electrostatic discharges.
For all interventions inside the generator

cabinet or the electrical units of the machine, Modifications
it is necessary to set the main switch in the Any modification made to the equipment
«Off» position and lock it with a padlock. without the intervention or authorization of
Charmilles Technologies is the customer’s
Depending on the case, the latter can be fit- sole responsibility. In such cases, Charmilles
ted either on the door or the inside of the Technologies disclaims all responsibility.
equipment.
Waste Disposal
Waste resulting from the EDM metal machin-
ing process must not in any circumstances
I be thrown into sewers, onto garbish dumps
or other sites.
0 General nature of waste

• Used dielectric.
• Lubricating oil.
• Used filters, charged with machining metal
35.*
waste and sludge.
• Miscellaneous wearing parts.
General recommendations
• If the dielectric overflows, this must not be
allowed to soak into the ground or to be
drained off through sewers.
• Contact the competent local authorities
to acquaint yourself with the regulatory
instructions concerning storage and elimi-
nation of waste.
• It should be noted that in most cases stor-
I
age and elimination of waste imply sort-
ing according to the nature of the pollutants
0
(plastics, metal, etc.).
• Consult the standards in force concern-
ing heavy, non-recyclable materials.
34.*
12 CHARMILLES 205 962 180/E/10.07.2001

Flow chart for elimination of EDM machine waste
(Switzerland)
ROBOFORM
machines
Type
Used Wearing
Electrical Filter Oil
dielectric part
Braid Door seal
Cardboard
Nature
loaded with
Metallic :
Copper FLUXELF 1-2 machining Anti-dust Hydraulic Acrylonitrile
Stainless
graphite oil particles (glass fiber) oil PVC foam
steel
(Fe,Cr,
Cu,Ni)
Elimination
Special incineration
Conventional elimination
Recovery (high temperature,
(incineration or others)
fume filtering,…)
38.*
CHARMILLES 205 962 180/E/10.07.2001

13
Documentation available
General
– Training manual
– Numerical control manual
– Technologies manual
– Maintenance manual
and also :
– Pocket guide
– Operating guide
– Various specialization courses
The first document to be studied is the training manual, which gives a basic explanation of
the machine and its use, and for further information, refers you to the more specific documents.
Entry
14 CHARMILLES 205 962 180/E/10.07.2001

Training manual
This manual is used in conjunction with “Basic Course” given by the Training Center
of Charmilles Technologies.
This document, arranged in chapters, is the entry key to the other manuals. Reading it is
essential in order to be able to make full use of the all the other documentation.
Each chapter starts with a description of the theoretical and practical objectives that must be
attained at the end of each day.
For each subject covered, the page layout highlights 4 zones in order to make learning easier :
– Zone 1: study objectives
– Zone 2 : information on the subject covered
– Zone 3 : evaluation exercise (test)
– Zone 4 : check of what has been learned (answers)
Each chapter ends with summary of the essential points followed by a final exercise with answers.
Zone 2
When the current is cut off, the sudden The eroded material then re-solidifies in the
reduction in temperature causes implosion of dielectric in the form of small spheres and is
the bubble, giving rise to dynamic forces removed by the dielectric. This material is
that have the effect of projecting the melted called pollution.
material out of the crater.
After reading this section, To generate a discharge between the two Under the effect of this field, electrons and
you should be able to : electrodes, a voltage greater than the break- positive free ions will be accelerated to high
down voltage of the gap (between the wire velocities and very rapidly form an ionized
– Quote the three condi- and workpiece) must be applied. channel that conducts electricity.
tions upon which the This breakdown voltage depends on :
gap voltage depends.
– Quote the main char- – The distance between the wire and the
acteristic of the ma- workpiece
chining fluid.
– The non-conductivity of the dielectric The erosion on the wire and workpiece is
– Describe briefly the six
dissymmetrical and depends notably on
stages of the principle
– The degree of pollution in the Gap polarity, thermal conductivity, melting points
of EDM.
of the materials, the duration and intensity of
the discharges, and the wire feed rate.
The erosion is called wear when it takes
place on the wire, and material removal
when it takes place on the workpiece.
At this stage, current can flow and the spark

takes place between the “electrodes” (wire
and workpiece), causing an infinite number
of collisions between the particles.
At the same time a bubble of gas due to
vaporization of the electrodes and the
dielectric develops and its pressure rises
steadily until it becomes very high.
At the start of the process, through the appli- A plasma zone is formed, which very quickly
cation of a strong electric field at the point reaches extremely high temperatures, in the
where the space between electrode and region of 8,000 to 12,000 degrees C,
workpiece is smallest, there will be pro- and which builds up under the effect of an
duced the strongest concentration of positive ever-increasing number of collisions to cause
and negative ions. instantaneous local melting of a certain
amount of material at the surface of the two
conductors.
n:
a. Oxidation on the part that is to be
? machined.
a. Its low resistance. b. Too much oxidation of the wire,
b. Its non-conductivity. preventing sparking.
c. Its temperature. c. Too high a concentration of negative
d. Its vaporization temperature. ions preventing the formation of the
conducting channel.
d. Particles in suspension filling the
1) b.
: machining area.
a. 12,000° C
2) a.
b. 6,000° C
c. 25,000° C
3) d.
d. 1,200° C
M2 – 2 4 990 670/E 11/93 4 990 670/E 11/93 M2 – 3
43.*/ang 44.*/ang
Zone 1 Zone 3 Zone 4
CHARMILLES 205 962 180/E/10.07.2001

15
To make it easier to pick out certain key points, the training course
manual contains a certain number of symbols, which are :
The “Caution” sign

which draws your attention when a point is important.
!
1.*
The “Calendar”
which indicates actions that have to be repeated periodically.
2.*
The “Expert”
which tells you when you can use the Program-Expert system
of aid for programming.
3.*
The “Exercise”
when there is an end of module exercise to revise your knowledge.
4.*
The “Telephone”
when a breakdown requires a telephone call to
Charmilles Technologies staff.
5.*
The “Snake”
where safety precautions and public health regulations are explained.
6.*
16 CHARMILLES 205 962 180/E/10.07.2001

Numerical control manual
In this manual, indicators at the bottom of Programming

the pages allow quick identification of the This chapter comprises :
chapters. – Command programming
– PROFORM programming
Numerical control – ISO programming
This chapter deals with the structure of the
machine screens : The command words are classified under
– PREP mode headings according to their function.
– EXE mode An alphabetical index also enables items to
– INFO mode be looked up directly.
– GRAPH mode
Options
Within each mode, each function is described Documentation concerning options may in
alongside the corresponding screen. certain cases come direct from the supplier
and hence have a different presentation
compared to the rest of the documentation.
FILES PREP
PREP EXE INFO GRAPH
File
This function is used for manipulating all the files stored in A
A
.ISO
.ISO
7560
7560
17-07-99
17-07-99
MEM: 1/1
the various units used.

CUAC .TEC $ 17408 17-07-99
ESSAI1 .ISO 5120 17-07-99
FRANCA .LCA $ 15872 17-07-99
(Selection of a unit causes display of its directory of files). GOMM .CMD
POINCON .ISO
1024
@ 1123
17-07-99
17-07-99
USER .GAP $ 15872 17-07-99
USER .OFS $ 1024 17-07-99
USER .PNT $ 512 17-07-99
USER .VAR $ 1024 17-07-99
It is possible to work on the files of a given directory or from <Free> 135168
one directory to another.
Changing of a unit is done before selecting a file (the file

can be proposed by default or selected by means of the
cursor).
DNC FS
PROGRAM- FILE EDITARE
EDITORE FILE
EXPERT TABELLE
COPY DELETE RENAME DISPLAY PRINT CAMBIO

UNITA
F1 F2 F3 F4 F5 F6 F7
COPY
PREP
PREP EXE INFO GRAPH
Copying of the contents of the selected file from the original
COPY
peripheral to the selected peripheral. A .ISO 7560 17-07-99
MEM: 1/1
CUAC .TEC $ 17408 17-07-99
ESSAI1 .ISO 5120 17-07-99
ESSAI1 .LCA
FRANCA .ISO $ 5120
15872 17-07-99
17-07-99
Two methods can be used : GOMM .CMD
POINCON .ISO
1024
1123
17-07-99
17-04-99
USER .GAP $ 15872 17-07-99
USER .OFS $ 1024 17-07-99
USER .PNT $ 512 17-07-99
USER .VAR $ 512 17-07-99
• Select the file to be copied (source) by means of the <Free> 135168
cursor arrow keys

• Press twice on F1 (copy)
• Choose the name of the destination unit in the func-
tions menu (F1 to F7) or complete the command : File :
CPY,... name of destination file
DNC FS
• Press once on F1 (copy) COPY DELETE RENAME DISPLAY PRINT CHANGE
UNIT
• Give the name of the source file in reply to the ques- ESSAI1
MEM: .ISO
*.*
tion FILE F1 F2 F3 F4 F5 F6 F7
• Validate with RETURN

• Choose the name of the destination unit or complete
the command : CPY, ... name of destination file
Indicator at bottom of page
Note
- WILD CARDs (*) are accepted in the source file name. FILE
FICHIERS
- opying of several files is thus possible (e.g. File : *.TEC)
CHARMILLES TECHNOLOGIES4 941 690/F/17.01.1995 4.2.3.1
CHARMILLES 205 962 180/E/10.07.2001

17
Technologies manual
This document groups together all the information directly linked to machining (electrodes,
dielectric, surface finishes, etc.) and the printed compilation of technology tables used by
the operator.
The technology files are classified according to the material/part pairs to be used (steel, copper,
graphite, carbide, tungsten).
Each technology is followed by its specific features and certain recommendations if appropriate.
Finally, important technical information specific to the machining operations are grouped
together under “Recommendations for machining”.
Choice of settings
Material pair Name of the
Copper
Cuivre File
Fichier CUAC.TEC
(electrode - part) UCUAC.TEC technology file
XCUAC.TEC
Acier
Steel
Choix de la
Enlèvement de matière (arrosage intérieur), mm3/min puissance
de départ
1000
P15/A12
SF [cm2]
461 482
600 P14/A11 472
Respect du détail
493
P Niveau d'intensité 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 441 452
400 483
Normal
432 463
I (A) Courant de pointe 1 1,5 2 3 4 6 8 12 16 24 32 48 64 96 128 P12/A9 443
421 473
453 P13/A13
200
412 423
P14
434
391 402
414
P11/A11
P14
100 10
P13
372 P10/A10
383
60 331 352 394
P12
P13
373 P9/A10
40
P12
P11
384
291
312 P8/A10
20 323
P10
P10 P11
280
270
271 293 334
282 P7/A9
P9
10 303 1
250
P9
314
6 262
240 251
273
P8
241
P6/A9
4
P8
232
242 294
P7
221 220 P5/A8

2
P7
253
P6
P6
200 264
1 0,1
P4/A8
P5
180
0,6
P5
212
201
0,4 191 223
140
P4
192
120 181 202
234
0,2
100 213
P3/A8
P3
Usure
0,1 224 0,01
volumétrique
0,08
P2/A8 0 > 0,1 %
0,06 193 0,1 > 0,3 %
0,05
0,04
182 203 0,3 > 1 %
P2
0,004
1 > 5 %
0,03
214
5 > 25 %
P1/A8 ≥ 25 %
0,02 0,002
0,01 0,001
P1
CH 10 15 20 25 30 35 40 45 50
RA 0,32 0,56 1 1,8 3,2 5,6 10 18 µm
18
18 CHARMILLES 205 962 180/E/10.07.2001

Maintenance manual
Please bear in mind that regular maintenance reduces the number of defects and breakdowns.
Preventive maintenance : indicates to operators when maintenance operations need to be carried

out, thanks to a table of periodic maintenance operations which refers them to detailed and
illustrated procedures.
Corrective maintenance, “troubleshooting”:

This chapter explains the functional tests to be performed to determine the causes of a breakdown,
and also describes the action to be taken.
To facilitate consultation, this chapter is arranged according to the 5 functions of the machine :
– Dielectric
– Change
– Erode
– Control
– Position
CHARMILLES 205 962 180/E/10.07.2001

19
20 CHARMILLES 205 962 180/E/10.07.2001
Description
General description of machines 1.3

ROBOFORM 35 1.4
ROBOFORM 2400 QCR 1.6
ROBOFORM 54/55 1.8
ROBOFORM 84 1.10
Description of machine functions 1.13

General 1.13
Control function 1.14
Man-machine interface 1.15
Remote control handset 1.17
DNC 1.18
Dielectric function 1.19
Position function 1.25
Change function 1.28
Erode function 1.30
Use of the screen and keyboard 1.33

General 1.33
Presentation of the screen modes 1.34
Selection of modes 1.35
Selection of a function 1.36
Contents of modes and menus 1.37
Keyboard 1.41
The files and their denomination 1.43
Text editor 1.45
Message display area 1.46
Command words 1.47

List of functions 1.47
Measurement cycles 1.51

General 1.51
The measurement tool 1.52
Offsets 1.53
Reference ball 1.54
Tool offset 1.55
External centering 1.57
Corner 1.58
Centering 1.59
Center 45 1.59
Centering X and Y 1.59
Edge 1.60
PAL 1.61
TAL 1.62
Measure speed 1.64
Recommendation 1.65
Summary 1.66
Revision of knowledge of chapter 1 1.67
CHARMILLES TECHNOLOGIES 205 962 230/E/23.02.2000

1.1
General description of machines
This manual is compatible with the following machines :
- ROBOFORM 35
- ROBOFORM 2400 (QCR optional)
- ROBOFORM 54/55
- ROBOFORM 84
The descriptions in the following pages refer to the machines in one of the available configu-
rations. Depending on the configurations, whether optional or in relation with EMC stan-
dards, the external aspect of the machines can vary. Nevertheless both this document and all
the documents supplied with the machine remain compatible.
Charmilles Technologies reserves the right to make modifications to its products. The machine
acquired and its options may be subject to minor last minute modifications not described in
this manual (for example paint finish, location of an accessory, etc.).
In the other chapters of this manual, the general arrangement illustrations are valid for all the
above-mentioned machines. If there is a difference as regards the utilization or the view, the
name of the machine concerned is indicated.

1.3
ROBOFORM 35
(17) (1) (2) (3)

(12) (13) (14) (15) (16)
(4) (5) (6)
(7)
(11)
(10)
(8)
(9)
(4) 5433
(18)
(24) (25)
(19) Rear view of the machine
(20)
(21)
(22)
(23)
(26)
(27)
5442

(1) Z axis
(2) Y axis
(3) X axis
(4) Flushing unit
(5) Lamp
(6) Man-machine interface
(7) Remote control
(8) DNC connection
(9) Generator cabinet
(10) Drop tank protection
(11) Drop tank
(12) Tool changer door
(13) Rotary tool changer
(14) Tool changer arm
(15) Connections for flushing/suction through the workpiece
(16) Spindle (C axis)
(17) Fume suction duct
(18) Indication of pressure of flushing through the electrode
(19) Indication of pressure of flushing through the workpiece
(20) Indication of vacuum of suction via the workpiece
(21) Pressure adjusting valve of flushing through the electrode/right lateral flushing
(22) Pressure adjusting valve of flushing through the workpiece/left lateral flushing
(23) Vacuum adjusting valve of suction through the workpiece
(24) Compressed air connection
(25) Pressure gauges
(26) Cooling liquid inlet/outlet
(27) Dielectric reservoir

1.5
ROBOFORM 2400 QCR
(14)
(1)
(13) (2)
(3)
(4)
(5)
(12)
(6)
(7)
(8)
(11)
(9)
(10)
5434
View
V of the machine without cabin or QCR
(16)
(15)

(1) Z axis
(2) Fume suction duct
(3) Lateral flushing valves
(4) Lamp
(5) Right lateral door
(8) Remote control
(9) Work tank
(10) Work tank door
(11) Cabin
(12) View from left : Left lateral door + QCR magazine (Quick Change
Robot optional)
(13) Front door
(14) QCR
(15) Dielectric reservoir
(16) Power cabinet (generator)

1.7
ROBOFORM 54/55
(1)
(2) (3)
(8) (9) (10)
(4)
(5)
(7)
(6)
(3)
(11)
(15)
(14) (12)
(13)

(1) Z axis
(2) Lamp
(3) Flushing unit
(5) Remote control
(7) Front door
(8) Tool changer door
(9) Rotary tool changer
(11) Pressure adjusting valve of flushing through the electrode/right lateral flushing
(12) Pressure adjusting valve of flushing through the workpiece/left lateral flushing
(13) Indication of vacum of suction via the workpiece
(14) Indication of pressure of flushing throug the workpiece
(15) Indication of pressure of flushing throug the electrode

1.9
ROBOFORM 84
(1)
(4) (5)
(2) (3)
(12)
(11)
(6)
(10)
(7)
(8)
(9)
(4)
(14)
(13)
1 . 10 CHARMILLES TECHNOLOGIES 205 962 230/E/23.02.2000

(1) Z axis
(3) Lamp
(4) Pressure gauges
(5) Flushing valves
(8) Remote control
(9) Tank
(10) Movable door
(11) Work tank
(12) Rotary Changer (optional)
(13) Flushing gauches
(14) Suction gauche

1 . 11
Description of machine functions
General
The ROBOFORM machine is the outcome of research carried out by

CHARMILLES TECHNOLOGIES in state-of-the-art electrical discharge machining (EDM).
It is a highly efficient machine that combine speed with accuracy.
Following our machine design philosophy, the ROBOFORM machine is arranged

to perform five functions inseparable from each other, so as to guarantee successful
machining applications.
These five functions are :
– CONTROL
– DIELECTRIC
– POSITION
– CHANGE
– ERODE
5 functions / 1 machine
Dielectric Position
CONTROL
Erode Change
050.*/ang

1.13
Control function
This function controls communication between the operator and the machine, and also
communications between various units of the machine/cabinet assembly.
From the operator’s point of view, the control function covers everything involving
communication with the machine, namely :
– The central unit

– The central memory
– The disk drive
– The keyboard and screen
– The DNC communication option
– The machine power supply

Man-machine interface
The front panel comprises the main switch, the screen, the read/write drive unit for magnetic
diskettes, power supply on/off switches and the emergency stop.
ROBOFORM 2400/84
Charmilles Technologies
Sélecteur de sécurité
O MODE AUTOMATIQUE
PORTES FERMEES
AUTORESTART
I I MODE MAINTENANCE
PORTES OUVERTES
ROBOFORM 35
I
Charmilles Technologies 1 O
Automatic restart 2
I 11

( * /

!"!!! !"!!! !"!!! %) % %*
# !"!!! !"!!! # !"!!! "! "! "! !
$ !"!!! !"!!! $ !"!!!
!"!!! !"!!! !"!!! + ,-. &
!"!!! ! / !
% !"!!!
O
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&' '!!'!! &' !'!!'!! ! !
!!
!
,
/!
+0

%

%&

*

.6- 76 5-7(-
2345 0 3

ROBOFORM 54/55

Charmilles Technologies
Sélecteur de sécurité Charmilles Technologies
Charmilles Technologies Charmilles Technologies

5
I
6
10 O
7
8
HELP
F1 F2 F3 F4 F5 F6 F7
! " # $ % & ' ( ) = ~ : _

ESCAPE
1 2 3 4 5 6 7 8 9 0 - \ DELETE
<
TAB Q W E R T Y U I O P @' } ] } ]
CONTROL A S D F G H J K L +; *.: ? / RETURN 9
SHIFT Z X C V B N M <, >. PAGE
UP
PAGE
DOWN
5435
1 Main switch 7 Indicator light confirming presence of a

voltage in the control cabinet
2 Disk drive
8 Power supplies “on” key
3 Screen
9 Keyboard
4 Lighting
10 Safety selector
5 Power supplies “on” key
11 Automatic restart
6 Emergency stop

1.15
Keyboard
The keyboard enables the operator to dialogue It is also used to enter or modify the data of
with the computer. a program concerning the machining of a
It is used to access the various modes (PREP, part.
EXE, INFO, GRAPH) and to execute commands
(tank filling and emptying, flushing).
811
11 Move displayed menu to left

12 User help (in process of development)
13 Functions (F1 to F7)
14 PREP mode
15 EXE mode
16 INFO mode
17 GRAPH mode
18 Move displayed menu to right
19 Stopping of filling and emptying commands
10 Tank filling
11 Tank emptying
12 Flushing through the part
13 Flushing through the electrode
14 Suction
15 Lateral flushing
16 Stopping of flushing commands
17 Execution
18 Suspension of execution
19 Cancellation of execution
20 End of program line, or execution of command
21 Cursor movement

Remote control handset
The remote control handset enables the
user to perform certain operations with
28 out having to use the keyboard.
1
1. Manual mode
2. Release of the electrode
27 3. Fixing of the electrode
2 4. Tank raising (ROBOFORM 35/54/55)
26
5. Increase of flushing pressure
25 STOP 3 6. Tank lowering (ROBOFORM 35/54/55)
7. Tank emptying
24 4
8. Selection of active/inactive mode
23 5 (Electrical touch)
QCR : active/inactive mode
22 6 9. Positive movement of X or R axis
7 10. Positive movement of Y or θ axis
21 11. Positive movement of Z axis
8 12. Positive movement of C axis
20
13. Speed of movement in manual mode,
9 fast (max. 15 mm/s)
19
14. Speed of movement in manual mode,
10 medium
18
15. Speed of movement in manual mode, slow
11 16. Negative movement of C axis
17 17. Negative movement of Z axis
18. Negative movement of Y or θ axis
12
16 19. Negative movement of X or R axis
20. QCR mode
13 R axis and θ axis (ROBOFORM 84)
15
21. Setting machine reference to 0
14 22. Edge measuring
23. Switching on and scwitching off of flushing
4773b
24. Decrease of flushing pressure
25. Return of electrode to machining area
in suspension mode
26. Stopping of machining
27. Retraction of the electrode from
the machining area
28. Emergency stop
Note :
Keys 24 to 28 do not exist on the remote control of the ROBOFORM 35/54/55.
CHARMILLES TECHNOLOGIES 205 962 230/E/ 02.12.1999

1.17
DNC
This link is used to exchange data between DNC uses the RS232 link available on your
a computer or a station and the machine. machine.
This connection will come in useful for trans-
ferring files onto your.

Dielectric function
The dielectric
The EDM process is carried out in a fluid The quality, viscosity and composition of the
that is a non-conductor of electricity, called dielectric used are important parameters for
dielectric. The purpose of this liquid is to : guaranteeing optimal sparking conditions.
All the specifications of the dielectrics used
– Evacuate the eroded micro-particles are shown in binder No. 3 “Technologies”.
– Cool the machining area Please note that Charmilles Technologies
– Permit the discharge of the spark uses Flux Elf 2 for creating technologies.
The illustrations on pages 1.4, 1.6 and 1.8

The dielectric used is mineral oil. show you the physical location of the
dielectric and where the various units of the
function are located.

1.19
Dielectric reservoir
The main purpose of the reservoir is to fill the work tank and receive dielectric from the tank.
Filling is done through closing of the emptying valve and opening of the filling valve.
A pump then transfers the liquid into the work tank. For emptying the process is reversed,
with the filling valve closing and the emptying valve opening, and the pump stopping
Apart from filling and emptying, the dielectric reservoir has other functions such as :
– Filtering
– Thermostabilization
– Flushing

Filtering
Filtering is vital since it removes the eroded particles from the dielectric fluid. These particles
must be eliminated because they tend to pollute and destabilize the machining area
(especially in the case of strong roughing).
To control this pollution, there is a battery of paper filters connected to the filtration and
injection pump.
The filters can retain particles of 50 microns.

The length of time before they need to be replaced depends very much on the type
of material being machined.

1.21
Thermostabilization
Thermostabilization is of great importance for the success of precision machining, and is

particularly important regarding the problem of expansion that can occur during machining
because of the production of great heat caused by the discharges.
ROBOFORM machines are equipped with a heat exchanger enabling the dielectric in the
reservoir to be kept at a constant temperature.
Setting the desired temperature is done by means of a manual regulator located at the rear
or the side of the machine.
Principle of operation
Cooling of C axis
To injections
Cold water Battery of filters
Heat
exchanger Injection and
filtration pump
Warm water
Tank
4284
In the diagram above, we observe that it is the filtration and injection pump that ensures
thermostabilization of the dielectric. Cooling takes place at the return pipe to the reservoir.
To guarantee good thermostabilization we recommend keeping the work tank full, so as
to create circulation of thermostabilized oil by means of the filtration and injection pump.
It should be noted that when the work tank is empty, the circulation pumps stop and the
temperature of the dielectric contained in the reservoir will become that of the room where
the machine is located.
To ensure safety if the dielectric temperature becomes too high, the machine is equipped
with safety probes calibrated at 45° C located in the work tank. These probes are directly
connected to the machining relay. If the dielectric exceeds 45° C, machining will stop
immediately.

Flushing controls
Flushing machines is controlled with the keyboard and two regulation valves located on the
side or center of the machine. In addition, three gauges indicate the pressure.
The keys on the keyboard are used for selecting the flushing mode (lateral, suction, etc.).
Valves (21) to (23) page 1.4 control the flushing pressure according to the flushing mode
selected.
Drawings representing all the possible cases of flushing enable you to select the correct
pressure valve.
Work tank filling
Work tank emptying

Stopping of filling
or emptying
Flushing through the electrode
Flushing through the part
Suction
Lateral flushing
Stopping of flushing
Example :
– Press the “Lateral flushing” key
– Turn the pressure adjusting valve (see item (21) page 1.4) for right flushing
– Turn the pressure adjusting valve (see item (22) page 1.4) for left flushing
– Press the “Stopping of flushing” key to stop all operations
7.*
We shall see in chapter 2 that it is possible to select flushing modes automatically.

1.23
Flushing systems available
– Lateral flushing
63.*
Left lateral flushing

Right lateral flushing
Interchangeable nozzle
– Flushing through the electrode, injection/suction
64.* 65.*
Suction (C axis rotation forbidden) Injection
Use the injection/suction connections located in the work tank.
– Flushing through workpiece injection/suction
66.*
Injection Suction
Injection pot
Use the injection/suction connections located in the work tank.

Position function
This function manages the axis movements of the machine, whether they are manual or
automatic.
The machine has four different axes : X, Y Z and C.
The X and Y axes control the movements of the part clamped on the table.
+
- Y
- X
+
The Z axis controls the vertical movements of the electrode, and the C axis controls rotation
of the electrode around the Z axis.
+
Z
–
4285
– +
C

1.25
Systems of axes
Each axis is equipped with an optical scale (graduated but not numbered), as with most
present-day numerical control machines.
The axis system used for reading optical scales is called ABSOLUTE axis system. It allows
the machine to know its position at all times, whichever axis is involved. Such a system is not
very practical for the operator and this is why we have a second more flexible axis system
called MACHINE axis system, which the operator can determine at will according to the
origins of the part being machined.
X
+ Y absolute O
AX + Y machine
+ X machine
0
AXO Y + X absolute
146.*/ang
There is yet another system of axes, the PART axis system, which is redefined each time a
part-program (PROFORM or ISO) is executed.
X
+ Y absolute O
AX + Y machine
+ Y part
+ X part
FROM/X,0,Y,0,Z,10
or G92X0Y0Z0
+ X machine
0
AXO Y + X absolute
147.*/ang

Summary : Taking of references
• The ABSOLUTE axis system is defined by Each optical scale has two reference points
the position of the scales on the machine from which the machine calculates the axis
frame, and is immovable. movements carried out. When commission-
This system is used by the software. ing the machine, it is necessary to perform a
reconnaissance of the reference points of
• The MACHINE axis system defines a each axis, so that the machine can incre-
position chosen by the operator who can ment the movements.
modify it according to requirements.
This is the system in which the operator Taking of references is done manually in EXE
works. mode under the “References” function (see
“Use of the numerical control”). Using the
• The PART axis system defines a position remote control, move the desired axis to the
of origin of use only for the execution of limit stop and return a few millimetres until
the part-program. the small red star in front of the axis disap-
This system is the reference used by the pears.
part-program.
This manipulation is not frequently needed,
N.B.: The PART and MACHINE systems of since a battery that can run 200 hours is
axes are often juxtaposed. built in to the numerical control.
When the operator fixes the coordinates in

the MACHINE axis system, the coordinates
will calculate a value AXO which is simply
the difference between the coordinates
of the ABSOLUTE system and those of the
MACHINE system, i.e.:
AXO = ABSOLUTE system coordinates

AXO – MACHINE system coordinates

1.27
Change function
The change function covers everything concerning tool changing, both manual and automatic.
There are two different types of tool changer :
Linear tool changer,

FO 35/2400 : 4 positions
FO 54/55/84 : 6 positions
Rotary tool changer,
FO 35 : 16 or 32 positions
FO 2400 : 20 or 40 positions
FO 54/55/84 : 24 or 48 positions
7.*
X v 71.*
The position of the electrodes on the “forks” of the changer is important for proper electrode
pickup. A safety pin has been placed in the changer in order to eliminate any risk of
damage. You must respect the positioning shown in the drawing below.

A choice of electrode supports is also available, with the following makes :
Erowa (ITS)
73.*
System 3R
72.*
Mecatool
74.*
Hirschmann System H (5 positions only)
75.*

1.29
Erode function
This is the primary function of the whole machine. It supplies the sparks necessary for the
machining process.
From the operator’s point of view, the description of the components used can be limited
o the following :
– The control cabinet, used for controlling the generator and its pilot
– The machining cables (supply of current to the electrode)
– The cable head located under the cover of the Y axis
– The grounding cables (connection of the part to ground)
– The measuring cables (enabling the pilot to control the spark)
The diagram on the following page shows the principle of

operation of the Erode function on ROBOFORM machines.
This task is divided into three parts :

– Man/machine relationship
7.*
– Spark production
– Machining

Man/machine relationship
CNC PREP EXE INFO GRAPH
DOWN
ORB
EXPAN
VECT
CONE...
DNC FS
F1 F2 F3 F4 F5 F6 F7
Machining order
Spark production
Generator
Machining order/Power unit interface
Power unit UP
Power cables
77.*
Machining
Contacts
Machining
cables
Cable head
C axis
Measuring cable
Electrode
Part
Grounding cable

1.31
Notes :
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
Exercices :
1) What are the flushing systems absent 3) Why is a filtering system necessary ?
on ROBOFORM 35/54/55. a. To guarantee dielectric at 20° C
a. Right lateral flushing b. To guarantee clean dielectric to prevent
b. Coaxial flushing pollution of the machining area and to
c. Flushing through the electrode ensure good machining accuracy
d. Multicavity flushing c. To guarantee constant viscosity at all
times
2) The machine axis system is : d. There is no filtering on ROBOFORM 35 Answers :
a. Fixed, since it depends on the optical
scales 1) b. and d.
b. The reference system used for machining
c. Modifiable according to the operator’s 2) c.
wishes
d. Controlled by the axis amplifier boards 3) b.

Use of the screen and keyboard
General Objectives :
The big difference between a conventional Thanks to these three functions, you will After reading this section,
machine and one with numerical control be able to control your machine and you should be able to :
is the absence of control handles and levers. even teach it to do certain operations
This has the advantage of avoiding the automatically. – Quote from memory
problems of concentration resulting from the the four screen modes
reading of verniers, and errors due to incor- Moreover, just like a human being, the of the machine and
rect manipulations. machine has a memory, known as the know their respective
All the operations carried out on this central memory. This is where all the functions.
ROBOFORM machine are, as a rule, information necessary for it – Write a short text by
performed by manipulations through the to operate properly is means of the editor
numerical control. stored, together with that is present in the
supplementary information PREP mode.
Your machine thus incorporates various such as machining 81.*
– Use properly the
functions which make it easy for you to programs, for example. seven functions useful
communicate with it by means of the three for manipulation of the
following senses : Apart from the central memory, it is also files.
possible to store data on
diskettes which have the
MO
advantage of being portable, ME T
MEMO CT
C
Sight, via the color rather like the memoirs an
screen. author might write in a book. 82.*
78.*
Speech, via the

79.*
keyboard.
Touch, via the remote

control.
80.*
MO
ME T
MEMO CT

1.33
Presentation of screen modes
The screen of your machine is subdivided into four tasks or modes. Each of them represents
a category of functions which are grouped together as follows :
– PREP contains all the functions for good preparation of your work.
– EXE contains everything that concerns the machining of your workpieces.
– INFO gives information on the progress of your machining jobs and the state of
your machine.
– GRAPH makes it possible to represent the machining path on your machine’s screen.
PREP EXE INFO GRAPH

PREPARE
Machine Part
X 0.000 X 0.000
Y 0.000 Y 0.000
z 0.000 z 0.000
c 0.000 c 0.000
r 0.000
13 April 1999
00 00 00
DNC FS
EDITOR PROGRAM- FILES EDIT

EXPERT TABLES
F1 F2 F3 F4 F5 F6 F7
The four modes can be used simultaneously, which means that while machining (EXE), you
will be able to prepare other jobs with the text editor (PREP) and display the machining with
INFO and GRAPH.

Selection of modes
Changing from one mode to another is done with the four blue colored keys on
your machine’s keyboard. These keys have identical symbols to those at the top of
the screen representing the four modes.
When a mode is selected, the contour of the screen will be of the same color as
the activated mode (see drawing below).
HELP
F1 F2 F3 F4 F5 F6 F7
! " # $ % & ’ ( ) = ~ : _
ESCAPE 0 - DELETE
<
1 2 3 4 5 6 7 8 9 \
TAB Q W E R T Y U I O P ’
@ }] }]
+ *. ?
CONTROL A S D F G H J K L ; : /
RETURN
PREP EXE INFO GRAPH
< > PAGE
PREPARE SHIFT Z X C V B N M , . UP
Machine Part PAGE

DOWN
X 0.000 X 0.000
Y 0.000 Y 0.000
z 0.000 z 0.000
c 0.000 c 0.000
r 0.000
05 April 1999
00 00 00
Preparation mode
DNC FS
EDITOR PROGRAM FILES EDIT

EXPERT TABLES
F1 F2 F3 F4 F5 F6 F7
PREP EXE INFO GRAPH

EXECUTION
Machine Part
X 0.000 X 0.000
Y 0.000 Y 0.000
z 0.000 z 0.000
c 0.000 c 0.000
r 0.000
Execution
05 April 1999
00 00 00 Execution mode
Com>
DNC FS
PROGRAM USER PILOT DIEL. ACTIVE MEASURING MANUAL

EXECUTION PARAMETERS EXPERT TABLES
F1 F2 F3 F4 F5 F6 F7
PREP EXE INFO GRAPH

SURVEY
Part Setting To go Offset E333 USER
X 0.000 0.000 X 0.000 TBi TRi TUi RFi

Y 0.000 0.000 Y 0.000 5.0 2.0 7.0 500
Z 0.000 0.000 Z 0.000
C 0.000 0.000 C 0.000 M C V P A Inv EL
R 0.000 3 0 5 8 7 0 1
T 0.000
T B R U RF SV PR
CL1: 244:00:00 CL2: 0:00:00 1 5 2 7 50 30 5
100 100
50 %
0 0
Information mode
IS MO CC CT TL DA USA Trend of efficiency
80 75 3 3 4 6 3
Pilot-Expert OFF
DNC FS
SURVEY MACHINE RUNNING MESSAGES DNC3 MODAL BLANK

PROGRAM STATE
F1 F2 F3 F4 F5 F6 F7
PREP EXE INFO GRAPH
[mm]
Y
200
100
0
Graphics mode
X
0 100 200 300 400 500 [mm]
DNC FS

1.35
Selection of a function
When you are in a page, you will see at To return to the previous line, the key with
the bottom of it some blue boxes, in other a blue arrow pointing upwards must be
words the menu, indicating the various pos- pressed. A menu line may have more than
sibilities of this page. These are selected by seven possibilities ; in which case move
means of the corresponding keys located along the line using the keys with a blue
on the keyboard. When the selection is arrow pointing right or left. These arrows
made, a new menu line will appear. The are blue on the screen if the line offers more
previous menu line will be displayed above, than 7 possibilities.
indicating the selection path followed.

Contents of the modes and menus
To enable you to perform your machining under favorable conditions, you must have a basic
knowledge of the contents of the modes and menus.
– PREP mode
As previously mentioned, the PREP mode contains everything necessary for the preparation of
your machining jobs.
4 main functions are indicated :
PREP EXE INFO GRAPH

PREPARE
Machine Part
X 0.000 X 0.000
Y 0.000 Y 0.000
z 0.000 z 0.000
c 0.000 c 0.000
r 0.000
13 April 1999
00 00 00
DNC FS
EDITOR PROGRAM- FILES EDIT

EXPERT TABLES
F1 F2 F3 F4 F5 F6 F7
EDITOR
... which will allow you to write and modify your programs.
PROGRAM
EXPERT ...will enable you to create your machining programs with the help of an
interactive support.
FILES
... will be the menu enabling a file to be copied, deleted, displayed on the
screen, renamed or printed out.
EDIT
TABLE ...will enable you, as you will see further on in this course, to change values
in order to improve your machining jobs.

1.37
– EXE mode
This mode contains the functions which will enable you to carry out your machining work.
So, as you will see further on, it is in these functions that you have to change the values to
make your machining more efficient.
Briefly, you will find the following functions in this mode :
PREP EXE INFO GRAPH

EXECUTION
Machine Part
X 0.000 X 0.000
Y 0.000 Y 0.000
Z 0.000 Z 0.000
C 0.000 C 0.000
r 0.000
14 April 1999
00 00 00 Execution
COM>-
DNC FS
PROGRAM USER PILOT ACTIVE MEASURING MANUAL

EXECUTION PARAMETERS EXPERT DIEL. TABLES
F1 F2 F3 F4 F5 F6 F7
DRAWING I/O
REFERENCE EXECUTION SERVICE
PARAMETERS
PROGRAM MEASURING
EXECUTION ...will enable you to check, ...will enable you to position
simulate, draw on the screen or machine a your electrode in relation to your workpiece.
part-program.
MANUAL
USER ... will give you the option of
PARAMETERS ...will be the page on which using the remote control.
you define the status of your machine.
REFERENCE
PILOT ... will set the references of
EXPERT ...will allow you to display, the absolute and machine axes systems.
adjust and modify the program parameters DRAWING
during machining. PARAMETERS ...will set the way in which the
program is to be represented on the screen.
DIEL
...brings together all the infor- I/O
mation and means of monitoring injection and EXECUTION ... is a page reserved for
suction of the dielectric. Charmilles Technologies After-Sales Service
ACTIVE personnel.
TABLES ...will enable you to select
SERVICE
the correct suitable tables according to the ...contains all the status items
electrode/workpiece material pair. such as date and time or the values by
default that allow your machine to work
properly.

– INFO mode
This mode contains the functions of machining monitoring and parameter checking.
No action is possible in this mode.
PREP EXE INFO GRAPH

SURVEY
Part Setting To go Offset E333 CUAC 8
X 0.000 0.000 X 0.000 TBi TRi TUi RFi

Y 0.000 0.000 Y 0.000 5.0 2.0 7.0 50
Z 0.000 0.000 Z 0.000
C 0.000 0.000 C 0.000 M C V P A Inv EL
R 0.000 3 0 5 8 7 0 1
T 0.000
T B R U RF SV PR
CL1: 244:00:00 CL2: 0:00:00 1 5 2 7 50 30 5
100 100
50 %
0 0
80 75 3 3 4 6 3
Pilot-Expert OFF
DNC FS
SURVEY MACHINE ACTIVE MESSAGES DNC3 MODE BLANK

PROGRAM STATUS
F1 F2 F3 F4 F5 F6 F7
I/O I/O SURV.

REFERENCES PILOTE AUTOMATE SERVICE
EXECUTION
These pages are :
SURVEY
...gives general information on the progress of the machining operation.
MACHINE
...indicates in big letters the position of the axes and will allow remote
monitoring of the operation of the machine.
ACTIVE
PROGRAM ...displays side by side the part-program and, as we shall see further on,
the command program.
MESSAGES
... shows on the same page the last messages to appear during your
operations.
DNC3
... allows the handling of communications by means of the RS232C
interface (option).
MODE
STATUS ...extension of the “survey” page comprising the parameters whose values
change less frequently.

1.39
BLANK
...will enable you to turn off the screen when you are absent. To preserve the
life of the screen, it must be turned off whenever you leave your machine for a lengthy
period.
REFERENCES
... displays the different references of your machine’s axes.
I/O
EXECUTION ... is a page reserved for the after-sales staff of Charmilles Technologies.
I/O
PILOT ... is a page reserved for the after-sales staff of Charmilles Technologies.
SURV.
AUTOMATE ... is a page reserved for Charmilles Technologies After-Sales Service personnel.
SERVICE
...will give you information on the software versions and your machine’s total
machining time. These two items of information must be noted and given to the Charmilles
Technologies staff, when you encounter a problem.
– GRAPH mode
Enables you to display the path of your electrode ; this mode has a maximum display
area and it is for this reason that the graphics parameters are defined in EXE mode
in the “Drawing parameters” page.

The keyboard
The keyboard, as we have already observed, is completely not separate from the screen.
It is this unit which will enable you to control your machine by means of the function keys,
mode keys and arrow keys.
In addition to the function keys, there is another method for giving orders to your machine,
these being the command words.
These command words are entered into the machine with the keyboard and appear on
the screen on the dialogue line located below the machine screen.
It is only possible to give an order to the machine if the prefix “COM>” appears in the
dialogue zone.
Hauteur de changement manuel Z 111.000
Com >
DNC FS
PROGRAM USER PILOT DIEL. ACTIVE MESURE MANUAL

EXECUTION PARAMETER EXPERT TABLE
F1 F2 F3 F4 F5 F6 F7
Further on in the manual you will be shown how to use these command words and expand
your “vocabulary” for communicating with your machine.
To end this section, we would like to show you how to select the language you wish to use
on your machine. You will need to select the service function of the EXE mode ; once this
function is activated, you have to choose the Language function.
PREP EXE INFO GRAPH

SERVICE
Machine Part
X 0.000 X 0.000
Y 0.000 Y 0.000
Z 0.000 Z 0.000
C 0.000 C 0.000
r 0.000
DNC FS
PILOT SERVICE
REFERENCE EXPERT DIEL.
DATE COMMUNIC. DNC3 LANGUAGE

LANGUES SECURITY
TIME
F1 F2 F3 F4 F5 F6 F7
F6

1.41
Assuming the first language displayed is French, you will obtain the following screen :
PREP EXE INFO GRAPH

LANGUAGE
Machine Part
X 0.000 X 0.000
Y 0.000 Y 0.000
Z 0.000 Z 0.000
C 0.000 C 0.000
r 0.000
Search and execution of ’langage’.CMD

Now, the NC searches : A:FRANCA .CMD
Type a new file name (6 car.) to install another language
Press F1 to start a search
Language :
DNC FS
SEARCH FINISH
F1 F2 F3 F4 F5 F6 F7

The files and their denomination
Before going further into the study of the Tables : defines all the machining parame-
menu levels, we shall establish a certain ters necessary or useful for the machine.
terminology, so that we speak the same
language : These are :
– The technology tables : all the generator
File : defines a set of data in any memory, parameters for the electrode/workpiece
such as the language files for selecting the combination.
language to be displayed on the screen. – The tool offset tables : all of the offset
parameters inserted manually by the op-
Program : indicates a sequence of informa- erator or automatically by the machine.
tion and instructions in a given language, – The Gap tables : allow memorization of
such as : an electrode offset (the radial value of
the spark) ; necessary in contouring.
– ISO programs : a language common to – The points table : makes it possible to
a large number of numerical control memorize points in the chosen system of
machines and which can be used by coordinates.
ROBOFORM machines. – The variables table : makes it possible to
– PROFORM programs : advanced lan- memorize variables that are external to
guage developed by Charmilles for die the machining or command program.
sinking machines, which facilitates the – The Tab tables : for writing programs by
programming of machining paths. means of PROGRAM EXPERT.
– Command programs : language used
for programming the automation of the
machine.
ROBOFORM Machine
ROBOFORM
50
LIBRARY
Shelf
Periph. (shelf)
Mem or A :
.
B.D
AVENTURE
AVENTURE
AVENTURE
MEMO
B.D.
B.D.
B.D.
B.D.
Book Content of shelf

Choice of book
e File
on th
GG moon
.
AVENTURE
B.D
PREP EXE INFO GRAPH
PREPARE
AVENTURE
AVENTURE
MEMO
A:
B.D.
B.D.
B.D.
B.D.
Prog. 1
Prog. 2
Prog. 3
Content of (book) file

Content of file book
PREP EXE INFO GRAPH

PREPARE
Pn/Prog.2
FROM/X.O.Y.O.210
DOWN/L.-20.H.-0.500.E.383
ORB/...

1.43
Note: A program can be stored in the form and concerning the type of file :
of a file.
A file can be something other than a program. RBF – Program written in Proform language
CMD – Program written in command
The memorizing of these files, tables and language (automation)
programs can be depicted in the following ISO – Program written in ISO language
manner (see drawing on previous page). TEC – Tables of technologies
Everyone has read a book. A book in fact OFS – User offset table
contains a collection of information stored GAP – Gap tables
on the pages. PNT – Points tables
VAR – Variables tables
This same book can itself be stored on a LNG – Language file
library shelf. The shelf itself may vary in size. BAK – Back–Up file
Once the book is put in its place, in order to $$1 – Damaged or incomplete file (to be
differentiate it from the others and make it deleted if it exists)
easy to retrieve it must have a name, that is TAB – Program Expert file
to say, the title of the book.
The contents of the book and even its title Note :

will enable it to be classified in a certain The Back-Up file (.BAK) enables the last
category (adventure, fiction, etc.). version but one of a program to be kept.
This file is particularly useful when drawing
The same goes for the program files, table up a program.
files, etc.
These files are handled in the PREP mode,
When we conduct a dialogue with a with files.
computer, we must always specify on which
shelf we want to look for the information, the It will be possible for you to :
title of the book we wish to consult and in
which category it is classified. – List the files of a peripheral with Files
– Display a file on the screen with Files –
Display
Examples of file naming : – Copy a file from one peripheral to
another with Files – Copy
Extension – Communicate with a PC with Terminal
(communication option)
A :TEST.RBF – Change the name of a file with Files –
Rename
Peripheral Name – Delete a file with Files – Delete
– Initialise a diskette with Files – Initialize
– Change peripheral, MEM :, A : or B :
where : with File – Change unit.
A: The peripheral (disk drive) – And finally, print your files with File –
TEST: The name (maximum 8 characters) Print
RBF: The type (maximum 3 characters)
Concerning “the library”, (called a

peripheral in computer language) we have
in particular :
MEM : Central memory of the machine

A : 31/2” disk drive
DNC1: Direct communication with PC
computer.
DNC3: Direct communication with PC
(option) computer.

Text editor PREP EXE INFO GRAPH
Insert EDITOR File: MEM:HHH.RBF
In this section, with the help of your teacher, 1:MOV,X20

2:SEP,CP1
3:MOV,X40,Y50,Z10
you will learn how to use your machine’s 4:SPG,TEST.RBF
text editor.
The text editor is used when you wish to

write a machining path program (RBF) or an
automation program for your machine DNC FS
(COMMANDS). We shall come back to EDITOR
PROFROM INSERT DELETE

PROGRAM
EXPERT
BLOCK MARK
FILE EDIT
TABLES
SAVE FINISH
these two types of programming in

LINE LINE BEGINNING FILE
F1 F2 F3 F4 F5 F6 F7
modules 3 and 4.
For the moment, we shall content ourselves The editor is very simple to use. You must
with teaching you to use the text editor. remember that it is possible to act on our
files in the following ways :
When you select the Editor page in the
PREP mode, you will have the following To open a file, you have only to give its
two options : name and press Return.
a) Select a file – When you wish to move within the

editor, use the , , and 94 * 95 * 96 * 97.*
b) Create a new file keys on the keyboard.
a) If you call up a file located in the MEM :

memory, you can easily amend one or – If you wish to delete one or several char-
several items of information. In addition, acters, use the DELETE key. Place the 102 *
this editor is important when machining cursor in front of the character to be

paths are programmed on a program- deleted.
ming station. You will quickly appreciate
the usefulness of this editor when you – When you want to search for text, you
have a small amendment to make in a can use “find text”. The cursor will
program coming from a programming move alongside this text.
station outside your workshop.
– If you press “find next”, it will position
itself on the next occurance of the text
PREP EXE INFO GRAPH found with “find text”.
MEM EDITOR
MEM: 1/1
TEST1 .CMD 1024 19-04-99 – You will be able to use the “Block” fea-
TEST2 .CMD 1024 21-04-99
TEST1 .RBF 512 19-04-99 ture, when you want to copy, move or
ESSAI1 .RBF 1024 19-04-99
ESSAI2
DEMO
.RBF
.RBF
512
612
19-04-99
21-03-99
delete a passage in your file. You must
<Free> 1520544 first position the cursor at the start of the
passage and press the “Mark start”
File: _
function. Then move it to the end of the
passage (the selected text will appear in
black) and press “Mark end”.
DNC FS
EDITOR PROGRAM FILE EDIT
EXPERT TABLES
CHANGE
UNIT
F1 F2 F3 F4 F5 F6 F7
– As soon as the block has been selected,

you can choose the desired action from
b) You will often type command programs the Block menu (copy, move, etc.).
directly with the text editor, as they are
simple and quick to write. – Once the work has been done, you can
save your program in your machine’s
memory with “save file”. To leave the
editor, you must press “Exit”.

1.45
Message display area
This message display area comprises 3 useful indicators :
Indicator 1 Indicator 3
Indicator 2
E0505: NON—EXISTENT FILE DNC FS
COPY DELETE RENAME DISPLAY PRINT CHANGE

UNIT
F1 F2 F3 F4 F5 F6 F7
1. The first displays what the machine wishes to tell you, and can concern an error or a
simple message.
You can press the HELP key for additional information regarding the message displayed on
indicator 1 (see page 53).
2. The second informs you about an action under way on the DNC peripheral.
3. The third continuously informs you whether you have a file open in the editor.
Exercises :
1) What is the mode that gives access to 3) A collection of information in any

file management ? memory is called :
a. EXE a. A program
b. PREP b. A file
c. INFO c. A table
D. GRAPH d. A back-up copy
Answers :
1) b. 2) What is the extension of a file contain-

ing a PROFORM program ?
2) d. a. ISO
b. CMD
3) b. c. PRF
d. RBF

Command words
List of functions Automation is effected by a series of succes-

sive orders which explain to the machine
As you surely know already, our machines step by step what it has to do, rather like a Objectives :
have the capacity to work automatically, person giving orders to a domestic animal.
day and night. The machine waits for your orders, which After reading this section,
are transmitted via the screen and the you should be able to :
In order to use its full potential, you must fully keyboard.
understand the concept of automation, which Thanks to this function, you will be able to – Understand the use-
in fact is very simple. domesticate your machine by means of fulness of the
orders. command words.
– Get your machine to
execute simple tasks
TCH by using the com-
mand words MOV,
TCH, SEP, etc.
– Quote from memory 6
command words and
use them properly.
105.*
– Fetch the tool and go back into position !
GOP
Z
Y
107.*
– Move to the memorized point !
SEP
MEM :
X = 132.560
Y = 50.567
Z= 0.154
C= 0.000
109.*
– Memorize the coordinates !

1.47
In order to be able to communicate with the MVR
machine, we have at our disposal a whole
series of words comprising a family called Enables you to order the machine to make a
“Command words”. movement in the MACHINES system of
coordinates, but this time according to the
These command words can be typed on the relative mode.
keyboard and then either executed one by Example :
one, or memorized and subsequently
executed automatically one after the other MVR,X15,Y15
without stopping. This automatic execution is
called “command program”. Y
In the first modules of this course, we shall 30

gradually introduce you to command words
which you can already use by typing them Y
on the keyboard. 20
X
Please note that supplementary information
on the command words can be found in
the NC manual. 10
–X X
MOV 111.*
–Y 10 20 30
Enables you to make a movement according
to the X, Y, Z and C coordinates of the
MACHINE system of coordinates that you If you repeat the command, the machine will
have just learned according to the absolute again move by X15 and Y15 from its present
mode. position.
Example :
MOV,X15,Y15 AREF
This command word enables you to find the

You will observe that if you repeat the ABSOLUTE references automatically on all
command MOV, X15, Y15, your machine axes.
will not move, since it is already at these Once the references have been found, the
coordinates. machine returns to the starting point of the
cycle.
When you use this cycle, take care to

avoid having too large an electrode in
Y
the spindle nose, because of the risk of
15 collision. the best procedure is to remove
! the electrode from the chuck before seek-
ing the reference.
1.*
10
If the references have been lost or in case
of restart, it is essential to execute AREF and
5
go back to the starting point of your job.
The command “SEP,CP…” allows you to
memorize the starting point of your machin-
–X X ing job (see following page).
110.*
–Y 5 10 15
This command word has no syntax, and all
you need to do is type “AREF” on the key-
board, press “Return” and start the cycle by
pressing the “START” key.
(See Operating guide).

SEP et GOP
SEP enables you to memorize the coordinates of a point. The said point is memorized in
the coordinates chosen by the operator. You just need to indicate the type of coordinates
selected (A for ABSOLUTE, M for MACHINE and P for PART) and the number of the line of
memorization (maximum127 lines) and then type the X, Y, Z and C coordinates.
For example :
I wish to memorize the MACHINES coordinates X10, Y10, Z100 on the line 27 ; I just have
to type on the keyboard.
COM> SEP,M27,X10,Y10,Z100
DNC FS
PROGRAM USER GENERATOR DRAWING ACTIVE MEASURING MANUAL

EXECUTION PARAMETERS PARAMETERS PARAMETERS TABLES
F1 F2 F3 F4 F5 F6 F7
HELP
F1 F2 F3 F4 F5 F6 F7
! " # $ % & ' ( ) = ~ : _

ESCAPE 0 - DELETE
<
1 2 3 4 5 6 7 8 9 \
TAB Q W E R T Y U I O P ' }] }]
@
+ *. ?
RETURN
< > PAGE

SHIFT Z X C V B N M , . UP
PAGE
DOWN
112.*/It
112.*/ang
And when I type : GOP,27
my electrode will automatically position itself at the memorized point in the memorized system
of coordinates.
It is possible to display the point table by following the sequence
PREP – EDIT TABLES – Function key F4 90.*
RETURN
You can see the various memorized points or you can directly memorize the point where the
machine happens to be thanks to the LOAD key (F2).

1.49
TCH
Enables you to perform tool changes automatically and manually.

Example :
TCH,2 Calls up electrode No.2
114.*
Please note that in certain cases automatic picking up is not possible because of the excessive
size of the electrode, which cannot fit in the changer.
It can however be placed manually in the spindle nose. To do this, you must type :
TCH, 2,M 2 specifies the number of your tool and M specifies that the change is done
manually.
You can also adjust the height of the Z axis for manual loading of the electrode, with a view
to rationalizing the movements during electrode changes. See manual tool change position Z
in the USER PARAMETERS page (EXE mode).
It sometimes happens that the machine shows you that it still has in memory the presence of
an electrode in the spindle nose, when in fact it was removed manually by means of the
remote control. To delete this “presence” from the memory you just have to perform a fictional
electrode deposit with :
TCH,0 which cancels the memorized offsets and the electrode presence.

Measurement cycles
General :
Objectives :
Measurement cycles allow a series of operations to be made which can be divided
into two categories : After reading this section,
you should be able to :
• Measurement of offsets between electrodes.
– Quote three general
• Measurement of the electrode position in relation to workpieces. rules to be followed in
order to make good
These cycles can be done manually (with the remote control and the front panel) measurements.
or automatically thanks to the use of command words. – Know the two set up
cycles which enable
electrode offsets to be
PREP EXE INFO GRAPH determined automati-
MEASURING cally.
Machine
X 0.000
Part
X 0.000
Tool:
Radius:
0
0.000 – Differentiate between
Y
Z
0.000
0.000
Y
Z
0.000
0.000
Diametre 1:
Diametre 2:
0.000
0.000 the nine types of
C 0.000 C 0.000
r 0.000
measurement cycle
REFERENCE BALL TOOL OFFSET EXTERNAL CENTERING CORNER
ZF: 0.000
DX:
DY:
0.000
0.000 DX: 0.000 DX: 0.000 available on the
R: 0.000 DZ: 0.000 DY: 0.000 DY: 0.000
DZ:
ZF:
0.000
0.000
DZ:
ZF:
0.000
0.000 ROBOFORM.
L: 0.000
X: -198.036 X: 0.000
Y: -156.716 Y: 0.000
Z: -825.467 Z: 0.000
C: 0.000
DNC
DNC FS
FS
PROGRAM USER PILOT DIEL. ACTIVE
EXECUTION PARAMETERS EXPERT TABLES MEASURING MANUAL
REFERENCE TOOL EXTERNAL CORNER EDGE
BALL CENTER
OFFSET CENTERING
F1 F2 F3 F4 F5 F6 F7
REFERENCE Allows the coordinates of the center of the reference ball to be

BALL
determined. This is done by means of the reference tool designed
for this purpose.
TOOL Makes it possible to automatically measure the offset(s) of an
OFFSET
electrode in relation to the reference tool so that they can be
taken into account during machining.
EXTERNAL Automatically positions the electrode at the center of a workpiece
CENTERING
by carrying out measurements on the outside of the latter.
CORNER Automatically positions the electrode at the corner of a workpiece.
CENTER Automatically positions the electrode in the center of a cavity,

by carrying out movements at 90 degrees for the measurements.
Automatically positions the electrode in the center of a cavity,

by carrying out movements at 45 degrees for the measurements.
EDGE Automatically positions the electrode in relation to a reference

surface.
CENTERING X Automatically positions the electrode in the center of a slot or

cavity on the X axis.
CENTERING Y Automatically positions the electrode in the center of a slot or

cavity on the Y axis.

1.51
Rules
The measurement cycles must be carried out in perfect conditions of cleanliness.
It is recommended to use the measurement tool and carry out the operations on
a workpiece that is free of grease, dielectric and burrs, and demagnetized.
In certain delicate cases, do the offset measurements on a bench designed for this
purpose, or better, machine your electrodes already in their electrode holder.
It is very important to carry out the electrical touches in an environment free of dielectric,
! and with air free to circulate. The presence of eroded particles in the dielectric will distort
the measurements.
1.*
It is also very important to check, during measurement movements, that the tool is not
touching the fixing clamps of the workpiece(s) although an anti-collision electrical touch
avoids damage to the equipment.
It is of course essential that the workpiece is grounded. All units that insulate the
workpiece to be measured must be eliminated. If this is not done, equipment may
be.
The measurement tool
The measurement tool and the reference ball will enable you to carry out your measurement
cycles in optimum conditions.
In order to allow your machine to do this, you must beforehand specify the physical
dimension of the measurement tool (radius).
116.*
The specification of this radius should be entered in the TOOL OFFSET table (USER.OFS)
which you can enter under :
90.*
PREP – EDIT TABLES – F 2 RETURN
It is possible to move the cursor up and down with the and

94.*
keys on your
95 *
keyboard, and move the cursor to the left with the “comma” key.
This table therefore makes it possible to memorize the position offsets of your tools.
The line numbers correspond to the tool numbers on the changer.
Concerning your measurement tool, take care to indicate, on the line corresponding to the
position of the tool on the changer, the value of the radius under the heading “RT”.
If your tool is already in the spindle nose, it is necessary to confirm your modification in the
offset table with :
! TCH,1 or TCH,M
1.*
It is important to note that all modifications of values in the offset table must be followed
by an automatic or external tool change.

Offsets
By definition a machine is not blessed with On the other hand a machine is blind and
intelligence or a sixth sense like a human cannot guess or estimate the dimensions of
being. Let us imagine that you wish to park the electrode in its spindle nose. So we
first a car and then a dump truck in a park- have to help the machine to determine the
ing place ; you will automatically take ac- TOOL OFFSETS of one electrode in relation
count of the different situations you are con- to another to ensure that the electrode is
fronted with when maneuvering the two positioned correctly in a cavity.
different types of vehicle.
∆=0 ∆<>0
The offsets can be taken into account on the four axes of the machine, namely X, Y, Z and
C. Offsets are always taken in relation to a reference tool (measurement tool or electrode).
If we consider the drawing below, the reference tool is the one in the middle, the tool to the
left will have positive offset in relation to the reference tool, and the tool to the right will have
negative offset.
+Z
+ Ref.
120.*
If we imagine for a moment that we are the machine and we take the tool on the right,
we must, in order to position the latter correctly, take account of the position of the
reference tool and then offset negatively the tool on the right by the value of the offset.
The example has been done with the Z axis but is valid for all the axes.
These offsets can be determined manually or with the automatic cycles REFERENCE BALL
and TOOL OFFSET.

1.53
Reference ball MTR
This cycle enables you to automatically Enables you to automatically determine the
measure the coordinates of the center of the position in space of the reference ball, in
reference ball. order to determine subsequently the tool
offsets carried out by the Tool Offset cycle.
The value of this sphere is to create a fixed
reference within the machine area.
This reference is fixed with the measurement

tool which as a general rule will be your
reference tool. This fixed point will enable
you to find the offsets of a tool in relation to
the measurement tool.
121.*
Measurement
tools
122.*
You must specify the radius R and the

position ZF.
You can also specify whether the machine
coordinates have to be set back to zero
Reference ball (redefined) at the end of the cycle.
At the start, the tool must be centered

approximately above the ball to be meas- Example :
ured. Prior to measuring, a certain number
of parameters must be specified under the MTR,R7.5,ZF5,X0,Y0,Z0.
MEASUREMENT PARAMETERS function
(F4), such as : X0,Y0,Z0 setting MACHINE coordinates
X to 0, Y to 0 and Z to 5 (automatic taking
ZF : position of the tip of the measure- into account of ZF).
ment tool in relation to the upper
surface of the reference ball at the
end of the cycle. This value is to
be specified so as to take
account of tools that are longer
than the measuring probe.
Radius : radius to the nearest micron of the

reference ball, needed in order to
obtain accurate coordinates.
At the end of the cycle, the machine

provides you with the possibility of inserting
new XYZ machine coordinates, in relation to
the position determined by the cycle.
This cycle can also be carried out automati-

cally thanks to the MTR command.

Tool offset MTO
This cycle makes it possible to automatically A cycle that allows automatic calculation of
measure the offset(s) of a tool, in relation to the tool offset(s). The DX,DY and DZ coordi-
the reference tool. nates must be specified before starting the
cycle.
X DX and DY
The X movement is equal to : DX/2 + R + 15
Y
15 R
Z
DX/2
123.*
DZ
Knowledge of the offsets enables you to link
up several operations using tools having 124.*
differences resulting from the way they are

held in the tool holder. This cycle must be done before machining,
with an empty work tank. Furthermore, it is
This measurement can only be made after important that the electrodes are picked up
the “reference ball” cycle has been done. by the TCH command (automatically) so that
the machine can memorize the offset values
At the start, the tool must be approximately in the correct place in the table.
centered above the reference ball, and the
C axis must be aligned (TAL). In addition, in
order for the measured values to be en- Example :
tered on the correct line of the offset table,
it is necessary for the measuring tools to TCH,1 picking up of
be loaded by the TCH command. In other electrode No.1
words, it is necessary for the machine to
know the number of the tool in the spindle MTO,DX10,DY10,DZ– 5 measurement of
in order to be able to enter the calculated offsets of
offsets into the correct place. eletrode 1,
moving the axes
Prior to measuring, a certain number of
parameters must be specified under the TCH,2 picking up of
MEASUREMENT PARAMETERS function electrode No.2
(F4), such as :
MTO,DX20,DY5,DZ– 5 measurement of
DX and DY: estimated X and Y + and – offsets of
movements needed in order electrode 2,
that the tool can be placed moving the axes
outside the reference ball to
go down along DZ. TCH,0 putting away of
electrode No.2
DZ : position at which the tool
must be placed on the Z
axis to make a correct
measurement along the X Notes
and Y axes. When you use the commands TCH,10 or
TCH 19,M etc.
This cycle can also be carried out automati- The number defining the tool will also select
cally thanks to the MTO command. the line of offsets corresponding to the tool.

1.55
MOF
This control word allows the type of shift to be chosen.

It can be used alone (MOF, 1) or associated with the TCH word (TCH, 1, MOF1).
This is an “à la carte” choice according to the machining or operation to be carried out.
For example, MOF, 0 does not take any shifting into account, while MOF, 1 takes only Z shifts
into account. Observe the different cases shown below and try to run them on the machine.
MOF,0 No offsets are taken into account, even if they are memorized in the table.
MOF,1 Only the Z or C offsets are taken into account (in cases of compensation
for electrode wear, for example).
Before machining After machining
–Z
125.* 126.*
MOF,2 The X Y Z and C offsets are taken MOF,3 The X Y Z and C offsets are taken
into account. In cases of rotation of into account. In cases of rotation of
the C axis, the rotation is done the C axis, the rotation is done
around the center of the spindle. around the physical center of the
A movement along C with MOF,2 electrode. In other words, the elec-
is not recommended. trode turns around its own axis
instead of around the machine axis
(spindle). To do this, the machine
will carry out a correction of posi-
tioning of the X and Y axes accord-
ing to the movements along C.
MOF,2 MOF,3
Center of the spindle
128.*
127.*
Physical center
of the electrode
Physical center of
Center the electrode
of the spindle

External centering
This cycle enables the center of a workpiece At the end of the cycle, the machine provides
to be measured automatically using a meas- you with the possibility of inserting new XYZ
urement tool. machine coordinates, in relation to the posi-
To carry out this measurement properly, the tion determined by the cycle.
workpiece must be well aligned and trued,
and the correct value of the measurement This cycle can also be carried out automati-
tool radius RT must be entered in the TOOL cally thanks to the MPM command.
OFFSET table.
MPM
Enables you to reproduce the “External

centering” cycle.
You must specify the DX,DY,DZ and ZF
coordinates.
DX DY
ZF
DZ
129.*
At the start, the tool must be close to the

geometric center of the workpiece to be
measured. Prior to measuring, a certain
number of parameters must be specified
under the MEASUREMENT PARAMETERS
function (F4), such as :
130.*
DX and DY: estimated movements needed

in order that the tool can be
placed outside the workpiece It is also possible for you to specify whether
to go down along DZ. the machine coordinates should be set back
to zero (redefined) at the end of the cycle.
DZ : position at which the tool must
be placed on the Z axis to Example :
make a correct measurement
along the X and Y axes. MPM,DX– 15,DY10,DZ– 5,ZF15,X10,Y5, Z0
X10,Y5,Z0 setting the X, Y and Z coordi-

nates back to 10, 5 and 0 respectively.
DZ
132.*
ZF : position of the tip of the meas-

urement tool in relation to the
upper face of the workpiece
at the end of the cycle.

1.57
Corner
This cycle enables the corner of a work- ZF : position of the tip of the meas-
piece to be measured using the measure- urement tool in relation to the
ment tool designed for this purpose. upper face of the workpiece
To carry out this measurement properly, the at the end of the cycle.
workpiece must be well aligned and trued,
and the correct value of the measurement At the end of the cycle, the machine provides
tool radius RT must be entered in the TOOL you with the possibility of inserting new XYZ
OFFSET table. machine coordinates, in relation to the posi-
tion determined by the cycle.
This cycle can also be carried out automati-

DZ cally thanks to the MPC command.
MPC
Enables you to reproduce the Corner cycle.

DY
DX You must specify the DX,DY,DZ and ZF
ZF coordinates, and in certain cases L.
L DZ
131.*
L
At the start, the tool must be located not far

above the geometric corner of the work-
piece to be measured. Prior to measuring,
a certain number of parameters must
be specified under the MEASUREMENT
PARAMETERS function (F4), such as :
DX and DY: estimated X and Y + and –

movements needed in order
that the tool can be placed
outside the workpiece to go 130.*
down along DZ.
DZ : position at which the tool must It is also possible for you to specify whether
be placed on the Z axis to the machine coordinates should be set back
make a correct measurement to zero (redefined) at the end of the cycle.
along the X and Y axes.
Example :
L: distance between two touches
on the same face, making it MPM,DX– 15,DY5,DZ– 5,L20,ZF15,X0,
possible to measure on work- Y0,Z0
pieces any corner whose val-
ue is not 90 degrees. X0,Y0,Z0 setting the X, Y and Z
coordinates at zero.

Centering CEN et CN2
This cycle allows determination of the center

of a hole, by a rough measurement followed Enable you to carry out a centering. It is
by 4 fine measurements, done in the 4 direc- also possible for you to specify whether the
tions according to the X and Y vectors. machine coordinates should be set back to
zero (redefined) at the end of the cycle.
Example :
CEN,X0,Y0 or CN2,X0,Y0
With CN2 you specify an angle of 45° for

the measurement movements.
Example :
134.* CN2,X0,Y0
At the end of the cycle, the machine will

show you the two diameters which correspond
to the dimension of the two axes measured.
In addition, at the end of the cycle, the

machine provides you with the possibility of
inserting new XY machine coordinates, in X and Y centering
relation to the position determined by the
centering. This cycle enables the electrode to be
This cycle can be done automatically thanks positioned in a slot, along either X or Y.
to the CEN command. At the end of the cycle the machine allows
you to modify the coordinates of the axis
which the measurement concerns.
Center 45
This cycle allows the same operation as the
centering cycle, but with an angle of move-
ment offset by 45 degrees.
45° angle
136.*
135.*
At the end of the cycle, the machine provides It is possible to use command words.
you with the possibility of inserting new XY
machine coordinates, in relation to the posi- Example :
tion determined by the centering.
This cycle can be done automatically thanks Along X : CEN,DX,X0
to the command CN2. Along Y: CEN,DY,Y0

1.59
Edge
This is a unidirectional cycle allowing the presence of a workpiece face to be detected by
electrical contact.
After detection of a first rough contact, the machine automatically performs a series of precise
touches at slow speed, and ends the cycle by positioning itself 0,5 mm from the face.
Please note that it is the edge (and not the center) of the electrode which is positioned and
displayed on the screen at 0.5 mm from the face, and that the value displayed on the screen
is the actual value increased or decreased according to the direction of the touch.
0,5 mm backward movement
R electrode
137.*
In addition, the machine gives you the possibility of inserting new X Y machine coordinates in
relation to the position determined by this electrical touch.
Concerning insertion of coordinates, it is possible to increase or diminish their value by an
amount equal to the electrode radius.
This cycle can be done automatically thanks to the EDG command.
EDG
The only little trick consists of the sign that In the manual EDGE mode, use the axis
you give to the coordinate, which gives the keys of the remote control. Hold the key
desired direction of movement. down until the first contact between the
electrode and workpiece and wait for the
Example : result of the measurement to appear on the
screen.
Y EDG,–Y
EDG,X EDG,–X
X
138.*
EDG,Y
In addition, in the same way as for

centering, you can redefine the machine
coordinates.
Example :
EDG,–X,X10
X10 restoring the X coordinate to the value 10.

139.*

PAL
This measurement cycle control allows the The parameters DX and DY cannot appear
face of a part to be aligned. It calculates in the same control. If the case occurred,
and records the angle of a face of the part the following error message would appear :
in the XY plane (about the Z axis). This ‘E1191: ILLEGAL DX OR DY PARAMETER’
angle of rotation is displayed under the letter and the control would be interrupted.
‘r’ in the machine coordinates display
(-360.0 < r < +360.0). Example :
PAL,DX10,V2
Measurement on the X axis, with a distance
of 10 mm between the two measurement
points. Variable 2 in the VAR table will take
the value of the angle measurement.
PAL,DY-20,ROT
Measurement on the Y axis, with a distance
points in the negative Y direction. Rotation
will occur immediately after the measurement.
PAL,DX-40,V3,ROT
Measurement of the part angle is performed Measurement on the X axis, with a distance
with the measurement tool. Two electrical of 40 mm between the two measurement
touches at a distance of DX or DY in a plane points in the negative X direction.
at a constant height Z allow calculation Variable 3 in the VAR table will take the
of the angle. Each of the two positions is value of the angle measurement. Rotation
determined by the average of three will occur immediately after the measurement.
approaches. When one of the measurements
is outside the average, the machine displays
the following error message :
‘E1190: MEASUREMENT OUT OF
TOLERANCE’ and the user will have to
restart the measurement.
The user will ensure that no obstacle gets in

the way of the tool on its path between two
measurement points.
Movement in DX or DY can be introduced
as positive or negative.
!
1.*
Syntax of the control :
PAL, [DXx], [Vn], [ROT]

or
PAL, [DYy], [Vn], [ROT]
DX : distance between two position measu-

rements in X. The measurement cycle will
use the X axis as a reference.
DY : distance between two position measu-

rements in Y. The measurement cycle will
use the Y axis as a reference.
Vn : number of the variable identifying

angle measurement in the VAR table.
ROT : taking account of rotation immediately

after measurement.

1 . 61
TAL ROTC : taking account of rotation immedia-
tely after measurement. When this parameter
This measurement cycle control relates to the is used, C will be corrected by the measure-
angular positioning of a tool. It calculates ment value.
and records the angle C between the current
position of the tool and its face to be positio- ZF : position of the tool on the Z axis at the
ned in the XY plane (about the Z axis). end of the cycle when ROTC is used.
This is a position relative to the cycle starting
When the C measurement is negative, it is position. If ZF is not specified, the tool will
standardized between 0° and 360°. remain in the measurement plane (i.e. ZF = 0).
The parameters DX and DY cannot appear

in the same control. If the case occurred, the
following error message would appear :
‘E1191: ILLEGAL DX OR DY PARAMETER’
and the control would be interrupted.
Example :
TAL,DX10,V2
Measurement on the X axis, with a distance
Measurement of the tool face angular shift C points. Variable 2 in the VAR table will take
is carried out by two electrical touches at a the value of the angle measurement.
distance of DX or DY in a plane at a The Z and C axes will not be modified.
constant height Z. Each of the two positions
is determined by the average of three TAL,DY-20,ZF10,ROTC
approaches. When one of the measure- Measurement on the Y axis, with a distance
ments is outside the average, the machine of 20 mm between the two measurement
displays the following error message : points in the negative Y direction. Rotation
will occur immediately after the measure-
‘E1190: MEASUREMENT OUT OF ment and the tool will position itself at a Z
TOLERANCE’ and the user will have height of 10 mm above its starting position.
to restart the measurement.
TAL,DX-40,V3,ROTC
If the C axis reference is not known at the Measurement on the X axis, with a distance
start of the cycle, the following message of 40 mm between the two measurement
appears : points in the negative X direction. Variable
‘E1193 : NO C REFERENCE’ and the mea- 3 in the VAR table will take the value of the
surement is interrupted. angle measurement. C rotation will occur
immediately after the measurement, at Z
height for manual tool change.
Control syntax :
TAL, [DXx], [Vn], [ROTC], [ZFz]

or
TAL, [DYy], [Vn], [ROTC], [ZFz]
DX : distance between two position

measurements in X. The measurement cycle
will use the X axis as a reference.
DY : distance between two position

measurements in Y. The measurement cycle
will use the Y axis as a reference.
Vn : number of the variable identifying

angle measurement in the VAR table.

We shall now look at a certain number of command words that are also part of another
family called USER PARAMETERS.
Words belonging to this family can be found and modified in the USER PARAMETERS page
in the EXECUTION mode.
Naturally, like all command words, they can also be modified directly using the keyboard.
PREP EXE INFO GRAPH

USER PARAMETERS
BLK: 0 BLD: 0 AXO X 148.083

CBC: 0 SIM: 0 INERTIE 2 AXO Y 132.379
COE: 0 TSIM: 1 AXO Z 180.359
OSP: 0 ART: 1 AXO C 0.000
ENG: 0 TFE: 1
VRF: 0 CHK: 1
CLE: 0.000 TOL: 0.005 MTOL: 0.005
Manual tool change position Z 245.000 EAO: 0

Dry run Speed: 15.000 mm/s EA1: 0
Rotation Speed: 0 rpm ESR: 0
ESP: 0
Measure Speed: 1 %
BLK :_
DNC FS
PROGRAM USER PILOT ACTIVE
PARAMETERS EXPERT DIEL MEASURING MANUAL
EXECUTION TABLES
BLK CBC COE OSP ENG VRF CLE
F1 F2 F3 F4 F5 F6 F7
MTOL
A parameter determining the allowable

difference between the electrical touches
made during a measurement cycle. It is the
operator who fixes its value according to
his positioning requirements. The value
generally recommended and used is
0.004 mm. The measured value is the
mean value of three electrical touches ; if it
exceeds the value set by the MTOL, the
machine will display the error «E0073 :
MEASUREMENT OUTSIDE TOLERANCES».
Mean
141.*

1.63
COE Measure speed
When COE is at 1, the machine will not This parameter will define the approach
take account of minor errors whose number speed at the time of measurement during the
is preceded by the letter E. On the other measurement cycles, with the exception of
hand if COE is at 0, machine EDGE.
operation will be suspended. This value is expressed as a percentage of
the maximum speed (10 mm/sec.).
For example : The standard value of this parameter is
The error E0073 “Measurement outside normally set at 20 %.
tolerances” is controlled by COE ; if COE is It is advisable to use 5 % for delicate
at 0 the machine will stop, and if COE is at workpieces.
1 the machine will repeat the measurement.
AXO,X, Y, Z, C
These are parameters defining the difference

between Absolute and Machine
coordinates.
It is a good idea to memorize their values

(in writing) in case the machine breaks
down while the operator is absent and
completely loses its positioning references.
+ Y ABSOLUTE + Y MACHINE
AXO X
+X
AXO Y
0 + X ABSOLUTE
142.*

Recommendation
We recommend that you machine your electrodes directly on their tool holders and then
measure their possible offsets on a measuring and pre-adjustment bench (see drawing
below).
The advantage of this method is that it enables you to prepare your electrodes (alignments
and offsets) while your Roboform is machining.
Comparator
Electrode with
electrode holder
Air cushion
positioning
system
143.*
Answers :
Exercices :
1) d.
1) The measurement cycle that 3) Measurements must be done ...
determines the center of the ball is : a. With the workpiece demagnetized and 2) b false. The speed
a. Centering the work tank full must be modified by
b. Centering ball b. With the workpiece insulated and the operator if need
c. Tool offset demagnetized be. In case of small
d. Reference ball c. With the workpiece free from grease electrodes, it should
and dielectric be set at 5 % in the
2) The approach speed for measurements d. With the workpiece magnetized and the "user parameters"
is determined automatically work tank empty page.
a. True
b. False 3) c.

1.65
Summary of Chapter 1
In this module you have discovered how the machine is subdivided into five functions.
CENTRAL CONTROL with the central memory, the disk drives, the keyboard and screen
DIELECTRIC with the filtration and thermostabilization
POSITION with the systems of axes, the four axes and the remote control
CHANGE with the various tool changers and electrode holders
ERODE with the generator and the contacts
You have also become familiar with the four screen modes :
PREP which contains all the preparatory functions of your machining jobs, copies of
files, text editor, etc.
EXE which comprises all the functions necessary for carrying out your machining
jobs, such as user parameters, measurement cycles, etc. This is also the mode
for entering the command words.
INFO which contains all the pages for monitoring your machining and the progress of
programs, etc.
GRAPH which displays the position of your electrode as compared to the program path.
You now know where to find information, and are able to copy a file and use the text editor
by means of the keyboard. You also know the location of the various controls for the four
flushing modes available on the machine.
Furthermore, in this module you have learned how to position your electrodes in relation to
your workpiece by means of the measurement cycles, and also the purpose of tool offsets.
You have learned that it is possible to use command words to give orders to your machine
(MOV, GOP, TCH, AREF,...). Certain words also enable you to start up a measurement cycle
(CEN, MPM, MTO,...) while others allow modification of parameters (MOF, MTOL,...).
This basic knowledge is sufficient to enable you to start using your machine.
You are now ready to answer the questionnaire on the following page of this manual.

Revision of knowledge – Chapter 1
1) What are the essential qualities of a dielectric and what operations are needed to 4.*
maintain these qualities ?
...........................................................................................................................
.
..........................................................................................................................
...........................................................................................................................
2) Pick the various possibilities offered by the PREP mode :

❑ a. Dry run of a program
❑ b. Editing of a program
❑ c. File management
❑ d. Creation of a program with PROGRAM-EXPERT
❑ e. Editing of a table of offsets
❑ f. Modification of the language
3) Pick the correct answer. A USER.OFS table contains :

❑ a. All the machining tool offset parameters
❑ b. All the parameters needed for the generator
❑ c. The succession of machining settings for a given job
❑ d. The parameters needed for the generator and the tool offsets
4) During automatic measurement of offsets, it is necessary to carry out the following

operations :
❑ a. Reference ball followed by tool offset
❑ b. Automatic tool pick-up, reference ball and then tool offset
❑ c. Tool pick-up, reference ball and then tool offset
❑ d. Tool pick-up, reference ball and then tool reference
5) In order for the X Y and Z parameters to be taken into account, the following
parameter is needed :
❑ a. TOF, 2
❑ b. MOF, 2
❑ c. BOF, 2
❑ d. MOF, 3
6) In the case of measurements needing high accuracy, they must be done :

❑ a. With the tank full and thermostabilized, with gauge blocks
❑ b. With the tank empty, using the measurement tool designed for this purpose
❑ c. With gauge blocks, the tank empty and measure speed at 20 %
❑ d. With gauge blocks, the tank empty and a micron by micron approach
7) The MTOL parameter has an influence on :

❑ a. The repetition of failed measurement cycles (outside tolerances)
❑ b. The tolerances concerning circular interpolations
❑ c. The tolerances concerning the minimum dispersion of electrical touches
❑ d. The tolerances concerning the maximum dispersion of electrical touches

1.67
8) Describe the 3 flushing systems of the machine :
.....................................................................................
.....................................................................................
.....................................................................................
9) What are the command words for :
Measurement by centering 90° .................................................
Measurement by edge touch .....................................................
Movement in the system of machine coordinates according to the absolute mode
...........................................................................................
10) With the text editor of your machine, create the following short text :
First name
Last name
Address
Telephone
Copy this text two times with the Block functions, then replace the word telephone with Tel.,
using the Search Text and Search Next functions.

The generator and the technology
The sparking distance (GAP) 2.3

Static GAP 2.4
Lateral and frontal GAP 2.4
Limit GAP (roughing) 2.4
Orbital GAP (dynamic) 2.4
The final (finishing) 2.5
Spark curves and generator parameters 2.7

The generator parameters 2.8
The main parameters 2.8
The secondary parameters 2.10
Presentation of the technology tables 2.15

The technology tables files 2.16
The name of the technology files 2.17
The definition of the different settings 2.18
The main parameters 2.19
The secondary parameters 2.19
Table loading 2.21

The selection 2.21
The command words 2.23
Machining protection strategies 2.24

Automatic supervision of machining 2.24
Programmable protection functions 2.25
Programmable functions for de-sensitizing during entry into the workpiece 2.25
Display and optimization of efficiency and defects 2.27

Pilot-Expert 2 .30
Flushing 2.33
Basic theory concerning flushing techniques for static machining 2.33
Injection flushing 2.34
Suction flushing 2.35
Combined flushing 2.35
Lateral sweep flushing 2.36
Flushing by stirring of dielectric 2.37
Pulsed synchronous flushing with withdrawal of the electrode 2.37
Command words linked with flushing 2.37
DIEL screen 2.38
Command words linked with machining 2.41
Summary 2.43

2.1
General objectives of the module :
At the end of this module, you should : • Be able to interpret the information given
by the survey page.
• Be able to choose and validate the
technologies and tables needed for a • Be able to carry out, in the light of
given machining job. machining conditions, simple optimiza-
tions on the secondary parameters.
• Be able to quote six different types of
GAP. • Be able to quote 5 command/para-
meter words and use them properly.
• Know the five basic types of flushing.

The sparking distance (GAP)
One of the features of EDM is that there is This under-sizing will be 2 times the radial
no contact between the “tool”, in this case GAP. Objectives :
the electrode, and the workpiece.
The sparking distance, or GAP, is an After reading this section,
essential characteristic of EDM. you should be able to :
The “range of action” of the electrode is 155.*
equal to its own radius plus the GAP. The – Describe four types of
Electrode
value of the GAP depends on the techno- GAP and explain their
logical conditions of the machining (genera- GAP GAP differences.
tor parameters and the power used). – Define theoretically
Let us consider an electrode that is static in the under-sizing of an
relation to the workpiece, and placed at a electrode.
Workpiece
convenient distance from the latter. – Distinguish between
the use of limit GAP
Electrode and final GAP.
T3
T2 GAP
Workpiece T1
154.*
Under-sized
electrode
In practice, depending on the operations

GAP carried out and the settings used, the GAP
Asymptotic value of the GAP can vary from about 1 mm to 1/100 mm.
But according to the type of machining, sev-
eral types of GAP need to be considered :
Time – the static GAP

T1 T2 T3 – the lateral and frontal GAP
– the orbital GAP (dynamic)
– the limit GAP (roughing)
When the generator is switched on, sparks – the final GAP (finishingl)
will take place between the electrode and
the workpiece, which will be marked by a All these gaps are no more than definitions.
groove of erosion that becomes deeper In each case they describe physical
with time, at first quickly and then more and magnitudes in different situations.
more slowly.
After a certain time the depth of the eroded

groove will stop increasing because the
distance between electrode and workpiece
will become too great to allow a spark to
occur. The maximum active distance (called
asymptotic GAP) is that where the probabil-
ity of a spark occurring becomes nil.
We thus observe that the GAP is a typical

characteristic of EDM die sinking, because
in order to obtain a given dimension, it is
necessary to take account of the GAP and
give a correct under-sizing to the electrode.

2.3
Static GAP
This GAP is measured when the electrode The lateral GAP is thus an asymptotic GAP
does not move (static electrode). It defines and the frontal GAP a dynamic GAP. From
the limit of action of sparking according to experience we know that the frontal GAP is
the principle described above under smaller than the lateral GAP.
“sparking distance”.
Lateral and frontal GAP Orbital GAP (dynamic)

These are terms used to define the GAP Orbital machining is a mode with simultane-
measured perpendicularly and frontally in ous work on the front and the sides of the
relation to the penetration axis of the electrode. In this case all the sides of the
electrode. During plunge cut machining electrode are dynamic working faces.
only the bottom of the electrode is working, The orbital GAP is thus identical all around
while the sides are inactive (static). the electrode.
156.* 157.*
Lateral
Gap
Frontal
GAP
Limit GAP (roughing)

This GAP is defined as the distance between the electrode and the bottom of the craters
obtained during machining.
158.*
This type of GAP determines, in the final analysis, the theoretical limit that the sparks must
not exceed. An additional safety margin is sometimes added, to avoid having the bottom
of roughing craters remaining after finishing.
It is this type of GAP that is used for under-sizing of electrodes.

The final GAP (finishing)
This GAP is measured between the electrode and the points of the craters obtained during
machining.
159.*
The final GAP is also called measured GAP, since this is the type of GAP that is used for
checking the surface finish and the final dimension by means of measuring instruments.
The notions of final GAPs and limit GAPs of course also apply to lateral, frontal and orbital
GAPs.
So one can talk about limit orbital GAP or final lateral GAP.
Exercices :
1) The limit of the spark’s range of action 3) The under-sizing of an electrode is

is called : equal to :
a. Lateral GAP a. The dimension of the cavity – the GAP
b. Frontal GAP b. The dimension of the cavity – 2 x the
c. Radial GAP GAP
d. Asymptotic GAP c. The dimension of the roughing electrode Answers :
– 2 x the GAP
2) The measured GAP is : d. The dimension of the cavity + 2 x the 1) d.
a. The orbital GAP GAP
b. The dynamic GAP 2) c.
c. The mean GAP
d. The limit GAP 3) b.

2.5
Spark curves and generator parameters
As we have seen previously, electrical discharge machining is done by a series of sparks.
The time has now come to study the phenomenon a little more closely and discover the form
Objectives :
of these discharges.
When you have read this
In very simple terms, we can summarize the phenomenon as consisting of a series of “open
section, you should be
contact” and “closed contact” positions, i.e. we allow a current to pass for a certain length
able to :
of time and then similarly stop it, making it possible to remove the eroded particles and cool
the machining area, which as we have said can reach 12 000 degrees C.
– Describe spark curves
The simplified diagram below shows the basic principle of material removal by electro-erosion.
briefly and bring out
their main parameters
– Quote and describe
Current passing briefly the five
machining modes of
the machine
– Quote the generator
parameters that the
operator can modify.
160.*
Time
on off A B
Naturally in reality things are not so simple, and interpreting the shape of spark curves can
sometimes be very complex.
It is nevertheless possible for us to show them in simplified form, and in this way help you to
understand certain parameters necessary for adjusting the spark generator.
Tension V = Volt
(Volt) V
P = Ampere
TA = Time A – duration
of spark
161.*
Time TB = Time B – time

(µ sec) that current is
Current
switched off
(Ampere)
Td = Time d – waiting
time needed to
P develop an
ionized channel
y
y
erg
erg
erg
T = Duration of a
en
en
en
cycle (period).
Time
Td TA TB (µ sec)
T
Please note that the surface under the curve represents the quantity of energy (spark) used
for removing material.

2.7
The generator parameters
Certain parameters are easily modified without physical variation in the spark ; these are the
secondary parameters.
The other parameters are called main parameters, since if you change their values you will
change the spark, in other words the GAP length.
These parameters are displayed on the screen in :
Main parameters M C V P A INV EL

1 0 5 7 8 0 15
Secondary T B R U RF SV PR
parameters 1 5 2 8 45 30 5
The main parameters
P et A
P and A are the fundamental parameters that determine the magnitude of the GAP (length of
spark).
This spark length will create a crater in the workpiece, which in turn will determine the
surface finish.
If P and A are energetic, the craters will be large and the surface finish coarse.
If P and A are moderate, the craters will be small and the surface finish fine.
P and A moderate
P
GAP
163.*
A t
P and A energetic
P
GAP
A t

P is the peak current available in amperes from 0.5 to 128 A according to the scale below :
Value of P 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Peak current Ampere (A) 0.5 1 1.5 2 3 4 6 8 12 16 24 32 48 64 96 128
A sets the pulse duration in micro-seconds ; it corresponds to time A (TA) presented on the graph.
Value of A 0 1 2 3 4 5 6 7 8 9 10 11 12 13
Duration in µs TA 0.2 0.8 1.6 3.2 6.4 12.8 25 50 100 200 400 800 1600 3200
To guarantee an even surface finish and accurate dimensions, it is necessary to provide, for
a given P and A, the same quantity of energy in each spark.
This mode is called Isopulse mode.
This parameter determines the machining mode used by the machine. We shall distinguish
two different types of modes :
- «isopulse» modes.
and - «relaxation» modes.
«Isopulse» modes
Mode M1 has the “classic” squared shaped which characterizes sparks of the isopulse type.
This mode is often employed for roughing or machining in which a large amount of material is
removed. Modes M7, M14 and M26 are related to the M1 mode by their spark shape but
they use different servo-control procedures.
Mode M7 is particularly suitable for users who wish to create their own technologies for exotic
materials. Its spark intensity is less harsh and allows machining to be monitored more easily.
P Modes 1, 7, 14 and 26
TA [µs]
Modes M2 and M3 have a shape that is a little less specific. The characteristic of these
modes lies in the shape of the spark, which will cause the wear on the electrode to vary. As
a general rule, a steep slope will cause more electrode wear than a gentle slope.
Modes M8, M15 and M27 are related to the M2 mode by their spark shape but they use
different servo-control procedures.
Modes M9, M16 and M28 are related to the M3mode by their spark shape but they use
different servo-control procedures.
P Modes 2, 8, 15 and 27 P Modes 3, 9, 16 and 28
TA [µs] TA [µs]
The use of «isopulse» modes can be classified as follows

M1 M7 M14 M26 Standard (Technology tables)
M2 M8 M15 M27 Standard / Wear compromise
M3 M9 M16 M28 Minimum wear

2.9
Relaxation mode
The M4 mode is used for finishing in the technologies developed by Charmilles. The mode
used is the «relaxation generator» mode.
P Mode 4
166.*
[µs]
The principle consists in charging a capacitor (condenser) which discharges at a chosen

moment, giving a very imprecise and variable curve ; however the use of capacitors
makes it possible to obtain better quality surface finishes.
The M6 mode is used for polishing in technologies developed by Charmilles. The method of
operation is too complex to be described in this course, but it is worth mentioning that this
mode also uses capacitors (condensers) during machining and can be compared to the M4
mode.
The relaxation mode is commonly called «Microfin» machining. The use of condensers
during machining in relaxation mode has the disadvantage of increasing the percentage of
wear considerably.
Gives the finishing capacitors. It is a code which allows the machine to choose the value of
the condensers.
Condensers are used exclusively in the M4 and M6 modes.
Is the parameter that sets the discharge ignition (or delay) voltage. The value indicated is
given in volts from 80 to 200 in steps of 40, according to the code given below :
Value of parameter V 2 3 4 5
No-load voltage 80 120 160 200
The secondary parameters
Rest time in micro-seconds. Determines the duration of the interval between two pulses.
Valueof B 0 1 2 3 4 5 6 7 8 9 10 11 12 13
Duration in µs TB Optimization 0.8 1.6 3.2 6.4 12.8 25 50 100 200 400 800 1600 3200
The figure 0 switches on the automatic regulation of rest times.

R et U
Set the “mechanical” time of up and down movement during retraction and during machining.
R sets the retraction time and U sets the machining time.
R period U period
167.*
Their values are set in seconds and correspond to a movement in one direction only. For a
complete up and down movement, multiply the time by 2.
Value of R and U 0 1 2 3 4 5 6 7 8
Time in sec. Optimization 0.1 0.2 0.4 0.8 1.6 3.2 6.4 12.8
The figure 0 switches on the automatic regulation of up and down movements.

The figure 9 (valid only in the case of U) stops these movements so as to stay in the
machining position.
RF
This parameter sets the reference arc voltage expressed in 1/2 volt units.
Each spark, after the delay time, goes into a machining phase with a lower voltage called
arc voltage. This voltage will always tend towards the reference line so as to guarantee
machining stability.
Reference arc
voltage
RF
Arc
Arc Arc voltage
voltage voltage 168.*
Time (µs)
This parameter is normally already defined by CHARMILLES TECHNOLOGIES in the tech-

nology.
But it is possible for you to modify it, and in particular to get the machine to optimize it, by
setting RF = 0.

2.11
SV 2. The operator applying firm pressure on
the lever with low rotation speed is com-
parable to a strong Servo and long TB.
This parameter, called «Servo», sets the
machining «pressure» or in other words the
distance between the workpiece and
electrode.
The Servo has an influence on speed, as it
controls the advance of the electrode on the
machining face.
When we step up machining it often has to
be stabilized with a suitable spark frequen-
cy, which is set by B (rest time between two
sparks). 170.*
As an analogy we can compare the action
of the Servo to the pressure applied by an
operator on the handle of an drill press and
TB to the rotation speed of the chuck.
Where : Short TB = High rotation speed

Long TB = Low rotation speed R
R RR
We can distinguish between three different CR
situations showing the relationship between
the Servo and TB :
1. The operator applying light pressure on

the lever with high rotation speed is
comparable to a weak Servo and short
TB.
The result could be unsatisfactory, with a
high risk of machining instability due to
short-circuits, since our electrode is too close
to the workpiece and the machining
frequency too low.
As a function of the modes selected, it will

be possible to refer to the following table.
Mode 1 14-26 4-6-7

169.* SV 10➝50 5➝50 50➝75
SV=0 initiates automatic regulation when T=0.
We obtain good stability but low efficiency

and long machining time.

3. The operator applying firm pressure on The value of the servo is expressed in %
the lever with suitable rotation speed is according to the diagram below.
comparable to a strong Servo and
suitable TB.
100 %
Weak
Servo
75
50
171.*
25
Strong
Servo
172.*
0%
This explanation is of course simplified,

because other calculations take place within
the machine in order to control the
“workpiece-GAP-electrode” balance.
This balance is called servo control.
We obtain good stability and good effi-

PR
ciency, since we have found a balance
between the pressure on machining and the
frequency set by the TB. Degree of protection of the machine against
destructive electric arcs, short circuits and
excessive pollution.
The parameter PR is set in the technology
at 5.
INV
This parameter controls the inversion of

polarity between the electrode and
workpiece. It is useful when we wish to
mount the workpiece in the machine’s spin-
dle and the electrode on the table.
INV = 0 Polarity between the electrode and

workpiece is that which is indicat-
ed in the technology setting.
INV = 1 Polarity between the electrode
and workpiece is the reverse of
that indicated in the technology
setting.

2.13
EL
Makes it possible to set the type of material used in machining according to a number
code.
1 = copper
2 = graphite
3 = copper tungsten
4 = steel
All the parameters that you have just discovered enable you to compose a «generator
setting». All this information is vital for the proper working of the generator.
Please note finally that when the value «T» is at 0 the machine will be taken under control by
«PILOT EXPERT» i.e. the machine will automatically optimize the parameters B, R, U, RF and
SV.
If you wish to modify the secondary parameters you must set the
parameter «T» at 1 so that the modifications are taken into account.
Defines the optimization of the power setting :
0: continuous optimization in relation to the machining conditions
1: no optimization, the secondary parameters given by the operator are taken

into account
2: continuous optimization in case of « Rib » applications.
Exercices :
1) Which parameter defines the off time 3) The secondary parameters are :
between two sparks ? a. B – R – U – RF – SV – PR
a. A (TA) b. M–P–A–C–V
b. B (TB) c. B – R – U – PR – P – A
c. SV d. B – R – U – P – A – SV
d. PR
Answers :
2) What needs to be done to increase
efficiency ?
1) b.
a. Increase B and weaken the Servo (SV)
b. Increase R and decrease U
2) c.
c. Decrease B and strengthen the Servo (SV)
d. Leave the machine to operate in
3) a.
automatic mode

Presentation of the technology tables
As we have already seen, the machine Polishing :
needs to know a certain number of para- Enables mirror-finish surfaces to be Objectives :
meters in order for its generator to have the obtained, which are very useful in
correct setting according to the machining to applications such as molds. After reading this section,
be done. you should :
The type of machining can vary, depending To do this, the generator uses a special
on the surface finish or accuracy that is machining mode, in which it takes much – Know the 4 areas of
desired. longer to obtain a mirror finish than to carry the GENERATOR
out roughing or finishing passes. TABLES page and
Very briefly, ROBOFORM machining can be briefly describe their
divided into the following three categories : To save time, it is generally necessary to content.
define a «cascade» of settings, that are – Understand the
progressively less energetic, until obtention definitions of the
Roughing : of the final surface desired. To help in pre- technology files.
For fast machining, with minimum wear, of a paring these sequences of settings, – Know the 2 items of
cavity using the most energetic setting pos- CHARMILLES TECHNOLOGIES provides information that the
sible in accordance with the dimension and technology tables that facilitate the work of code of a machining
shape of a given electrode. preparation and programming. setting provides you.
These parameters of technology have been

Finishing : worked out by CHARMILLES TECHNOLOGIES
Allows fine surface finishes to be obtained, after much testing and are found in the form
using a low-energy setting. Please note that of :
since less energetic settings are used
compared to roughing, machining times are technology tables «files» available on
longer. diskettes called technology diskettes and
transferable to the machine’s memory.
ROBOFORM
Technology
176.*

2.15
The technology tables files
We have already seen a large number of parameters that enable the sparks and
machining to be controlled.
To make your task easier CHARMILLES TECHNOLOGIES has created technology files bringing
all these parameters together in the form of computerized tables, thus sparing you the labori-
ous task of data acquisition and reducing the risk of error.
You can display these tables under the mode PREP – EDIT TABLES
PREP EXE INFO GRAPH

EDIT TABLES
MEM: 1/1
UCUAC .TEC $ 2048 29-04-91
UGRAC .TEC 3584 08-08-92
USER .OFS $ 1536 05-09-92
USER .VAR $ 1536 05-09-92
USER .PNT $ 1536 05-09-92
USER .GAP $ 1024 05-09-92
<Free> 68345
HELP
F1 F2 F3 F4 F5 F6 F7
Fichier:
! " # $ % & ’ ( ) = ~ : _
BACK
0 - DELETE
<
SPACE
1 2 3 4 5 6 7 8 9 \
ESCAPE Q W E R T Y U I O P ’ }] }] DNC FS
@
EDITEUR
+ *. ?
RETURN
*.TEC *.OFS *.VAR

< > PAGE
SHIFT Z X C V B N M , UP
F1 F2 F3 F4 . F5 F6 F7
PAGE
DOWN
PREP EXE INFO GRAPH

TABLES EDITOR SETTING
OSCUAC 14 MEM:UCUAC .TEC

1 6
E M C V P A T RF B R U SV PR BVIT
493 1 0 +2 15 13 1 61 10 2 6 20 5 15
482 1 0 +2 15 12 1 63 9 2 6 20 5 18
483 1 0 +2 14 13 1 60 10 2 6 20 5 14
472 1 0 +2 14 12 1 62 9 2 6 20 5 15
473 1 0 +2 13 13 1 60 10 2 6 20 5 16
461 1 0 +2 14 11 1 59 8 2 6 20 5 18
463 1 0 +2 13 12 1 62 9 2 6 20 5 20
452 1 0 +2 13 11 1 58 8 2 6 20 5 15
453 1 0 +2 12 12 1 64 9 2 6 20 5 21
441 1 0 +2 13 10 1 58 7 2 6 20 5 18
443 1 0 +2 12 11 1 57 8 2 6 20 5 17
432 1 0 +2 12 10 1 60 7 2 6 20 5 21
433 1 0 +3 11 10 1 55 7 2 6 20 5 11
434 1 0 +3 11 11 1 56 8 2 6 20 5 15
421 1 0 +2 9 9 1 59 6 2 6 20 5 17
E :
DNC FS
TEC OFS VAR PNT GAP
LOAD
F1 F2 F3 F4 F5 F6 F7
This GENERATOR TABLES page is divided into 4 parts :
– the name of the technology files

– the definition of the various settings
– the main parameters
– the secondary parameters

the name of the technology files
Is given according to a code of letters specifying the materials pair, and also the status of
the table.
Example :
If we have a table called :
this signifies that it relates to a technology table (TEC extension)
U F CU AC . TEC
the secondary parameters of which are modifiable (U = user)

concerning low-depth machining (application)
with a copper (CU) electrode
and a steel (AC) part to be machined
In fact, all tables are defined according to the following letter code :
Modification option
without : non-modifiable file (read-only)
U : modifiable secondary parameters
Type of application
without : standard
C : contouring
F : small depth
L : blades
M : micro-machining
P : polishing
Electrode material / part pair

Nature of electrode
AC : steel
CU : copper
CUW : cupro-tungsten
GR : graphite
GF : fine graphite
GM : medium graphite
GG : coarse graphite
Nature of part
AC : steel
AL : aluminum
AM : ampcoloy
CW : tungsten carbide
TI : titanium

2.17
If you have machining jobs involving exotic materials, you can easily adapt a standard
technology table. Start by selecting a table «X» with a material pair close to your exotic
materials ; you can modify the name of your technology with any name not exceeding
6 characters. Nevertheless you retain an indication of your original technology in case
you might wish to remodify the table from its source.
If you wish to contact CHARMILLES TECHNOLOGIES concerning a technology table or
advice on technologies, do not fail to give the version of the original table.
PREP – EDIT TABLES
Original technology Version of the Your technology

or technology source technology modified or renamed
PREP EXE INFO GRAPH

EDIT GENERATOR TABLES
OSCUAC 14 MEM: UCUAC. TEC
1 6
493 1 0 +2 15 13 1 61 10 2 6 20 5 15
The definition of the different settings
This is done with a number code, which gives you :
PREP EXE INFO GRAPH

EDIT GENERATOR TABLES
UCUAC 4 MEM:UCUAC4.TEC
EL: 1
Class
442 493
482
483
472
473
461
463
452
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
+2
+2
+2
+2
+2
+2
+2
+2
15
15
14
14
13
14
13
13
13
12
13
12
13
11
12
11
1
1
1
1
1
1
1
1
61
63
60
62
60
59
62
58
10
9
10
9
10
8
9
8
2
2
2
2
2
2
2
2
6
6
6
6
6
6
6
6
20
20
20
20
20
20
20
20
5
5
5
5
5
5
5
5
15
18
14
15
16
18
20
15
441
453 1 0 +2 12 12 1 64 9 2 6 20 5 21
441 1 0 +2 13 10 1 58 7 2 6 20 5 18
Charmilles CH 443
432
1
1
0
0
+2
+2
12
12
11
10
1
1
57
60
8
7
2
2
6
6
20
20
5
5
17
21
Value 433
434
421
1
1
1
0
0
0
+3
+3
+2
11
11
9
10
11
9
1
1
1
55
56
59
7
8
6
2
2
2
6
6
6
20
20
20
5
5
5
11
15
17
E :
423 TEC
F1
OFS
LOAD
F2
VAR
F3
PNT
F4
GAP
F5 F6 F7
DNC FS
181.*/ang
– The Charmilles CH value
Indicates the surface finish that we obtain with the group of parameters included in this
setting.
These numbers are not specific to CHARMILLES TECHNOLOGIES but come from the VDI
3400 standards (see appendix 1).

– The class
As we have already seen, the principle of EDM enables cavities to be made in a block of
material. The other side of the coin is that wear will occur on the electrode.
The degree of wear will depend on the parameters making up the setting. There is thus a
need for a fast and simple means for determining the class of wear, displaying the various
settings available for a given surface finish. There are 5 classes of wear, as follows :
Wear 220 Machining with condenser,"Microfin"
221 Much wear but favors speed
222 Compromise between wear and speed
223 Machining with low wear

182.*
No wear 224 Machining with very low wear
(Fictional CH22 settings, used only by way of example)
Certain groups of settings of the same surface finish are made of 1 or 2 settings only,
sometimes with jumps from one class of wear to another. This classification has been drawn
up to correspond as closely as possible to levels of wear actually encountered.
We shall come back to the phenomenon of wear in greater detail when we deal with
programming of machining jobs.
The main parameters
These parameters, which have already been described, are fixed and must not be modified
by the operator. The main reason is the fact that if the operator did modify them, it would
have an effect not only on the GAP, but also on other hidden parameters, so that the final
result could by no means be guaranteed.
To sum up, never modify these parameters !

!
1.*
The secondary parameters
These parameters, which have already been described, are variable and can be modified
by the operator. It is generally recommended that you optimize your machine, in order to
save time and improve machining stability. Please note that optimization will not have any
effect on the surface finish.
To sum up, you can modify these parameters !

!
1.*

2.19
Notes :
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
Exercices :
1) Which 2 items of information are 3) The secondary parameters are

given to you by a machining setting ? modifiable :
a. Material removal and speed a. True
b. The chronological number of the setting b. False
and the surface finish
c. The class of wear and the surface finish
d. The class of wear and any chronological
Answers : order
1) c. 2) An UGRAC.TEC table is :
a. Not available
2) b. b. A Graphite – Steel user table
c. A Fine Graphite – Steel table
3) a. d. A Fine Graphite – Steel user table

Table loading
The selection Objectives :
As you are now aware, a large number of technology files stored on diskettes are available, After reading this section,
containing the information concerning the generator settings of your machine. you should :
You can select three different forms of tables : – Be able to transfer

and activate all the
– The non modifiable tables, such as «CUAC.TEC», «GRAC.TEC» etc... tables needed for a
machining job.
– The modifiable tables such as «UCUAC.TEC», «UGRAC.TEC» etc., with a «U» defining – Know the 5 types of
the freedom for modification or saving. table that it is possible
to activate and dis-
– The modifiable tables generated by «Program Expert» in relation with the Proform play.
program, such as «CLIENT.TEC», «SLOT.TEC» etc..., you can give any name to this type – Be in a position to
of table (see page 156 in module 3). know whether your
table is correctly
Before each job, you must select the table that you want to use and above all make your activated.
wishes known to the machine.
This is done in the EXE – ACTIVE TABLES mode (F5)
PREP EXE INFO GRAPH

ACTIVE TABLES
USER .OFS $ 1536 05-09-92

USER .VAR $ 1536 05-09-92
USER .PNT $ 1536 05-09-92
USER .GAP $ 1024 05-09-92
<Free> 68345
HELP
F1 Fichier:
F2 F3 F4 F5 F6 F7
! " # $ % & ' ( ) = ~ : _

BACK
0 - DELETE DNC FS
<
SPACE
1 2 3 4 5 6 7 8 9 \
EXECUTION PARAMETRES PARAMETRES PARAMETRES ACTIVER
PROGRAMME UTILISATEUR REGIME DESSIN TABLES MESURES MANUEL
ESCAPE Q W*.TECE R *.OFS
T Y U I O P ' }]
@
}]
*.VAR *.PNT *.GAP
+ *. F5 ?
CONTROL A SF1 D F F2 G H F3 J K L
F4
; : /
RETURN
F6 F7
< > PAGE

PAGE
DOWN
183.*/ang
By using the +
184.* keys and then pressing RETURN you can activate the table you wish
to use.
An activated table can be recognized by the fact that a «$» symbol appears on its line.
Please note that it is impossible to activate two tables of the same extension at the same
time.

2.21
Activation is a simple operation, provided the relevant file is stored in the machine’s
memory (MEM :), which implies that the file must be copied into the machine’s central
memory before its activation by the operator. It is not possible to activate a technology
straight from diskette.
ROBOFORM
Technology
MEM 185.*
If you look at the EDIT TABLES screen you will observe other tables such as :
– USER.OFS, which is used to memorize all the offsets between the tools which it has been
possible to measure on a measuring bench or determined by the automatic measurement
cycles REFERENCE BALL and TOOL OFFSET (see the «Measurement cycles» chapter in
module 1).
– USER.PNT, which enables you to memorize points within the limits of your work tank
using the type of coordinates that you prefer (absolute, machine or workpiece coordinates)
and to be able to go to that point by means of the GOP command (see the «Command
words» chapter in module 1).
– USER.VAR, which is used in advanced applications to memorize variables that will be

used in a program in Proform or command language.
– USER.GAP, which is used during a contouring program.
These four tables are to be considered from the «USER’S» point of view, i.e. that the table
supplied is a blank grid that is to be filled in when necessary.
The initial name of the table can be changed and it can be stored on diskette under its new
name.
An example of application consists in memorizing the starting points of a series of

machining jobs and transferring them to diskettes. In this way they are protected and
can be re-used if one day the same series of parts needs to be produced again.

The command words
It is possible to activate a table directly, by means of the keyboard, with simple command
words.
Don’t forget that it is important for the table to be transferred beforehand into the machine’s
memory (MEM :).
To activate a technology table, type :
TEC, UCUAC
To activate a table of offsets, type :
OFS, USER
To activate a points table, type :
PNT, USER
To activate a table of variables, type :
VAR, USER
To activate a table of GAPs, type :
GAP, USER
Exercices :
1) Activation of technology tables can be 3) What is the purpose of a table of

carried out by retrieving the files offsets (USER.OFS)?
directly from the technology diskette. a. To memorize points in space
a. True b. To memorize tool offsets
b. False c. To memorize variables
d. To memorize GAPs
Answers :
2) In what way can you see whether a
table is already activated : 1) False. It is essential to
a. The table is automatically activated if it copy the file into the
is present in the memory MEM : machine’s memory.
b. There is no way of knowing
c. If a «$» symbol appears on the line of 2) c.
the table
d. If a «£» symbol appears on the line of 3) b.
the table

2.23
Machining protection strategies
During machining a ROBOFORM machine encounters very varied conditions. The machin-
ing protection strategies have been defined to allow you to obtain, with maximum safety, Objectives :
the desired results regarding both dimensions and surface finishes.
After reading this section,
During machining, the Numerical Control carries out measurements which make it possible you should :
to evaluate machining conditions and the state of the process under way.
– Be able to describe
In cases of : the protection mecha-
– Short circuits nism on your machine.
– Abnormal discharges – Know the 4 protection
– Contamination (machining residues, conductive environment) functions available on
– Generation your machine.
– Know the 3 functions
The machine will set in motion a certain number of actions (optimizations) which will make available on your
it possible to avoid destructive effects (icicles, arcs, pitting and marks) caused by the cases machine for desensi-
of defective machining quoted above. tizing during initial en-
try into the workpiece.
Automatic supervision of machining

The machine constantly measures and analyses the quality of machining, and can do the
following in case of difficulty :
– cause an immediate stoppage (message «A0855 stop on bad machining»).

– set in motion the automatic optimization of B, R and U (message «A0856 diminishing
performance») to a gradually increasing extent until :
normal machining is restored (message «A0858 correct machining restored»)
or
machining stops (message «A0855 stop on bad machining»).
– set in motion the automatic optimization of B, R and U (message «A0856 diminishing
performance») to a gradually increasing extent, and in case of optimization failure, carry
on machining with maximum protection.
These different options can be selected thanks to the protection functions presented in the
table below.
To activate these functions, you just have to enter them at the beginning of the PROFORM
program (see chapter 3).

Programmable protection functions
These functions give you the effect on machining in the case of optimization by the operator
or PILOT EXPERT.
Program- PILOT EXPERT ON PILOT EXPERT OFF Conditions of use

mable (T = 0) (T = 1)
functions
AUXF/52 Protection, then Protection, then Small deep (30 mm

stoppage in case of stoppage in case of and over) slots
persistent bad working. persistent bad working.
AUXF/53 Same as 52 Immediate stoppage in Function with the

case of bad working. highest security. Used
infrequently
AUXF/59 No stoppage in case No stoppage in case Do not use with high P

(by default) of persistent bad of persistent bad values (P ≥ 11),
working. Machining working. Machining specially graphite
continues with continues with
maximum protection maximum protection.
AUXF/60 Same as 59 No attempt at Small scale machining,

correction in case of difficult and with low
bad working. No precision (e.g. cooling
stoppage. holes, contouring).
Requires the presence
of the operator.
Programmable functions for de-sensitizing during entry

into the workpiece
In certain cases when new machining jobs are being started, especially with new electrodes,
a certain time needs to pass before machining gets properly under way. This time depends
on the electrode surface and the initial power.
In this situation, the chosen protection measures may prove to be too severe or sensitive.
The functions for de-sensitizing during entry into the workpiece are designed to make the
protections momentarily less severe, but do not cancel the selected programmable protection
functions.
These functions are :
AUXF/24 de-sensitization for 30 seconds

AUXF/25 de-sensitization for 2 minutes
AUXF/26 de-sensitization for 8 minutesF
AUXF/27 allows cancellation of M24, M25 and M26
AUXF/32 attack protection,Power Control Expert
! The context for the use of these functions is generally when starting up a
machining job.
1.*
N.B. AUXF/24, 25 and 26 only affect the following PROFORM program line.

2.25
Notes :
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Exercices :
3) What is the programmable function

1) What is a bad spark ?
that enables machining to be
a. A spark that is too short
de-sensitized for 2 minutes ?
b. A spark without delay time
a. AUXF/24
c. A spark with a delay time too long
b. AUXF/25
d. A static spark
c. AUXF/26
Answers : d. AUXF/27
2) What is the programmable function
that enables an immediate stop to be
1) b. made in case of bad machining ?
a. AUXF/52
2) b. b. AUXF/53
c. AUXF/59
3) b. d. AUXF/60

Display and optimization of efficiency
and defects
To give you an idea of the machining conditions and to make it easier for you to optimize,
the EXE–GENERATOR PARAMETERS and INFO–SURVEY pages give you a wide range of
Objectives :
information by means of bar graphs.
INFO – SURVEY
you should :
– Know what informa-

tion is given by the
PREP EXE INFO GRAPH 7 bar graphs.
SURVEY – Be able to take into
Part To Go Offset Setting E333 ULCUAC
account the 5 optimi-
X 0.000 0.000 X 0.000 TBi TRi TUi RFi
zations proposed
Y 0.000 0.000 Y 0.000 5.0 2.0 7.0 50 by Charmilles
Z 0.000 0.000 Z 0.000
C 0.000 0.000 C 0.000 M
3
C
0
V
5
P
8
A
7
Inv
0
EL
1
Technologies.
R 0.000 0.000
T 0.000
T B R U RF SV PR
CL1: 244:00:00 CL2: 0:00:00 1 5 2 7 50 30 5
100 100
50 %
0 0
80 75 3 3 4 6 3
Pilot-Expert OFF
DNC FS
SURVEY MACHINE RUNNING MESSAGES DNC3 MODAL BLANK

PROGRAMS STATE
F1 F2 F3 F4 F5 F6 F7
There are 3 display zones :
– Zone 1, display of efficiency, a “favorable” section where we see the level

of good sparks.
– Zone 2, display of defects, an “unfavorable” section that we try to keep
close to 0.
– Zone 3, display of stability, which we try to keep as stable as possible.
100
50
0
IS MO CC CT TL DA USA
80 76 3 4 4 5 3
203.*
Zones 1 2 3

2.27
So after modifying a parameter you can
Zone 1
see if efficiency goes up or down, and take
any action you think appropriate.
Let us consider the bar graphs, 2 in number,
that indicate machining effectiveness and
efficiency.
Zone 2
100
During machining a host of events can
upset your machining, such as a short
circuit, too much pollution, etc.
50
To help you estimate the defects you have
4 bar graphs. But when a bar graph
indicates a defect, what must you do ?
0 204.*
IS MO
75 72
IS gives the instantaneous efficiency (calcu-

lated over 2 pulses).
MO gives the mean efficiency (calculated

over 8 pulses).
206.*
The aim is to obtain the best possible effi- CC CT TL DA

ciency, but machining efficiency varies 8 5 6 9
according to the settings. With good ener-
getic settings we attain efficiency of about
80 % depending on the machining jobs.
With finishing settings, however, the figure CC short circuit indicator
is more in the region of 5 –10 %. action: adjust the parameter SV by
increasing its value (increasing the
GAP).
On the SURVEY page you have a graph
displaying the trend in efficiency. CT contamination indicator (machining
residues, conductive environment)
action: improve flushing by increas-
ing pressure or pulses. In certain cas-
es adjust the parameters SV and TB
by increasing their values.
100
TL indicator of generation of TL = long
time (series of sparks without Td)
%
action: increase SV + TB.
0 DA abnormal discharge indicator

Trend of efficiency (sparks with low arc voltage)
Pilot-Expert OFF
action: increase TB by one posi-
tion.
GES DNC 3 MODAL ET

STATE
F5 F6

In cases of machining in automatic machine A low position (negative) shows that the
optimization mode (T = 0) the machine, if electrode is tending to move away from the
necessary, will optimize itself, that is it will workpiece.
automatically modify the parameters
B–R–U–RF. A high position (positive) means that the
electrode is approaching the workpiece.
The value of the modified parameters are
displayed as Bi–Ri–Ui–RFi. If the machining trend stays in either the
negative or positive part an optimization
becomes necessary, by adjusting the
INFO GRAPH secondary parameters or flushing.
E
Setting E333 CUAC 8
TBi
5.0
TRi
2.0
TUi
7.0
RFi
50 Instantaneous
0.000
M
3
C
0
V
5
P
8
A
7
Inv
0
EL
1
values of
T B R U RF SV PR B–R–U–RF
1 5 2 7 50 30 5
optimized by
100
the machine
%
0
Trade of efficiency
Pilot-Expert OFF
DNC FS
7.*
S DNC3 MODAL BLANK
STATE
F5 F6 F7
Advices :
It is difficult to offer a miracle recipe for

optimization but we can give you some
recommendations :
• Only vary the secondary parameters.

Zone 3
• If you make a modification, wait at least
The last bar graph, called USA, gives a 30 seconds before carrying out a new
visual indication of machining stability. optimization.
A position near the middle represents the ideal • Correct first and foremost the machining
situation of stability with a perfect distance defects, since they are often the cause
between the electrode and workpiece. of instability.
• If you are completely lost set the para-

meter T to 0 and let the machine find a
compromise.
• Re-read the first part of chapter 2 and

carry out any machining job to enable
you to manipulate the secondary
parameters and get a better idea of
their effects on machining.
The motor is Stable The motor is

moving the machining moving the
electrode electrode
away from towards the
the orkpiece workpiece

2.29
PILOT-EXPERT
This function is used to adjust or modify the parameters for the active settings.
PREP EXE INFO GRAPH

PILOT-EXPERT
Part To go GENERATOR
X 0000.000 0000.000 B 00 R 0 U 0 RF 00 SV 00 T 0 PR 00
Y 0000.000 0000.000 00.0 00.0 00.0 00 00
Z 0000.000 0000.000
C 0000.000 0000.000 M 00 C 00 V 000 P 00 A 00 Inv 0 EL 00
R 0000.000
T 0000.000 CL1: 000:00:00 VPULS 00.000
CL2: 000:00:00 SPAC
R gime E000 000000 TPU: 000000 mn Pilot Expert II
Pulsations Machining
100
NO 00000
BN 00000 %
TL 00000
CT 00000
CC 00000 0
RAZ 0 % 100 Efficiency evolution
DNC FS
B R U RF SV T PR
F1 F2 F3 F4 F5 F6 F7
M C V Inv EL
F1 F2 F3 F4 F5 F6 F7
CL1: CL2: MACHINING ZERO

TIME PULSATIONS
F1 F2 F3 F4 F5 F6 F7
This page also provides the following information :
Workpiece
X, Y, Z, and C coordinates in the part axis system as defined in the program.
Specified dimension
Value supplied to the part program. Dimension to be reached by the current line of the
program.
CL1
Total time elapsed between the last power-on or the last ZCL command.
CL2
Machining time elapsed between the last power-on or the last ZCL command.
TPU
Machining time to be completed before passing on to the instruction of the following
programme.
The initial value comes from the parameter "P" of the current instruction. The time can also
be modified by the operator during machining.
This function is only valid if the current instruction contains the parameter "P".
VPULS
Pulse rate (1 to 15 mm/sec.)
SPAC
SPAC parameter status (green is active, white is inactive).

PILOT EXPERT
Status of Pilote Expert (green active, white inactive). If T= ø or T= 2 active ; if T=1:
inactive.
NO
Pulse counter (0 to 65535) with a status indicator and bar graph showing the NO
position in relation to the average of the other default settings.
BN
Low level.
TL
TL rate : TB time long.
CT
Rate of contamination.
CC
Frequency of short circuits.
ZERO PULSATION
Enable the NO, BN, TL, CL and CC counters to be set back to zero. green
All the above counters are automatically set to zero at the start of machining.
blue
- The black outline on the bar graph represents the target dimension.
- The green bar represents the target dimension as machining progresses.
- The blue bar represents actual machining progress.

2.31
Notes :
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Exercices :
1) What must be done if there is too 3) When optimizing, it is necessary to

Answers : much contamination ? modify the parameters quickly.
a. Stop the flushing a. True
1) d. b. Decrease TB b. False
c. Decrease pulses
2) b. d. Improve the flushing
3) False ; we must let the 2) What do the IS and MO bar graphs

machine operate with represent ?
the modified a. Machining defects
parameter for a b. Machining efficiency
minimum of 30 sec. c. There are no such bar graphs
d. Machining stability

Flushing
Flushing is a very important parameter ; it forms an integral part of optimization of the
generator’s secondary parameters, the two being interdependent. Objectives :
Without correct and judicious flushing, it is not possible to obtain the results that you should
expect from one of the standard technologies developed by Charmilles Technologies. After studying this section,
you should :
Basic theory concerning flushing techniques – Be able to position

for static machining your lateral flushing
nozzles correctly
Flushing, that is the circulation of dielectric between the electrode and workpiece, is very to obtain good
important in EDM. Suitable flushing conditions are essential in order to obtain maximum efficiency.
efficiency. – Know the 2 command
words concerning
Charmilles Technologies machines are equipped with servo mechanisms with ultra-rapid flushing, and their
advance and withdrawal. This device simplifies the problems of flushing and makes it syntax.
possible to machine the most complicated molds without any major difficulty. – Be able to quote the
situations where
We shall now analyze what happens in the GAP during machining when there is no injection and suction
flushing : can be used at the
same time.
At the start of machining the dielectric is clean, that is free of eroded particles and
carbon residues resulting from cracking. Since the resistance of a dielectric is greater
when it is clean than when it is loaded with particles, a certain time is needed to
overcome this resistance and allow ignition of the first discharge.
186.*
The particles created by the first discharges reduce the dielectric’s resistance, thus allowing
the discharges to develop more easily. Flushing conditions are thus improved.
187.*

2.33
However, if the particle density becomes too great in certain points in the GAP, there is a
reduction in the resistance, which encourages the formation of abnormal discharges which
can degenerate into arcs and cause damage to the workpiece and electrode.
These excess particles must be eliminated by flushing, that is the circulation of the dielectric
fluid in the GAP.
188.*
! In EDM, flushing is just as important as the electrical parameters of

the generator.
1.*
Flushing must not be too strong nor too weak ; the greatest efficiency is obtained with
a certain degree of contamination in the dielectric (environment with slight pollution).
Different flushing modes can be employed depending on the problems to be dealt with.
Charmilles Technologies machines enable all the following flushing modes to be used.
Injection flushing
190.*
189.*
In this flushing mode, the dielectric fluid is injected under pressure either under the
workpiece via a pot (a support that helps both clamping and flushing) or through the
electrode.
In the first case, the pre-drilled workpiece is mounted on a pot connected to piping.
In the second case it is the electrode that is drilled and the dielectric is fed through it, either
via the electrode holder, or directly onto the electrode.
Injection flushing has the disadvantage of making the cavity become conical.
This taper effect is caused by the particles working their way along the electrode, creating
conducting bridges favoring lateral discharges. This problem generally disappears during
finishing when the electrode machines with a translation movement and a dynamic GAP.

Suction flushing
191.* 192.*
In this flushing mode the liquid is sucked up either from under the workpiece by the pot, or
by the electrode. Compared to injection flushing, this technique makes it possible to avoid
unwanted lateral sparks by preventing particles from circulating along the vertical sides.
The hole thus obtained is virtually straight.
Combined flushing
This mode, combining suction and injection, is frequently used for machining molds or dies
of complex shapes. It allows evacuation of gases and particles in the convex parts
of the workpiece and ensures good dielectric circulation throughout the machining area.
193.*

2.35
Lateral sweep flushing When the flushing direction is not parallel
to the side of the electrode, turbulence
This mode has to be used when it is not develops and only a small amount of
possible to provide one or more holes dielectric penetrates into the GAP, resulting
either in the electrode or workpiece. in inefficient flushing, and bending of
These cases arise during machining of the electrode if the latter is narrow.
dies for the manufacture of medals and
cutlery or machining of deep narrow slots
that are found in molds for the plastics Incorrect
industry.
Correct
This type of flushing requires the use of
injection nozzles or ramps that have to be
carefully oriented to ensure the perfect
coverage of the whole surface of the
electrode. This technique is always used
with the pulsator (R and U) which
facilitates the flow of liquid when the
electrode is withdrawn.
195.*
In the case of flat machining, the angle of
the nozzle must be adjusted according to
the entry angle of the engraving. In cutlery If the flushing is well directed, a maximum
dies and when the longitudinal forms are amount of dielectric passes through the
not plane, special ramps having the shape GAP. When machining a slot, the film of
of the profile must be used. liquid must be projected onto the longest
side of the electrode, from its edge for
example, so that the dielectric is forced to
go along the side of the electrode and thus
clean the cavity.
Correct
Incorrect
194.*
196.*
Correct

Flushing by stirring of dielectric
This mode is obtained by using a pulsation movement of the electrode (R and U). When the
electrode is raised, the volume increases, which causes the arrival of clean liquid which
mixes with the contaminated liquid. When the electrode goes down again the particles are
evacuated.
197.*
This flushing mode is useful, since it enables very deep holes to be machined without forced
circulation of dielectric.
Pulsed synchronous flushing with withdrawal of the electrode

During machining of small cavities (1 cm2) and/or fine details using copper electrodes, it is
possible that the latter can develop abnormal wear around the injection area. Moreover,
this wear increases with flushing pressure.
198.*
To overcome this problem, Charmilles Technologies has developed a method for

synchronizing the injection of dielectric during electrode withdrawal ; the feeding
of dielectric under pressure into the GAP only takes place while the electrode is
going up, that is when no machining is taking place.
Command words linked with flushing

As you already know, flushing can be controlled manually by means of the keyboard (see
module 1). It is also possible to use command words.

2.37
DIEL screen
The DIEL function in EXE mode brings together all the information and means of monitoring
injection of the dielectric.
ROBOFORM 35 ROBOFORM 2400

PREP EXE ;; INFO GRAPH PREP EXE INFO GRAPH
DIELECTRIC DIELECTRIC
Injections TANK Injections

STATUS WAIT STATUS WAIT
EL : 0 45 mm 45 EL : 0
LL : 0 LR : 0 Max LL : 0 LR : 0
CV 1 : 0
CV 2 : 0
CV 3 : 0 bar
PA : 0 CV 4 : 0 PA : 0 FLI
–> 0.00
0
Suction Suction
CV 1 : 0
CV 2 : 0
CV 3 : 0 bar
PA : 0 CV 4 : 0 PA : 0 FLA
–> 0.00
DNC FS DNC FS
STATUS FLUSH/EL FLUSH/LL FLUSH/LR FLUSH/PA STATUS FLUSH/EL FLUSH/LL FLUSH/LR FLUSH/PA FLI
F1 F2 F3 F4 F5 F6 F7 F1 F2 F3 F4 F5 F6 F7
ASPIR/PA FLUSH/CV1 FLUSH/CV2 FLUSH/CV3 FLUSH/CV4
F4 F5 F6 F7 F1 F2 F3 F4 F5 F6 F7
F1 F2 F3
ASPIR/PA ASPIR/CV1 ASPIR/CV2 ASPIR/CV3 ASPIR/CV4 FLA

F1 F2 F3 F4 F5 F6 F7
ROBOFORM 54 ROBOFORM 55
PREP EXE INFO GRAPH PREP EXE INFO GRAPH
DIELECTRIC DIELECTRIC
Injections Injections TANK
STATUS WAIT STATUS WAIT
EL : 0 EL : 0 45 mm 45
LL : 0 LR : 0 LL : 0 LR : 0 Max
PA:0 PB:0 PA:0 PB:0
0
Suction Suction
PA : 0 PA : 0
DNC FS DNC FS
STATUS FLUSH/EL FLUSH/LL FLUSH/LR FLUSH/PA FLUSH/PB STATUS FLUSH/EL FLUSH/LL FLUSH/LR FLUSH/PA FLUSH/PB
F1 F2 F3 F4 F5 F6 F7 F1 F2 F3 F4 F5 F6 F7
ASPIR/PA ASPIR/PA
F1 F2 F3 F4 F5 F6 F7 F1 F2 F3 F4 F5 F6 F7
ROBOFORM 84
PREP EXE INFO GRAPH
DIELECTRIC
Injections
STATUS WAIT
EL : 0
LL : 0
PA : 0
DNC FS
STATUS FLUSH/EL FLUSH/LL FLUSH/PA

F1 F2 F3 F4 F5 F6 F7

The STATUS control can take three states :
ON, WAIT and OFF. It allows flushing to be adjusted.
Attention: The ON position starts selected flushing immediately.
Type of injection
FLUSH/EL injection by the electrode
FLUSH/LL left-side injection
FLUSH/LR right-side injection
FLUSH/PA injection by the part
FLUSH/PB injection by the part
FLUSH/CV1..4 multicavity injection
Mode of injection
0 no injection
1 continuous injection
2 pulsed injection
3 alternating and pulsed injection
4 0° orbital side injection
5 90°orbital side injection
The injection mode is a numerical code between 0 and 5.

Each press on the desired key, FLUSH/EL for example, immediately selects a higher code
or 0 if the last selection was 5.
Suction
ASPIR/PA suction
ASPIR/CV1..4 multicavity suction
Mode of suction
0 no suction
1 continuous suction
2 pulsed suction

2.39
Notes :
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Exercises :
Answers : 1) The position of the lateral nozzles has 3) What sort of flushing can be
no influence on machining : recommended for an electrode of
1) False ; it is very a. True very complex shape ?
important to position b. False a. Lateral flushing with a set of 4 or 5
the flushing nozzles nozzles
correctly. 2) Which type of flushing allows b. Flushing with simultaneous injection and
machining of deep holes ? suction
2) a. a. Flushing by stirring of dielectric c. Pulsed flushing through the electrode
b. Suction flushing d. No flushing
3) b. c. Combined flushing

Command words linked with machining
We remind you that the command words can be used directly as such by typing them on
the keyboard, and that they can all be stored under the same file and that the latter can
be executed under the form of a program called “command program”, i.e. program of Objectives :
automation of the machine.
After going through this
Always keep in mind that supplementary information on the command words can be found section, you should :
in chapter 5 of your user’s manual.
– Be able to quote from
memory the 4
command words and
TOF et RLD use them properly.
– Know where to find
the parameter ZCL so
These are two words that allow loading of the following : as to be able to set
the counters back to
– Offsets in the USER.OFS (TOF) table zero.
– Generator parameters in a TECHNOLOGY (RLD) table
We remind you that a USER table is a blank table that you must fill in according to your
needs or experience. It is up to the operator to fill in these tables. A technology table
can be easily modified by a simple optimization or an adaptation of technology for a pair
of exotic materials.
These parameters can be modified automatically thanks to the words TOF and RLD.
Examples : Com> TOF,T4,X1.345,Y—2.784,Z-10.43,C183.2
DNC FS

F1 F2 F3 F4 F5 F6 F7
makes it possible to load an offset on X,Y,Z,C on line 4 (tool No. 4 in the USER.OFS table)
Com> RDL,E343,U9,R2,SV20,RFO
DNC FS

F1 F2 F3 F4 F5 F6 F7
makes it possible to modify the generator parameters on the current technology table (table
transferred to MEM : and activated) under the setting 343.
REX
Up till now we have always been considering the loading of tables into the machine’s
memory, but never the activation of the information in this memory.
As regards the technology tables, a table can contain over 70 different settings.
It becomes obvious that we are going to have to make a choice between these
different settings !
This choice is made by means of the command REX.
Caution ! The selection of the setting is done only on the current technology !
table (table transferred into MEM : and activated).
1.*

2.41
Example :
REX,E343
loading into the generator of setting 343 of the current technology table.
We shall see later how it is better if we select the settings with the PROFORM program.
This command word is used mainly in advanced applications.
ZCL
This is another very practical word which allows you to set to zero the clocks available in
the INFO–SURVEY page.
PREP EXE INFO GRAPH

SURVEY
Part To Go Offset Setting E333 ULCUAC
X 0.000 0.000 X 0.000 TBi TRi TUi RFi

Y 0.000 0.000 Y 0.000 5.0 2.0 7.0 50
Z 0.000 0.000 Z 0.000
C 0.000 0.000 C 0.000 M C V P A Inv EL
R 0.000 0.000 3 0 5 8 7 0 1
T 0.000
T B R U RF SV PR
Clocks CL1: 244:00:00 CL2: 0:00:00 1 5 2 7 50 30 5
showing 100 100

total
time and 50 %
machining
time 0 0
80 75 3 3 4 6 3
Pilot-Expert OFF
DNC FS
SORVEGLIANZA MACCHINA PROGRAMMI MESSAGGI DNC3 STATO SPENTO

IN CORSO MODALE
F1 F2 F3 F4 F5 F6 F7
As you can observe, there are two clocks, one that calculates the total work time and one
that calculates machining time (spark production). If we type :
ZCL the two clocks are set at zero.

ZCL,1 the total time clock is set at zero.
ZCL,2 the machining time clock is set at zero.
Exercices :
1) The command ZCL,2 makes it possible 2) The command REX makes it possible
to : to :
a. Set the machine’s clock at zero a. Activate a table
b. Set the machining time clock at zero b. Activate certain information in a table
c. Set the total time clock at zero c. Activate a setting from the selected table
d. Set the total time clock and machining d. Load certain parameters in a technology
Answers : time clock at zero table
1) b. 3) Which of these syntaxes is correct ?

a. TOF,T2,X,3.678,Y,– 2.876,Z,23.453
2) c. b. TOF,4T,X4.876,Y3.564
c. TOF,T1,X10
3) c. d TOF,Z– 16.564,C123.4

Summary of chapter 2
In the course of this module you have seen the operation of the principle of EDM, used by
your ROBOFORM machine.
You have learned an important concept, the sparking distance or GAP, and you have seen
that there are several types of GAP, such as :
– Static GAP (asymptotic)

– Dynamic GAP
– Limit GAP
– Final GAP
This sparking distance is controlled by a large number of parameters :
– The main parameters with P and A which are the most important and which should not
be modified because they have a direct influence on the GAP length.
-– The secondary parameters which on the other hand can easily be modified to optimize
a machining job (efficiency).
All these parameters are assembled in tables called technology tables available on diskette
and which must be copied into the machine’s memory if they are to be used.
The tables are named according to material pairs.

A technology table is divided into groups of parameters called settings, and are coded
according to the surface finish and class of wear.
In this module you have become aware of the importance of flushing during machining.
There are several types of flushing :
– Lateral flushing
– Through the electrode
– Through the workpiece
– Injection flushing
– Suction flushing
The position of the flushing nozzle and the choice of type of flushing are vital factors for
efficient machining.
Flushing can be controlled by command words.
You have understood what type of information is given to you by the bar graphs which are
divided into 3 zones :
– Machining efficiency
– Display of defects
– Machining stability
You can optimize the machine with B–R–U–RF–SV or leave it to optimize itself, with Pilot
Expert set at ON (T= ø or T= 2).
The machine is equipped with protection mechanisms and automatic monitoring of

machining ensuring a high level of safety for the production of parts.
In this module we have discovered many command words which enable us to activate
tables (TEC, OFS, etc.), modify parameters (TOF and RLD), select a setting (REX) and
set the clock to zero (ZCL).
You can now answer the questionnaire for chapter 2.

2.43
Revision of knowledge of chapter 2
1) What is meant by “asymptotic GAP”?
............................................................................................................................
............................................................................................................................
2) The M4 relaxation mode is used for finishing.

❑ a. True
❑ b. False
3) Write the parameters in their respective positions on the drawing below :
Voltage V
(Volt)
Time
(µ sec)
Current
(Amperes)
212.*
Time
(µ sec)
4) What are the 2 most important parameters for guaranteeing the GAP length ?
❑ a. TA & TB
❑ b. P & Td
❑ c. P & A
❑ d. V & T
5) In what machining situations is it advisable to set RF = 0?

❑ a. At all times
❑ b. Deep cavities
❑ c. Cavities with sharp corners
❑ d. Badly adapted flushing
6) Concerning validation of tables, which of these statements is correct ?

❑ a. To validate a table, it must be copied beforehand into the machine’s central
memory.
❑ b. To validate a table, it must be retrieved directly from the “Technology” diskette
supplied with the machine.
7) Which of these settings causes most wear ?

❑ a. 222
❑ b. 224
❑ c. 221
❑ d. 220

8) For what type of electrode is combined flushing useful and why ?
............................................................................................................................
9) Which of the following words enables you to call up a setting by means of the
keyboard ?
❑ a. REX
❑ b. RLD
❑ c. TOF
❑ d. TEC
10) What is the significance of the following bar graphs :

2.45
Machine language and machining
Preparation of work with PROGRAM-EXPERT 1.1 3.3

General remarks 3.3
PROGRAM-EXPERT according to your level 3.3
Concrete example of a machining job with one electrode 3.7
Access to PROGRAM -EXPERT 3.7
Data input pages 3.8
Selection of priorities 3.15
Automatic results 3.16
The CHOICE column 3.17
Generation of the program 3.21
Concrete example of a machining job with two electrodes 3.23
Data input 3.23
Selection of priorities 3.25
Automatic results 3.26
Generation of the program 3.28
PROFORM programming 3.31

Structures and definitions of a program 3.31
Programming words 3.33

Control function words 3.33
Technology activation words 3.35
Elementary operations words 3.36
Elementary movements without machining 3.36
Elementary movements with machining 3.37
Plunge cut machining 3.37
Machining in orbital mode 3.38
Machining in plane orbital mode 3.39
Machining in conical mode 3.39
Geometric modifier words 3.40
Machining in corners 3.40
Rotation of the spindle 3.40
Spatial machining 3.40
Machining by orbital translation in space 3.40
PROFORM editor 3.43
Working procedure for machining 3.47
Description of technology curves 3.51

Programming : general concepts 3.51
Terminology concerning technology curves 3.52
Technology curves 3.53
Command words and parameters linked to programming 3.61

Command words 3.61
User parameters 3.62
Summary 3.63

3.1
General objectives of the chapter :
At the end of the chapter, you should be

able to :
• Understand the PROFORM syntax and • Manipulate and correct a PROFORM

the general structure of a program. program by means of the PROFORM
• Quote and describe the PROFORM editor.
words for the following functions :
– Definition of origin • Start a machining job without an instruc-
– Movements without machining tor, making use of the working procedure
– The main machining cycles to be found in your manual.
• Use PROGRAM-EXPERT in automatic • Know and quote 2 command words per-

mode. taining to programming.

Preparation of work
with PROGRAM-EXPERT 1.1
General remarks Objectives :
PROGRAM-EXPERT is a programming aid After studying this section
software that will enable you to carry out the you should :
majority of your applications with electrodes
having appropriate shapes. – Know the 4 stages
you have to go
PROGRAM-EXPERT will also help you to through to draw up a
save time during programming, thanks to its program using
ease of use (data input page) and flexibility Program-Expert.
(automatic calculation of GAPs when modifi- – Be able to select the
cations are made). level best adapted to
your capability.
This software can be used by operators of – Know what are the
all levels, from beginners to masters of EDM. limits of Program-
Expert.
8.*
PROGRAM-EXPERT according
to your level
– For beginners :
Being a beginner is not a handicap - we

were all beginners once. PROGRAM-
EXPERT will suggest an automatic
sequence, and by following this avenue
!
you will be putting your trust in the techni- 1.*
cians of CHARMILLES TECHNOLOGIES

who have worked out these strategies.
It should however be pointed out that
The experience gained by these experts PROGRAM-EXPERT is not adapted to
over the years will compensate your lack machining of the Contouring or Vectorial
of knowledge as a beginner. type.
– For users of intermediate and

advanced levels :
As a general rule:
When you have worked in EDM for
some time you yourself will have gained The algorithms of PROGRAM-EXPERT are
experience relevant to your own applica- based on experience acquired over a
tions. In the light of your observations wide spectrum of applications. Unfortunately
made during your work you will be able certain special cases of machining are
to adjust certain parameters that modify outside the scope of the calculations.
the structure of your programs. But in no circumstances will PROGRAM-
EXPERT present unreasonable solutions
causing damage to your applications.

3.3
To create a program by means of PROGRAM_EXPERT in automatic mode, you need to have
loaded the files .TAB and .TEC of the material pair in question, and to have validated the
four stages defined below.
PREP EXE INFO GRAPH
PROGRAM-EXPERT
Page 1/3: TECHNOLOGY PARAMETERS
• Data Input * Application..................... Standard

PREP EXE INFO GRAPH
* Technologie..................... CUIVRE/ACIER
PROGRAM-EXPERT
* Type de translation............. DOWN/ORB
Enables you to define the main Page 2/3: ELECTRODE AND POSITIONING PARAMETERS
* Final surface finish............ 24 CH
elements for drawing up your * Distance electrode part......... 5.2 mm

* Respect of* dDepth
tail............... NON
of cut....................
PREP EXE
5.4 mm
INFO GRAPH
* Program depth................... 10.0 mm
machining program (there are * Attack protection............... OUI
* Correction for manual finishing. 0.02 mm
PROGRAM-EXPERT
* PAGE DOWN *pour

Axispasser
of cut..................... Z
two input pages). la page ELECTRODE
Page 3/3: PROGRAM PARAMETERS
* Frontal surface area............ 23.3 cm2
* Flushing........................
* Total surface area.............. 45.2 cm2 LATERAL
50.4 mm DNC FSCONTINUOUS
* Flushing mode...................
* Electrode length................
*Micro
Number Polissage
of electrodes............ CALCULATE
Standard Lames Surface usinage
* Roughing
* PAGE DOWN pour passer tool
la page number............
PROGRAMME, PAGE UP retour 3
TECHNOLOGIE
F1 F2 F3 * Finishing
F4 F5tool number...........
F6 F7 5
* Program name roughing/finishing. EBFI

FINI DNC FS
* Program name finishing..........
ELECTRODE * -------------------------------- Generate

DESCRIPTION
F1 F2 * PAGE DOWN
F3 to pageF4TECHNOLOGY,F5PAGE UP toF6go back toF7ELECTRODE
DNC FS
Generate
F1 F2 F3 F4 F5 F6 F7
PREP EXE INFO GRAPH

• Selection of priorities PROGRAM-EXPERT
SELECTION OF PRIORITIES
This stage allows you to select TYPE OF WEAR: Very low Low Average
TYPE OF SECURITY: Low Average High

the best compromise between speed,
wear and surface finish depending 1 LOW WEAR
on the requirements of you machining job. 3

2 SPEED
SURFACE FINISH
DNC FS
OK SPEED LOW SURFACE

WEAR FINISH
F1 F2 F3 F4 F5 F6 F7
PREP EXE INFO GRAPH
• Automatic results
PROGRAM-EXPERT
AUTOMATIC RESULTS
PROGRAM-EXPERT gives you the results PROPOSED CHOICE ELECTRICAL

Roughing power P12 48 A
of the calculation taking account of CH Roughing 45
U/S Roughing
the input parameters and the priorities.
0.593
CH Tool 35
U/S Tool
This stage gives you the maximum Final power
0.219
P6 8 A
roughing setting, the undersize of the

electrodes and the final power. DNC FS
OK P2-P4 P4-P5 P6 P7
F1 F2 F3 F4 F5 F6 F7
PREP EXE INFO GRAPH

• Program generation PROGRAM-EXPERT
DISPLAY OF MACHINING PROGRAM

Roughing/finishing program :EBAU.RBF
Generation of the program takes place instan-

1:PN/EBAU
2:;SELECTION OF PRIORITIES
3:;SPEED
4:;SURFACE FINISH
taneously after validation of the results and is

5:;LOW WEAR
6:AUX/22
7:TECHNO/F,EBAU
8:FLUSH/LL,1
immediately ready for execution.

9:FLI/1
10:L1=-25
11:AXE/Z
12:FROM/X,0,Y,0,Z,10
13:TOOL/11
14:DOWN/L,L1+0.036,H,-0.580,E,453,RET
15:DELAY/30
16:DOWN/L,LL,H,-0.580,E,432
17:ORB/L,LL,H,-0.415,E,432
18:ORB/L,LL,H,-0.330,E,412
19:ORB/L,LL,H,-0.260,E,402
20:ORB/L,LL,H,-0.190,E,391
DNC FS
PROGRAM
OK FINISH
F1 F2 F3 F4 F5 F6 F7
Programming completed

Notes :
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
Exercices :
1) Put the programming stages of 3) For which types of machining jobs is

PROGRAM-EXPERT in the correct PROGRAM-EXPERT not adapted ?
chronological order : a. DOWN-ORB machining
a. Program generation b. Contouring
b. Selection of priorities c. EXPAN machining
c. Data input d. Vectorial machining
Answers :
d. Results
1) c, b, d, a.
2) PROGRAM-EXPERT is designed for :
a. Beginners
2) d.
b. Intermediate level operators
c. Advanced operators
3) b and d.
d. Users of all levels

3.5
Concrete example of a machining job
with one electrode
You wish to machine a square cavity with sides of 20 mm and a depth of 20 mm, with a
final surface finish (CHf) of Charmilles No. 35 (5.6 Ra).
Objectives :
The electrode is in copper and the part in steel.
After studying this section
– Fill in correctly the two

data input pages and
know the significance
of the various items.
– Create a program for
one electrode.
– Modify the maximum
roughing power and
validate the undersize
of an electrode.
20 20
261.*
Access to PROGRAM-EXPERT 1.1

This is done in PREP mode (F4 key).
On the dialogue line you must type the name of the program to be created (max. 6 characters)
and press “Return”.
A questionnaire covering two screens will then be displayed ; use the “Page down” and
Page up” keys to move from one screen to the other. The cursor is moved with the direction
keys . 262 *
The function keys F1 to F7 give you a choice of reply to the item indicated by the cursor.
PREP EXE INFO GRAPH

PROGRAM-EXPERT
PAGE
UP
* Application..................... Standard
* Technology......................
PREPCOPPER/STEEL EXE INFO GRAPH
PROGRAM-EXPERT
* Type of translation............. DOWN/ORB PAGE
Page 2/3: ELECTRODE AND POSITIONING PARAMETERS UP
* Distance electrode part......... 5.2 mm
* Respect of d tail............... * NO PREP
Depth of cut.................... 5.4 mm EXE INFO GRAPH
* Program depth................... 10.0 mm
* Attack protection............... * YES
Correction for manual finishing. 0.02 mm PROGRAM-EXPERT
* Axis of cut..................... Z Page 3/3: PROGRAM PARAMETERS

* PAGE DOWN to access page ELECTRODE
* Frontal surface area............ *23.3 Flushing........................
cm2 LATERAL
* Total surface area.............. *45.2 Flushing
cm2 mode................... CONTINUOUS
DNC FS
* Electrode length................ 50.4 mm
* Number of electrodes............ CALCULATE
* Roughing tool number............ 3
Standard Rib Surface Micro Polish
* Finishing
* PAGE DOWN to page PROGRAM, PAGE UP to go back tool number...........
to TECHNOLOGY 5
F1 F2 F3 F4 F5 F6 F7
* Program name finishing.......... FINI
DNC FS
PAGE
DOWN * -------------------------------- Generate
ELECTRODE
DESCRIPTION * PAGE DOWN to page TECHNOLOGY, PAGE UP to go back to ELECTRODE
F1 F2 F3 F4 F5 F6 F7
DNC FS
PAGE
DOWN
Generate
F1 F2 F3 F4 F5 F6 F7
Making use of the data presented above, we shall go through the various items we have to
fill in so as to obtain a machining program.

3.7
Data input pages • Type of translation
This item enables you to select the type of

• Application
instruction that is going to be generated in
the PROFORM part-program.
This first parameter defines the type of appli- At present only the DOWN/ORB,
cation involved in the machining job that you DOWN/EXPAN, ISOG, only DOWN and
wish to carry out. A distinction is made simple SQAR functions are available. If how-
between the following cases : ever you wish to use different PROFORM
– Standard functions, it is possible to change them man-
– Rib ually by means of the PROFORM editor
– Surface while keeping the same technological pack-
age (settings and GAPs).
– Micro
– Polish
for which technology tables have been • Final surface finish
developed.
The value to be entered is that of the final
surface finish that you wish to obtain. During
its calculation, PROGRAM-EXPERT will take
the CH value nearest to your requirement.
(For example : if you settle for CHf = 13,
PROGRAM-EXPERT will take CH = 14, since
CHf 13 does not exist).
It is preferable to set a
lower surface finish
(18 CH instead of 20 CH)
and set priority for speed
• Technology ! when selecting priorities
(see page 3.33) in order
1.*
to avoid extending the
It is here that you will be able to select your machining time.
technology depending on the materials pair
used for the job.
The most common pairs are Copper/Steel
• Respect of detail
and Graphite/Steel.
Depending on your selec- You saw in the previous chapter that there is
tion, you must nevertheless a difference between wear and respect of
ensure that the necessary electrode.
! technology files are stored
in the machine’s memory
Wear is a normal phenomenon in EDM,
and we try to limit it by selecting settings
1.*
(MEM :). causing low wear.
1.*
On the other hand, respect of electrode
For copper and steel, these are : depends on the power of roughing that we
impose on the electrode. If the setting is too
CECUAC.TAB (PROGRAM-EXPERT software) energetic the electrode will be destroyed.
UCUAC.TEC (copper/steel technology)
The aim of PROGRAM-EXPERT is to save you
and for graphite and steel : time by selecting energetic settings for both
roughing and finishing.
CEGRAC.TAB (PROGRAM-EXPERT software) But in many cases your electrodes are made
UGRAC.TEC (graphite/steel technology) up of details, have sections of small dimen-
sions, or are difficult to make.
In such cases it is possible to moderate the
roughing and finishing settings by bringing
detail treatment into play.

The first analysis will be the selection of the If you have electrodes of
roughing power according to the section of less than 4 mm2 section,
your electrode. or made up of small points,
! we advise you to select
YES.
The first analysis will be the selection of the
1.*
roughing power according to the section of
your electrode. Detail treatment also has additional effects,
particulary on free-form electrodes ; these
will be dealt with later on in this manual.
– If you select NO:
The roughing setting will be energetic.
• Attack protection
– If you select YES:
The roughing setting will be moderate This option makes it possible to start machi-
in relation to the surface area of your ning with a generator power higher than
electrode. normal for the surface area in question.
Particularly suitable for free-form surfaces,
this option can lead to a certain amount of
The second analysis will be the selection electrode wear, so it must not be used in too
of the power of the final settings. systematic a manner.
When this option is activated, the command
– If you select NO: AUX,32 will be generated before all the
The final settings will be selected on a DOWNs of the machining program.
line of high power.
Application to our example
– If you select YES:
PROGRAM-EXPERT will limit the current PREP EXE INFO GRAPH
density on the details of your electrode PROGRAM-EXPERT

during orbits, so as to avoid destroying * Application..................... Standard
Standard
them. This limitation will be done by * Technology...................... COPPER/STEEL
selection of a line of lower power. * Type of translation............. DOWN/ORB
* Respect of d tail............... NO
In general the intermediate orbital settings * Attack protection............... YES
will not be modified when detail treatment is * PAGE DOWN to access page ELECTRODE
selected. DNC FS
Standard Rib Surface Micro Polish
F1 F2 F3 F4 F5 F6 F7
Detail treatment NO
Notes :
...........................................................
...........................................................
274.*
...........................................................
Simple electrodes ...........................................................
...........................................................
...........................................................
Detail treatment YES
...........................................................
...........................................................
...........................................................
...........................................................
...........................................................
275.*
...........................................................
Complex electrodes

3.9
Example 4
• Distance electrode part Ref. X or Y=0
10
The value to be entered will set the absolute
distance in the PART system, on the penetra- 30
tion axis, between the PART origin and the AXE/
bottom of the electrode. X or Y
Example 1 269.*
AXE/Z
To be
machined
Depth of penetration = 30
Programmed depth = 30
266.* 10 Electrode – part distance = – 10
Ref. Z=0
30
• Depth of cut
To be machined
Programmed depth = – 30 In the case of deep machining this value is
Electrode – part distance = 10 important since it determines the types of
machining safety needed to prevent defor-
mations in the cavities.
Example 2 AXE/Z It is to be entered as a positive value
enabling the actual depth of the cavity to be
defined. (An approximate measurement is
amply sufficient.)
• Program depth
50
30
This is the absolute coordinate, on the pene-
5 Ref. Z=0 tration axis, of the arrival point of your elec-
trode in relation to the PART origin.
267.*
To be machined This value will appear under the “L” of the
Depth of penetration = 30 DOWN and ORB lines
Programmed depth = 5 (DOWN/L,•30,H,•0.7,E,453).
Electrode – part distance = 50
Example 3 AXE/Z
268.* 10
Ref. Z=0
50
30
To be machined
Programmed depth = – 50
Electrode – part distance = 10

• Correction for manual finishing – In cases of manual touching up
(polishing)
This item will enable you to adjust the

dimension of your cavity to the mean value
of the tolerances or to leave extra thickness
of material to allow for a possible manual
pass (polishing). 272.*
The drawings below will help you under-

stand how the adjustment functions. 0,01 0,01
– In cases of uniform tolerances

0,01
Dimensions concerned :
Width : – 0.02 of the nominal dimension
Depth : – 0.01 of the nominal dimension
50 +0,02
0 Correction for manual finishing : – 0,01
0,005 0,005 30 +0,02

0
As you will have observed, the value intro-
duced has a twofold effect on the width of
the cavity and a single effect on the depth.
0,005
Dimensions concerned in order to be

within the tolerance : Application to our example
50 + 2 x 0,005 = 50,01
30 + 0,01 = 30,01
Correction for manual finishing : 0,005 mm PREP EXE INFO GRAPH
Programmed depth : – 30,005 mm PROGRAM-EXPERT
Page 2/3: ELECTRODE AND POSITIONING PARAMETERS

* Depth of cut.................... 20.00 mm
* Program depth................... -20.00 mm
– In cases of varying tolerances

Notes :
...........................................................
...........................................................
50 +0,02
0 ...........................................................
...........................................................
0,005 0,005 30 +0,03
0 ...........................................................
...........................................................
...........................................................
0,005
...........................................................
Dimensions concerned in order to be
within the tolerance : ...........................................................
50 + 2 x 0,005 = 50,01
30,03 – 0,015 = 30,015 ...........................................................
Correction for manual finishing : 0,005 mm ...........................................................
Programmed depth : – 30,01 mm
...........................................................

3 . 11
• Axis of cut • Electrode length
The parameter entered here will allow you This parameter will make a small modification
to determine the machining axis. at the start of the PROFORM program, in
order to compensate expansion phenomena.
This value is approximate and measurement
using a ruler is sufficient. However, with strong
roughing (P>P11) it is preferable to round
up to a value higher than the one measured,
the aim being to take account of expansion
of the part (workpiece) and mountings.
The “Z” axis is entered by default.
• Frontal surface area

• Total surface area
Under these items it is not possible to intro- 277.*

duce a value directly.
X
You therefore have to describe the electrode
on a description table (accessible with the
F1 key).
PREP EXE INFO GRAPH
PROGRAM-EXPERT
ELECTRODE DESCRIPTION
PREP EXE INFO

Position Form PROGRAM-EXPERT
of stair of stair [mm] [mm]
Page 2/3: ELECTRODE AND POSITIONING PARAMETER
0.0 RECTANGLE Length : 8.00 Width : 8.00

* Depth of cut.................... 20.00 mm
* Program depth................... -20.00 mm
* Axis of cut..................... Z
DNC FS * Frontal surface area............ 4.00 cm2

* Total surface area.............. 20.00 cm2
* Electrode length................ 40.00 mm
RECTANGLE POLYGON CIRCLE
F1 F2 F3 F4 F5 F6 F7
278.*/ang * PAGE DOWN to page PROGRAM, PAGE UP to go back to TECHNOLOGY
The “form of stair” will enable you to define ELECTRODE
the shape of your electrode and the dimen-

DESCRIPTION
F1 F2 F3 F4 F5 F6
sions :
– Rectangle with its length and width ELECTRODE DESCRIPTION
Position Form
of stair of stair [mm] [mm]
– Polygon with the number of sides and 0.0 RECTANGLE Length : 20.00 Width : 20.00
their width
– Circle with its diameter

Notes :
In the case of a simple electrode, you just
need to define the form on stair 0.0 (attack-
...........................................................
ing surface of the electrode).
...........................................................
The case of free-form electrodes will be
...........................................................
dealt with later on in this manual.
...........................................................

• Flushing • Roughing tool number
• Flushing mode • Finishing tool number
You have at your disposal all types of flush- This is where you will be able to validate
ing with which you are already familiar, i.e. your electrode numbering.
lateral, through the electrode, etc. This number will display the “TOOL” function
in your PROFORM program.
It is also possible for you to select whichever This number corresponds to the position on
flushing mode you prefer. the tool changer and to the line of parameters
of tool offsets stored in the OFFSETS table.
Do not hesitate to re-read the paragraph on If you do not wish to have a “TOOL” func-
flushing in Module 2. tion in your program, because you want to
work in parallel with a command program,
then you must enter “0” as the tool number.
• Program name roughing/finishing

• Program name finishing
Under these items, you can change the

name of your programs proposed here by
default according to the title entered at the
281.* start of PROGRAM-EXPERT.
If you only give a name under the first item,
you will obtain a complete program from
roughing to finishing.
• Number of electrodes
But if you give a name under both items,
You have a choice of 3 possibilities : you will obtain two separate programs, one
for roughing and one for finishing. This sec-
– CALCULATE: This mode calculates ond alternative is very practical if for exam-
automatically the number ple you wish to work with a command
of electrodes ideally suited program, in cases of multicavity machining.
your requirements.
– 1: In this case, you force
PROGRAM-EXPERT to create PREP EXE INFO GRAPH
a program with one single PROGRAM-EXPERT

electrode. There are indeed * Flushing........................ LATERAL
situations where machining * Flushing mode................... CONTINUOUS

must be done with a single * Roughing tool number............
* Finishing tool number...........
1
2
tool, for reasons of produc- * Program name roughing/finishing. EBFI

tion costs. But you are likely * -------------------------------- Generate
to reduce the speed perfor- * PAGE DOWN to page TECHNOLOGY, PAGE UP to go back to ELECTRODE
mance of your machine,

if your electrode is large
and you want a relatively
fine surface finish (< CH24).
– 2: In this second case you

force PROGRAM-EXPERT to
create a program with two
electrodes.

3 . 13
Into the same program
Program name roughing/finishing... Alex1
Program name finishing............
1:PN/ALEX1
2:AXE/Z
3:FROM/X,0,Y,0,Z,10
4:TOOL/1
5:DOWN/L,-20,H,-0.365,E,392
6:0RB/L,-20,H,-0.260,E,372,RET
7:TOOL/2
8:DOWN/L,-20,H,-0.3,E,373
9:ORB/...
283.*
Two separated programs

Program name roughing/finishing... Alex1
Program name finishing............ Alex2
1:PN/ALEX1
2:AXE/Z
3:FROM/X,0,Y,0,Z,10
4:TOOL/1
5:DOWN/L,-20,H,-0.365,E,392
6:0RB/L,-20,H,-0.260,E,372,RET
7:END
1:PN/ALEX2
2:AXE/Z
3:FROM/X,0,Y,0,Z,10
4:TOOL/2 Notes :
5:DOWN/L,-20,H,-0.3,E,373
6:0RB/...
7:ORB/...
8:ORB/...,RET
9:END ...........................................................
...........................................................
...........................................................
...........................................................
PREP EXE INFO GRAPH
PROGRAM-EXPERT
...........................................................
...........................................................
* Flushing........................ LATERAL
* Flushing mode................... CONTINUOUS
* Number of electrodes............ CALCULATE ...........................................................

* Finishing tool number........... 2

...........................................................
* -------------------------------- Generate ...........................................................

* PAGE DOWN to page TECHNOLOGY, PAGE UP to go back to ELECTRODE
...........................................................
DN
Generate
G n rer A
...........................................................
...........................................................
F1 F2 F3 F4 F5 F6 F7
F1
...........................................................
...........................................................
Now that you have completed the two data
...........................................................
input tables, you must press F1 “Generate”
so as to get to the “Selection of priorities” ...........................................................
page.
...........................................................
...........................................................
...........................................................
...........................................................
...........................................................
...........................................................
...........................................................
...........................................................
...........................................................

Selection of priorities On the table above, the different priority
options are classified according to perfor-
PREP EXE INFO GRAPH
mance as regards speed and quality.
PROGRAM-EXPERT The aim of this is to make you become
aware of the influence of these parameters
TYPE OF WEAR : Very low Low Average on machining jobs.
TYPE OF SAFETY : Low Average High
1 SPEED
3
SURFACE FINISH
MINIMUM WEAR
Note :
– Before validating, the selection can be
DNC FS
cancelled by re-using the key associated
OK SPEED
MINIMUM SURFACE
with a criterion.
– Depending on the “Detail treatment”
WEAR FINISH
F1 F2 F3 F4 F5 F6 F7
286.*/ang
function and the “Electrode description”,
Table of priorities
the six possible permutations in the table
Information window of priorities will favor wear of “Low,
“Medium” or “Very low” type.
The table of priorities
This table will be useful for you for establishing The information window
machining priorities according to your needs.
There are three different criteria : When the table of priorities is completed,
an information window appears on screen
– Speed (F2) to show you the type of wear and type of
– Surface finish (F4) safety that PROGRAM-EXPERT will take into
– Minimum wear (F3) account for its calculation.
With the function keys (F2 to F4) you can This table cannot be modified directly, but
select the order of priorities. nevertheless it is possible to make changes
to the parameters by altering the order of
priorities.
Quality and accuracy
As a general rule :
• Small electrode + Detail Treatment YES

Type of wear : Very Low or Low
1 SURFACE FINISH
2 MINIMUM WEAR
3 SPEED • Small electrode + Detail Treatment NO
1 MINIMUM WEAR Type of wear : Low or Medium
2 SURFACE FINISH
3 SPEED • Large electrode + Detail Treatment YES
1 SURFACE FINISH or NO
2 SPEED Type of wear : Low or Medium
3 MINIMUM WEAR
1 MINIMUM WEAR
2 SPEED
3 SURFACE FINISH
1 SPEED
2 SURFACE FINISH 1 SPEED
3 MINIMUM WEAR
1 SPEED 2 MINIMUM WEAR

2 MINIMUM WEAR
3 SURFACE FINISH 3 SURFACE FINISH
285.* 287.*
Speed performance

3 . 15
Automatic results
After validating the table of priorities, you will see a new page displayed on screen, called
“Automatic results”.
This results page contains :
A PROPOSED column what the machine has calculated

A CHOICE column what you can modify
An INTENSITY column peak current of the setting
PROPOSED : This column presents the selection made by Program-Expert according to the
values entered under input. It is not possible to modify the values of this part
since they will serve as a reference if you decide to alter the CHOICE column.
PREP EXE INFO GRAPH

PROGRAM-EXPERT
AUTOMATIC RESULTS
PROPOSED CHOICE ELECTRICAL
Roughing power P12 48 A

CH roughing 45 Roughing
U/S roughing 0.641
CH tool
U/S tool Finishing
Final power P7 8 A
DNC FS
OK DELETE INCREASE DECREASE
F1 F2 F3 F4 F5 F6 F7
CHOICE : In this column you are able to modify the parameters that you desire, within
certain limits (these limits will be specified later). Any modification gives
rise to a completely new set of calculations. If the finishing section
disappears after these calculations, it means that PROGRAM-EXPERT has
determined that a single electrode is sufficient.
INTENSITY : This column enables you to see the peak current of the roughing and finishing
setting.
The parameters that the machine will utilize are :
• Either those of the PROPOSED column, if you have made no modifications.

• Or those of the CHOICE column, if you have modified any of the parameters.
Validation is done with the VALIDATE key (F1).

The CHOICE column • Roughing power
In this column it will be possible to change

the undersize of your electrode or vary the As you are aware, roughing power is deter-
roughing setting to try to modify the machin- mined in relation to the frontal surface area
ing performances. of the electrode (see “respect of electrode”).
If you have already done a job with high
It is wise to follow a certain order when power and obtained a good result, you can
making modifications to avoid having to easily repeat it by modifying the parameter P.
change a parameter several times. We pre- The extent of modification has the following
sent here a logical sequence starting with
the validation of the final power and the PROPOSED CHOICE ELECTRICAL
roughing power. Roughing power P12

?
48 A
CH roughing 45
U/S roughing 0.641
CH tool
U/S tool
• Final power Final power P7 8 A
limits :
Roughing power P12 48 A – Upper limit : one point above the P

CH roughing 45 proposed by PROGRAM-EXPERT
U/S roughing 0.641
CH tool – Lower limit : controlled by the power
U/S tool of the final gradation
Final power P7 ? 8 A
This parameter will select a gradation of set-

• CH Roughing
tings within PROGRAM-EXPERT and define
the last Isopulse curve to be used during fin-
ishing. This indicator is useful for operators who are
used to working with CH values, and can
Depending on the case be utilized instead of “Roughing power”.
PROGRAM-EXPERT will
select a curve for the final If you modify the roughing power you will
gradation have an effect on the GAP, which, depen-
ding on the modifications, will be larger
!
P8
or smaller.
P7
1.*
• Roughing power and radial

P6
undersize (U/S)
PROGRAM-EXPERT will display the GAP

P5
modifications under the U/S Roughing line,
showing you the optimum GAP value for the
290.* selected roughing power.
We have seen that it is possible to modify
Determination of the final gradation PROPOSED CHOICE
depends on the dimension of the electrode. Roughing power P12 P13 CHOICE
CH roughing 45 46 P11
– Small dimension = low power in U/S roughing 0.641 0.697 42
final gradation CH tool 0.513
– Large dimension = high power in U/S tool
final gradation Final power P7 P7
This choice must also take account of the P7
detail treatment.
This choice will also depend on experi-
ence gained with similar jobs carried out
the roughing power and that it has repercus-
sions on the radial undersize (U/S).
!
previously. 1.*

3 . 17
• Undersize of electrodes • Validation of actual U/S
without modification of power
Under the item “U/S roughing” we find the

optimum GAP value corresponding to the Thanks to PROGRAM-EXPERT, you can also
roughing setting. this value is important, since fix the undersize of your electrode without at
it will give you the undersize of your electrode. the same time having to alter the roughing
To adopt this value for making your tools is power.
the best way to work, since material removal
values and the settings are optimum. This can be done by using the BLOCK key
But the electrodes are usually already made (F3).
before programming, so it becomes neces-
sary to adapt the machining program. PREP EXE INFO GRAPH
PROGRAM-EXPERT offers you the possibility PROGRAM-EXPERT
of adapting the actual undersize of your AUTOMATIC RESULTS
electrodes by modifying roughing power PROPOSED CHOICE ELECTRICAL

upwards or downwards. Roughing power P12 48 A
CH roughing 45
U/S roughing 0.641 0.700
CH tool
U/S tool
Final power P7 8 A
• Validate with “RETURN” DNC FS
BLOQUER
OK˚ EFFACER BLOC
GRAIN
F1 F2 F3 F4 F5 F6 F7
The first stage is to validate the actual under- F3

size with the RETURN key on the keyboard.
– If the value is greater, the roughing When you activate this function the power is
power will increase according to the lim- not altered, unless you impose an undersize
its seen previously, i.e. by one power point that is too small for the roughing power
at the most. The undersize will also vary, being used.
because PROGRAM-EXPERT will give the
optimum U/S for the new roughing setting Such a case of too small a value will lead to
as well. the complete recalculation of a new “rough-
ing power – optimum undersize” combina-
PROPOSED CHOICE CHOICE
tion, as seen previously.
Roughing power P12 P13
CH roughing 45 46 But what are these limits and where are they
U/S roughing 0.641 0.700 RETURN 0.697 to be found ?
CH tool
U/S tool
Final power P7 P7
– The upper limit : The theoretical limit is
set at a radial undersize of 30 mm. This
is a really extreme case and is rarely
used.
– If the value is smaller, PROGRAM-EXPERT
will calculate a new combination with a – The lower limit : This is set at – 5% of the
roughing power with an optimum radial optimum radial undersize proposed by
undersize close to the value that you PROGRAM-EXPERT.
have entered. The minimum power will
be limited by the power of the final gra- Example :
dation. The undersize U/S has a value of 0.593
(table of results above).
5 % of 0.593 mm = 0.029 mm
CH roughing 45 37 The minimum radial undersize is :

U/S roughing 0.641 0.200 RETURN 0.195 0.593 - 0.029 = 0.564 mm
CH tool
U/S tool
Final power P7 P7
PROGRAM-EXPERT will recalculate a new
“roughing power – optimum U/S” combina-
tion starting from a new lower value of
0.564 mm.

To sum up, it is possible for you to “play” For the upper tolerance there are no serious
with PROGRAM-EXPERT to find a solution problems since it is limited by the maximum
giving you a compromise between a rough- excentration radius (30 mm). For the example,
ing power and an undersize suitable for however, we shall limit the U/S to 0.7 mm.
your electrodes that have already been
made.
We advise you to determine the undersize

of your electrodes before you make them, as 297.*
this will enable you to obtain an optimum sit-

uation. 0.700 18.600 0.700

20
On our table of results we have an optimum
radial undersize, for the roughing electrode,
of 0.593 mm.
This means a maximum undersize of 0.700

mm and an electrode side of 18.600 mm
minimum.
For the lower tolerance, the explanation above

0.641 18.718 0.641 has shown us that the limit is set at – 5 %.
The calculation carried out showed us that
the minimum radial undersize is 0.564 mm,
so the maximum side length is 18.872 mm.
20
You can observe that PROGRAM-EXPERT

has decided that a single electrode is
required to machine our cavity. 0.609 18.782 0.609
The optimum side dimension of our electrode

is 18.814 mm. But unfortunately it is impos-
sible to make an electrode with a perfect 20
dimension, and so we need a tolerance.
We have already seen that two limits exist,

an upper and a lower limit.

3 . 19
• Validation of the undersize
After machining of our electrode, we measured a side of 18.600 mm ; this dimension is

within the tolerance seen previously. It is possible for us to enter the actual undersize of our
electrode in the CHOICE column and press the BLOCK function.
0.700 18.600 0.700
20

! "

0.700

! "

OK DELETE BLOC

HELP
HELP
F1 F2 F3 F4 F5 F6 F7
! " # $ % & ' ( ) = ~ : _

BACK
SPACE 1 2 3 4 5 6 7 8 9 0 - \ DELETE
<
ESCAPE Q W E R T Y U I O P @' } ] } ]
CONTROL A S D F G H J K L +; *.: ? / RETURN
< >
SHIFT Z X C V B N M , .
PAGE
UP
PAGE
DOWN
299.*/ang

Generation of the program
After the last modifications in the “Automatic Results” table it just remains for you to VALIDATE
with the F1 key to generate your program.
PROGRAM-EXPERT will generate three files :
– An “.STR” file containing all the input parameters (data typed onto the screen by the operator).
– An “.RBF” file containing the PROFORM program.
– A “.TEC” file containing the settings used by the PROFORM program.
The program obtained for our example is ALEX1.RBF
1:PN/ALEX1
2 :COORD/METR
3 : ; SELECTION OF PRIORITIES
4: ; SPEED Reminder of priorities
5: ; MINIMUM WEAR
6: ; SURFACE FINISH
7 :AUXF/22
8 :TECHNO/F,ALEX1 Selection of the technology
9 :FLUSH/LL,1,LR,1 Lateral flushing (left and right)
10:L1= – 20+0.043 Programmed depth (sec. 0.043)
11:AXE/Z
12 :FROM/X,0,Y,0,Z,10 Origin
13 :TOOL/1 Tool pickup
14 :AUXF/32 Machining safety
15 :DOWN/L,L1,H,– 0.700,E,463 First sinking
16 :ORB/L,L1,H,– 0.623,E,452
17 :ORB/L,L1,H,– 0.511,E,443
18 :ORB/L,L1,H,– 0.409,E,432 Grain refinement
19 :ORB/L,L1,H,– 0.305,E,412 (or gradation of setting)
20:ORB/L,L1,H,– 0.190,E,391
21:ORB/L,L1,H,– 0.115,E,372
22 :ORB/L,L1,H,– 0.066,E,352,RET
23 :TOOL/0 Tool deposit
24 :FLUSH/LL,0,LR,0 Stopping of flushing
25 :END
Note : If during the input stage you do not indicate a program name, there will be no
“RBF” and “TEC” files.
To exit PROGRAM-EXPERT, press key F1 (validate) once again.

!
1.*

3 . 21
Notes :
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Exercises :
1) The penetration depth is : 3) What is the purpose of the “BLOCK”

a. The distance between the bottom of the key ?
electrode and the part origin a. To optimize a roughing power with an
b. The depth that the electrode must reach undersize
c. The actual depth of the machining oper- b. To validate an undersize without modify-
ation ing the roughing power
d. The total distance of electrode movement c. To select a final surface finish (CHf)
Answers : d. To optimize a final power with an under-
2) During electrode description, what size.
1) c. “forms of stair” are available ?
a. Rectangle
2) a, c and d. b. Triangle
c. Circle
3) b. d. Polygon

Concrete example of a machining job
with two electrodes
You wish to machine a conical cavity
• Detail treatment
according to the drawing below, having a Objectives :
depth of 15 mm, and you wish to obtain
a final surface finish of CH 24 (1.6 Ra). If you enter “NO”, PROGRAM-EXPERT will After studying this section
The material pair is Copper/Steel. select a series of settings that will not spare you should be able to :
You have two electrodes of the same under- your electrode ; no power value will be less
size, U/S = 0.550 mm. than 4 amperes, i.e. P5. – Program a machining
job with two elec-
This choice is highly likely to wear away the trodes of the same
2 electrodes U/S 0.550 mm
details on your electrode. undersize.
– Program the machin-
302.*
ing stairs (layers) on
an electrode of free-
form shape.
10
– Manage the CH tool
and U/S tool parame-
P9 ters.
10
Ø 15
P8
300.*
P7
P6
15
P5
P5
Without detail treatment
Ø3
If you enter “YES”, PROGRAM-EXPERT will
make sure it selects “gentle” settings so as
to preserve the details on your electrode.
The settings can go below 4 amperes to
Data input ensure a very low current density on the
very narrow sections.
According to the example above, we can
complete page 1 as follows, up as far as
detail treatment.
303.*
PREP EXE INFO G

PROGRAM-EXPERT
P8
P7
P6
For free-form surfaces, PROGRAM-EXPERT
will create a progression of powers in P5
relation with the changing profile of P4
the electrode, and the detail treatment P3
will have important consequences on the
With detail treatment
selection of settings.

3 . 23
• Electrode description In practice you should avoid programming
large differences of position when the sur-
face area is small, because machining time
It is fortunate that the selection of settings in will be too long.
relation to the surface area of the electrode
is done automatically, but this is unfortu- The solution, in order to gain time, is to
nately not the case with the stairs (layers). determine a logarithmic progression of
Grading of the stairs with the corresponding stairs.
setting is done by using the “Electrode
description” table.
PREP EXE INFO

305.*
PROGRAM-EXPERT
PARAMETRES GENERAUX
* Electrode frontal surface area..

* Electrode length................
1.53
5.71
cm 2
cm 2 Stair 10.0
* Electrode length................ 50.00 cm
Stair 7.0
ELECTRODE DESCRIPTION
Stair 3.0
Position Form Stair 0.0
of stai of stair Stair 1.5
0.0 CIRCLE Diameter : 2.00
Stair 0.5
Note :
– The surface area of the last stair will

determine the roughing power displayed
Under this table it will be possible for you to in the automatic results. This area will
grade the stairs (layers) of increasing power also determine the optimum radial under-
in accordance with the shape of your elec- size (U/S).
trode.
– It is also the surface area of this last stair
that will be displayed under “Electrode
frontal surface area” of the second data
input page.
!
1.*
A maximum of ten stairs are allowed.

The depth of the last stair must not exceed
the depth of penetration.

• End of data input
* Flushing........................ LATERAL
* Flushing mode................... CONTINUOUS

* Finishing tool number........... 2
* Program name roughing/finishing. ALEX2

* Program name finishing..........
* -------------------------------- Generate
* PAGE DOWN to page TECHNOLOGY, PAGE UP to go back to ELECTRODE
DNC FS
Generate
AUTOMATIQUE
F1
F1 F2 F3 F4 F5 F6 F7
Selection of priorities
For our example, we shall give top priority to low wear to conserve the cavity shape as well
as possible, and second priority to speed to obtain a medium “quality/speed” range.
PREP EXE INFO GRAPH

PROGRAM-EXPERT
TYPE OF WEAR Very low Low Average
TYPE OF SAFETY : Low Average High
1 MINIMUM WEAR
2 SPEED
3 SURFACE FINISH
DNC FS
MINIMUM SURFACE
OK SPEED WEAR FINISH
F1 F2 F3 F4 F5 F6 F7
307.*/ang

3 . 25
Automatic results • Validate with RETURN
Contrary to the preceding example in which

a single electrode was sufficient, PROGRAM- PROPOSED CHOICE CHOICE

EXPERT has considered that two electrodes CH roughing 41 43
are needed for this second job. U/S roughing 0.409 0.550 RETURN 0.530
CH tool 32 32
This is why we see results displayed under : U/S tool 0.185 0.185
Final power P5 P5
– CH tool
We observe that the roughing power has
– U/S tool increased. This reaction is logical, since the
U/S of 0.550 mm leaves room for a larger
GAP. The power increment is limited to one
point.
The value of U/S roughing which is now
P10 24 A
Roughing power
CH roughing 41
indicated is optimum for the roughing power.
U/S roughing 0.409
CH tool 32
U/S tool 0.185 Now let us try to enter the value of 0.550 mm
Final power P5 4 A under “U/S tool” by validating with the
“Return” key. We observe a rise in the
Of course it is possible to modify these “CH tool” power. This rise is limited by an
results, but subject to certain limits. The prin- upper ceiling determined by PROGRAM-
ciple of operation of these two parameters EXPERT. The indicated undersize value is
is identical to that of “U/S roughing” and now optimum for the “CH tool” power.
“Roughing power”. A modification to “U/S
tool” will have an influence on “CH tool” PROPOSED CHOICE CHOICE
and vice versa. Roughing power P10 P11 P11
CH roughing 41 43 43
U/S roughing 0.409 0.530 0.530

CH tool 32 32 35
U/S tool 0.185 0.550 RETURN 0.185
• CH tool and U/S tool Final power P5 P5 P5
CH tool will set the surface finish of the elec- These manipulations enable you to adopt
trode change in the program. the undersize of your electrodes or your
power values to the electrodes available to
U/S tool will give or set the radial undersize you.
of your finishing electrode.
he result is calculated according to the total

surface area of your electrode and the final
surface finish to be obtained.
The extent of modification is relatively wide
for CH tool, so that you can “play” with
the radial undersize to try to adapt it as well
as possible to your finishing electrode.
!
To understand this principle properly, and the 1.*
similarity of work between roughing and fin-

ishing, we shall try to impose the undersize The modifications to undersize or power
of our electrodes (0.550 mm) in the case of values that you can make in the CHOICE
our concrete example with two electrodes. column are quite likely to disturb your
selections made while filling the input
In a first phase we shall try to enter our page.
undersizes by using the “Return” key to see
how PROGRAM-EXPERT reacts. Then we
shall actually set our values of 0.550 mm
with the “Block” key.

The “Detail Treatment”, for example, influ- Lower limit : Optimum U/S – 5 %
ences the choice made by PROGRAM- Upper limit : according to the limit of excen-
EXPERT as regards roughing and finishing tration (30 mm), otherwise there would still
settings. If you modify these settings, you will be a modification of powers.
then lose the benefit of the detail Treatment.
• Validation of actual U/S without mod- CH roughing 41 41
ification of power
U/S roughing 0.409 0.550 BLOCK 0.550
CH tool 32 32
U/S tool 0.185 BLOCK 0.550

Final power P5 P5
If you wish to enter your undersizes without
altering the choice proposed by PROGRAM-
EXPERT, you can at any time use the
“BLOCK” function (F3).
This key, as you will recall (example with
1 electrode), enables you to impose your Application to our example
actual undersize without modifying the
roughing power. This function is also valid In our example we are not trying to modify
with U/S tool : it is possible for you to the powers, because we do not want to
impose the actual undersize of your finishing modify the choice made by PROGRAM-
electrode without modifying CH tool. EXPERT with the Detail Treatment parameter
activated.
It is obvious that the undersize values must
remain within the range of lower and upper Our undersize values are within the toler-
limits explained earlier. ances and no modification will be made to
the powers.
Notes :
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3 . 27
Generation of the program
After validation, we obtain the following program :
Program «ALEX2.RBF»
1:PN/ALEX2
2 :COORD/METR
3 : ; SELECTION OF PRIORITIES
4: ; MINIMUM WEAR Reminder
5: ; SPEED of
6: ; SURFACE FINISH priorities
7 :AUXF/22
8 :TECHNO/F,ALEX2
9 :FLUSH/LL,1,LR,1
10:L1=-15+0.041
11:AXE/Z
12 :FROM/X,0,Y,0,Z,10 Origin
13 :TOOL/1 Tool No.1 pickup
14 :AUXF/32 Machining safety
15 :DOWN/L,-0.5,E,253
16 :AUXF/32
17 :DOWN/L,-1.5,E,294 Machining stairs
18 :AUXF/32
19 :DOWN/L,-3,E,294
20:AUXF/32
21:DOWN/L,-7,E,303
22 :AUXF/32
23 :DOWN/L,-10,E,394
24 :AUXF/32
25 :DOWN/L,L1,H,-0.550,E,414
26 :ORB/L,L1,H,-0.386,E,402
27 :ORB/L,L1,H,-0.283,E,383 Roughing machining
28 :ORB/L,L1,H,-0.209,E,373
29 :ORB/L,L1,H,-0.161,E,352
30:ORB/L,L1,H,-0.140,E,323,RET
31:TOOL/2 Tool No.2 pickup
32 :L1=-15
33 :DOWN/L,L1,H,-0.550,E,323
34 :ORB/L,L1,H,-0.130,E,0,P,72
35 :ORB/L,L1,H,-0.098,E,303 Finishing machining
36 :ORB/L,L1,H,-0.075,E,293
37 :ORB/L,L1,H,-0.054,E,273
38 :ORB/L,L1,H,-0.041,E,262
39 :ORB/L,L1,H,-0.030,E,251
40:ORB/L,L1,H,-0.018,E,241,RET
41:TOOL/0 Tool deposit
42 :FLUSH/LL,0,LR,0 Stopping of flushing
43 :END

Notes :
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Exercices :
1) What is the definition of CH tool ? 3) When you wish to impose an electrode

a. It sets the surface finish of the electrode undersize, what key must you press ?
change a. RETURN
b. It defines the surface finish of the electrode b. VALIDATE
c. It defines the final surface finish of the cavity c. It is not possible to impose an undersize
d. It defines the position of the electrode on d. BLOCK
the changer
Answers :
2) What is the maximum number of stairs
that can be defined to describe an
1) a.
electrode ?
a. 5
2) c.
b. 12
c. 10
3) d.
d. 15

3 . 29
PROFORM programming
The programs for our machines have been Structures and definitions
written in accordance with a certain number of a program Objectives :
of rules which have been standardized and
codified, either in the Charmilles language After reading this section
PROFORM, designed for easy creation of Everyday vocabulary : you should :
die sinking machining programs, or in the
ISO international language (standards Syntax – Be able to quote the
6983-1 and 6983-2). This is the set of rules of a language which words for start and
governs the order of the words and the end of program.
In this course we shall deal only with the construction of sentences (blocks). – Know the letter for
PROFORM language, but we nevertheless calling up a setting.
give you, in chapter 5 of the user’s manual, the Characters – Know the letter
ISO codes corresponding to the PROFORM A character is a unit of information generally defining the Gap.
words. representing alphanumerical symbols.
Putting it very simply, die sinking machining Word

operations can be divided into 2 categories : A word is a unit of syntax consisting of a char-
acter followed or not by one or more digits.
– Static machining Such combinations enable us to define a
(1 electrode per setting) function, a dimension, a parameter, etc.
214.*
Structure of a program :
Each program comprises 4 essential zones

of information :
– The start of program word (title)
– The origin (starting position of our electrode)
– The commands for movements in relation
to the origin
– The end of program word
Static machining
– Dynamic machining
(1 electrode for several settings) PN Start of Program word
216.*
215.*
FROM/X,0,Y,0,Z,1,C,0 Origin
Geometric
Blocs segments and
Dynamic machining
commands
With the coming of numerical control, which has

facilitated programming, static machining is no End of
longer frequently employed, and the remainder END program word
of this manual will concentrate on dynamic
machining which is very widespread today.

3 . 31
Structure of a block :
A block is a program line containing information concerning movements with or without

machining, changes of tools, and the values of Gaps (space between the part(workpiece)
and electrode) and generator settings.
The order in which they are found is :
1: PN/EXAMPLE
2 : FROM/X,0,Y,0,Z,1
3 : TOOL/1
4 : AXIS/Z
5 : DOWN/L,– 10, H,– 0.35 , E,363
6 : ORB/L,– 10, H,– 0.3 , E,363 , RET
7 : TOOL/0
8 : END
In your programs you must not forget :
– to enter the picking up and putting away of your electrode

– to indicate the origin (starting position of the program)
– to include the word RET, which makes the electrode
come out of the cavity and return to the “FROM” location
– to specify the selected generator setting with E
– to give the gap value with H
General remark :
The words in a block can be placed in any order, so the setting can be entered before the
depth, the Gap before the setting and so on.
Exercises :
1) What instruction must always be typed 3) What does the letter “H” define ?
at the end of a line in order for the a. The generator setting
electrode to come out of the cavity b. The Gap
bottom ? c. The depth
a. GOAX d. The origin
b. VECT
c. DOWN
d. RET
Answers :
2) What are the two words that define
1) d. the start and end of a program ?
a. FROM
2) a and b. b. END
c. PN
3) b. d. BEGIN

Programming words
First of all it is necessary to distinguish Let us now examine these words in a more
between different word families in the systematic manner. Objectives :
PROFORM language.
The main ones are : The most important words will be explained After reading this section
in this manual, and you will find additional you should be able to :
The control function words information in the NC manual.
The miscellaneous operations words – Quote a word for
The technology activation words movements without
The elementary operations words The control function words machining.
The geometric modifier words – Quote and describe
The words defining spatial machining 6 basic machining
operations PN (PN/ALEX212) cycles available on
Roboform.
– The control function words enable you to Defines the name of the program ; you are – Understand the essen-
define the start, the temporary stopping free to write any text following the “/” sign. tial function of the
and the end of a program or part of a word FROM.
program (sub-program).
– The miscellaneous operations words
allow you to start a variety of operations FROM (FROM/X,0,Y,0,Z,1)
such as changing electrodes, switching
on flushing, defining delays, etc. Sets the part (workpiece) origin of the
– The technology words enable you to program.
use the machine to activate automatically
one or several selected technology You have already seen on page 27 of this
tables. manual that there are two systems of axes
– The elementary operations words define on ROBOFORM machines, the absolute
the standard machining cycles used on system and the machine system.
ROBOFORM machines.
– The geometric modifier words can be There is also a third one, the part system of
combined with the standard machining axes which will be redefined by the word
cycles. “FROM” every time a PROFORM program is
– The words defining spatial machining executed.
operations allow machining to be done
along any angle of penetration.
+ Y ABSOLUTE X
O
AX + Y MACHINE
+ Y PART
+ X PART
FROM/X,0,Y,0,Z,10
+ X MACHINE
0 217.*
AXO Y + X ABSOLUTE

3 . 33
The word FROM defines the position of the The origins can also be determined with the
electrode in relation to the part (workpiece) command word SPA
origin. (SPA,X,-125,Y,-100,Z,10).
! Before starting a machining job, it is

essential to position the electrode in relation
to the part (workpiece) according to the
Example on page 3.59.
1.*
values indicated under FROM.
The origin thus established will make it

possible to fix the coordinates of depth and AXE (AXE/Z)
movement for all the PROFORM words.
Selection of the main machining axis.
Axis of Z PART Most PROFORM words require a reference

electrode axis to know which direction to follow.
on the
position Depending on the position of your cavities,
X=0Y=0 you can orient the main axis in the direction
0 5 mm of the plunge.
X PART You have a choice between X, Y and Z
(Z by default).
FROM/X,0,Y,0,Z,5 Z
X PART
219.*
18.75 mm
0 220.* X
X PART
Y
FROM/X,0,Y,0,Z,18.75
Z PART
10 mm Z
0
X PART
221.*
Y PART
0 X
29 30
X PART
100 mm
15 12
218.*
Example with DOWN
125 mm 1:FROM/ X,– 15,Y,0,Z,0

2 :AXE/ X
3 :DOWN/ L,12,H,– 0.5,E,323,RET
FROM/X,–125,Y,–100,Z,10 4 :END

END AUXF
(END) (AUXF/22)
The word that determines the end of a A word that activates the auxiliary “M”
program. functions of the ISO code.
(The list of functions is given in the NC
manual).
MACRO (MACRO/M1)
TERMAC (TERMAC)
DELAY (DELAY/30)
Words defining the start and end of a
sub-program. Delay time expressed in seconds
(These words are not dealt with in this e.g. 30 = 30 seconds.
course, but an example of programming is
given in appendix 4).
COORD (COORD/ABS)
STOP (STOP) Determines the mode of the coordinates and

the measurement units.
Suspension of machining.
(COORD/ABS) Absolute coordinates
(COORD/INCR) Relative coordinates
(COORD/INCH) Units expressed in inches
(COORD/METR) Units expressed in mm
The miscellaneous operations

words
TOOL (TOOL/3)
The technology activation
Commands a tool change (Similar to the words
command word “TCH”).
FLUSH (FLUSH/LL,3) TECHNO (TECHNO/F,UCUAC)
Enables of flushing (Similar to “FLH”). This word activates the technology of your
choice that is present in the machine’s
memory (MEM :).
(Similar to “TEC”)
ASPIR (ASPIR/PA,1)
Enables of suction (Similar to “ASP”). Note :
It is possible to invert the polarity with :
TECHNO/F,UCUAC,INV

3 . 35
Elementary operations GOAX
words
Here we present the words that you will be Déplacement sur 1 axe à la fois avec pré-
using while working with your ROBOFORM définition de l’axe sélectionné avec le mot
machine. These words will enable you to AXE.
carry out the machine’s elementary machin-
ing cycles. Attention : le déplacement s’effectue avec
la touche électrique déclenchée.
Elementary movements without

! machining
1.*
GOTO
+Z
Movement on up to 4 axes at the same time 20
(synchronized) according to the part +Y
system of axes. It is mandatory to insert the 10
word FROM in front of a GOTO.
(Similar to MPA) –X +X
223.*
+Z –10
+C (–15)
–20
+Y
–C –Y
–Z
–X +X
222.* AXE/ AXE/Z
GOAX/L,–,H,– GOAX/L,–20,H,–5
–Y
X=0
–Z
20
GOTO/X,–,Y,–,Z,–,C,–,(R,–)
R : Minimum radius of the electrode (optional)

Y=0
X=0
225.*
20
Y=0 4
Z=0 1 A B
224.*
1:FROM/X,0,Y,0,Z,1 (position A)
Z=0 1 10 2 :AXE/X
3 :GOAX/L,20 (position B)
4 :GOAX/L,0 (position A)
5 :END
1:FROM/X,0,Y,0,Z,1,C,0
2:GOTO/X,20,Y,–4,Z,10,C,90
3:GOTO/X,0,Y,0,Z,1,C,0
4:END

Elementary movements with Plunge cut machining
machining
DOWN
VECT
Movement during machining on 1 axis at a
Movement during machining on 4 axes at time. The axis is pre-determined by the word
the same time (synchronized). Also called AXE.
vectorial machining.
A
228.*
226.*
The depth is fixed by the coordinate “L”

VECT/X,–,Y,–,Z,–,C,–,R,–,E,–,RET according to the part system of axes.
“H” gives the size of the Gap or sets the start
of the orbit (see ORB).
Cross section A
31,3
Z=0 1 Z=0 10
8
19 20
Ø 32
229.*
227.*
1:FROM/X,0,Y,0,Z,10
1:FROM/X,0,Y,0,Z,1,C,0 2:AXE/Z
2:VECT/Z,–8+0.35,E,373 3:DOWN/L,–20,H,–0.35,E,373,RET
3:VECT/Z,0+0.35,C,–270,R,32/2,E,373 4:END
4:GOTO/X,0,Y,0,Z,1,C,0
5:END
The parameter “R” only really comes in

useful within the following limits :
40 mm < R < 200 mm

3 . 37
Machining in orbital mode The DOWN inserted before the orbits
defines the radial undersize of the electrode
and the height of the cone of orbital
translation. The undersize of the electrode
ORB
appears under the “H” of the DOWN
preceding the first ORB.
Movement during machining on 3 axes at
the same time with pre-definition of the
selected direction with the word AXE.
The advantage of this cycle is in the time
saving obtained thanks to the programming
by a gradation of settings (succession of
orbits) and the surface finishes that can be 20
obtained with it.
Another feature of this mode is its capacity 5
to carry out three-dimensional machining
with electrodes of any radial undersize.
The electrode moves on a cone at 45° 12
H= (20–22)/2
until the final programmed dimension is H= –1mm
obtained.
22
232.*
1:FROM/X,0,Y,0,Z,5
2:AXE/Z
3:DOWN/L,–12,H,–1,E,373
4:ORB/L,–12,H,–0.35,E,373,RET
5:END
15
230.*
5
AXE/
ORB/L,–,H,–,E,–,RET
12
H= (15–22)/2
H= –3.5 mm
The orbit is generally preceded by a DOWN
which marks the end of the plunge cut 22
machining and the start of the orbits.
233.*
1:FROM/X,0,Y,0,Z,5
2:AXE/Z
3:DOWN/L,–12,H,–3.5,E,373
4:ORB/L,–12,H,–0.35,E,373,RET
5:END
! 231.*
Caution : the maximum possible
excentration radius is 32 mm, but the
recommended maximum is 10 mm.
1.*
DOWN
ORB H
234.*
Excentration
radius

Machining in plane orbital mode Machining in conical mode
EXPAN CONE
Movement during machining on 2 axes. Movement during machining with genera-

The axis is pre-determined by the word AXE tion of a taper by definition of the angle in
the programming line. Very often used for
The special feature of this mode is its generation of extrusion dies.
capacity to carry out two-dimensional The machining axis is selected with the
machining with electrodes of any undersize. word AXE.
The initial radius of the movement is given
by the final radius of the previous operation.
(In general EXPAN).
235.*
237.*
AXE/
CONE/L,–,H,–,A,–,E,–,RET
Ø 32 23,3
1
1 Z=0
Ø 34
19
Ø 52 12°
24
236.*
238.*
1:FROM/X,0,Y,0,Z,1 24
2:AXE/Z
3:DOWN/L,–19,H,–0.35,E,373 1:FROM/X,0,Y,0,Z,1
4:EXPAN/R,(52–32)/2–0.35,E,373,RET 2:AXE/Z
5:END 3:DOWN/L,–24,H,–0.35,E,373
4:CONE/L,1,H,–0.099,A,12,E,373
5:GOTO/X,0,Y,0 (ou 5: GOAX)
6:END
Example of utilization :
EXPAN also makes it possible to adjust a
screw thread produced by means of the Remarks :
word HELIC (see the NC manual). • It is possible to use GOAX instead of
GOTO, in line 5.
• By combining CONE and EXPAN it is
possible to create a movement favoring
deep machining operations.

3 . 39
Geometry Rotation of the spindle
modification words
SPIN
Machining in corners
Controls spindle rotation, clockwise or

counter-clockwise as desired. Rotation
ANGUL
speed can be programmed from 0 to
a maximum of 100 r.p.m.
This can be combined with the words Examples :
EXPAN, ORB and CONE. SPIN/DIR,S,50 Clockwise rotation
at 50 r.p.m.
SPIN/REV,S,100 Counter-clockwise
rotation at 100 r.p.m.
SPIN/OFF Stops rotation
Spatial machining
Machining by orbital
translation in space
239.*
ANGUL/A,–,B,–
ANGUL/OFF ORB3D
Machining on 3 axes at the same time

according to a penetration vector.
90°
Z
X’
225° 45°
Z’
X
90°
240.*
30
242.*
32 13 The angle of the penetration vector is given

by ANGX and ANGZ, and the plunge is
included in the cycle.
1:FROM/X,0,Y,0,Z,1
2:AXE/Z Z part
3:DOWN/L,–13,H,–1,E,402
4:ORB/L,–13,H,–0.194,E,383 X part
5:ORB/L,–13,H,–0.099,E,372,RET
6:ANGUL/A,45,B,90
7:DOWN/L,–13,H,–1,E,402
8:ORB/L,–13,H,–0.194,E,383 Y part ANG Z+
9:ORB/L,–13,H,–0.099,E,372,RET
10:ANGUL/A,225,B,90
241.*
11:DOWN/L,–13,H,–1,E,402
12:ORB/L,–13,H,–0.194,E,383
13:ORB/L,–13,H,–0.099,E,372,RET ANG X- Penetration
14:ANGUL/OFF
vector
15:END

R The value entered under “L” is always
US positive. The direction is given by the
penetration vector.
The undersize USR must be greater than or

equal to the roughing Gap.
(”H” of the first ORB3D).
243.*
L = 15 mm
STEP determines the number of vectors
1:PN/ORB3D making up the ORB.
2:FROM/X,22.5,Y,–22.5,Z,10,C,135
STEP, 10 (min) for roughing 4
3:AXE/Z 5 3
4:FLUSH/LL,1,LR,1 6 2
5:ORB3D/ANGX,135,ANGZ,10,USR,2,
7 1
STEP,5,L,15,H,–0.180,E,323
6:ORB3D/ANGX,135,ANGZ,10,USR,2, 8 245.*
12
STEP,8,L,15,H,–0.089,E,293 STEP,10 → 25 for finishing 9 11
10
STEP,10,L,15,H,–0.059,E,282
STEP,10,L,15,H,–0.023,E,250,RET
9:END
The words that we have covered in this
manual are only a selection from a vast
number listed in chapter the NC Manual.
But we have presented the words most use-
ful to you as a beginner, in particular FROM,
AXE, DOWN and ORB.
7.*
!
1.*
The “L” movement of the cycle is done

incrementally in relation to the current
position of the electrode without taking
account of the FROM coordinates.
Exercises :
1) The PROFORM word allowing a move- 3) Where must you position your elec-
ment to be made without machining is : trode at the start of a machining job ?
a. FROM a. Anywhere within the space of the tank.
b. VECT b. At X0 and Y0 of the machine system of
c. GOTO axes.
d. DOWN c. According to the values indicated with
Answers :
the word FROM in your program.
2) Which PROFORM words are the most d. At X0 and Y0 of the part system of axes.
1) c.
useful for you as a beginner ?
a. FROM – AXE – ORB – DOWN
2) a.
b. AXE – CONE – EXPAN – VECT
c. FROM – ANGUL – ORB – VECT
3) c.
d. FROM – VECT – CONE – EXPAN

3 . 41
PROFORM-Editor
While most programs are created ready for use by means of PROGRAM-EXPERT 2, there
are certain cases where a small modification can be quickly made with the help of the Objectives :
PROFORM editor.
After reading this section
Here are some examples : you should be able to :
Change the origin with the function FROM – Quote a word for
Modify the penetration axis movements without
Add an auxiliary function (AUXF/22) machining.
etc. – Quote and describe 6
basic machining
Small simple programs for jobs not requiring PROGRAM-EXPERT 2 can also be written with cycles available on
this editor. Roboform.
– Understand the essen-
It is worth noting that this editor can be used while machining is in progress. tial function of the
word FROM.
To access the editor, you must select the Editor page in the PREP mode, which gives you the
text editor described on page 1.35 of this manual.
PREP EXE INFO GRAPH

EDITOR
MEM 1/1
Square .RBF 512 26-06-91
TEST .STR 512 28-05-91
<Free> 1808384
PREP EXE INFO GRAPH

EDITOR
1:PN/CARRE
2:FROM/X,Y,O,Z,O
3:VECT/X,10
4:VECT/Y,10
5:VECT/X,0
6:VECT/Y,6
7:GOTO/X,-5,Y,10
8:GOTO/X,-5,Y,0
File: 9:END
DNC FS
PROGRAM
EDITOR EXPERT
F1 F2 F3 F4 F5 F6 F7
312.*/ang
DNC FS
PROGRAM EDIT
RETURN EDITOR EXPERT
FILES TABLES
PROFORM INSERT DELETE BLOCK MARK SAVE EXIT

LINE LINE START FILE
F1 F2 F3 F4 F5 F6 F7
You can then use all the facilities provided by the text editor.
By pressing the “PROFORM” key (F1) you will display a complete menu with all the Proform
words available : you are now in the Proform editor.
You can pinpoint a function line by pressing the and keys and the selection of the
function is done by means of the keys F1 to F7.
315.* 316.*
You are allowed to work upwards through the program, in order to modify parameters,
by using the and keys.
313.* 314.*

3 . 43
PREP EXE INFO GRAPH
PROFORM EDITOR
0:PN/VIERECK
1:FROM/X,0,Y,0,Z,0
2:VECT/X,10
3:VECT/Y,10
4:VECT/X,0
5:VECT/Y,10 Function window
6:GOTO/X,-5,Y,10
7:GOTO/X,-5,Y,0
8:END
Validation of
1:FROM/X,0,Y,0
Z:
function
HELP
F1 F2 F3 F4 F5 F6 F7
DNC FS
! " # $ % & ' ( ) = ~ : _

BACK
0 - DELETE
<
X Y Z SPACE 1 C2 3 4 5 6 7 8 9 \
F1 F2 F3ESCAPE Q F4W E F5
R T Y F6 U I F7
O P ' }] }]
@
318./ang* + *. ?
RETURN
< > PAGE

PAGE
DOWN
Comma for moving on to next parameter
When a function is selected, a window appears, allowing you to enter your values under the
parameters of the PROFORM function.
To move from one parameter to another, use the “comma” key on the keyboard, or the
function keys. When you have finished press RETURN to validate the programming line.
PREP EXE INFO GRAPH

PROFORM EDITOR
0:PN/VIERECK
1:FROM/X,0,Y,0,Z,0
2:VECT/X,10
3:VECT/Y,10
4:VECT/X,0
5:VECT/Y,10
6:GOTO/X,-5,Y,10
7:GOTO/X,-5,Y,0
8:END
PROFORM menu
PN FROM END MACRO TERMAC CALL ? =

AUXF AXE DELAY STOP TECHNO COORD TANK Function keys
TOOL SPIN GOAX FLUSH ASPIR
GOTO DOWN ORB ANGUL EXPAN CONE SPHER
HELIC VECT LINE ARC GAP MODE RETRACT
SQAR DIAG PYR ISOG ORB3D SQAR3D ISOG3D
HELP
DNC FS
F1 F2 F3 F4
EDITER F5 F6 F7
EDITOR FICHIERS
TABLES
PN FROM END MACRO TERMAC CALL ? =

! " # $ % & ’ ( ) = ~ : _
BACK
0 - DELETE
<
F1 F2 F3 SPACE 1 F4
2 3 4 F5 5 6 F67 8 9F7 \
ESCAPE Q W E R T Y U I O P ’ }] }]
@
+ *. ?
RETURN
< > PAGE

PAGE
DOWN
To insert a PROFORM line you just have to position the cursor at the desired place and press
ESC to display the menu of available functions.
After selecting the function and entering the parameters, press RETURN to validate the line.

When you have completed your modifications or programming, you can exit the PROFORM
editor by pressing the key (Menu up).
319.*
To delete a line you have to position the cursor on the desired line and press the key F3
“Delete line”.
Saving of the file in the machine’s memory is done with “Save file”, and to exit the editor
you must press “Exit”.
If you wish to exit the Proform editor without saving the program, press “Exit” and “Quit”.
Notes :
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
Exercises :
1) What are the two possibilities for 3) Use the Proform editor to enter this
moving from one parameter to another small program :
while entering values under a Proform PN/DOWN – GOTO
function ? FROM/X,0,Y,0,Z,10
a. The “comma” key on the keyboard DOWN/L,-15,E,421,RET
b. The RETURN key GOTO/X,40
c. The NEXT key DOWN,L,-15,E,421,RET
d. The function keys GOTO/X,20,Y,-20
DOWN,L,-15,E,421,RET Answers :
2) How do you save a program ? GOTO/X,0,Y,0
a. By pressing “Exit” and “Quit” END 1) a. et d.
b. By pressing “Save file” and “Exit”
c. By pressing “ESC” and “Save file” 2) b.
d. Saving is automatic

3 . 45
Working procedure for machining
In this manual you have learned many When you have become accustomed to
different aspects of the machine such as file working with your machine you should still Objectives :
management, machining technology, discipline yourself to using this procedure,
Proform language, etc. since it includes all the points that are After reading this section
essential to a successful machining job. you should be able to :
The time has now come for you to rational-
ize all this knowledge and apply it to an The working procedure for machining – Carry out measure-
actual case of machining which will incor- consists of 8 headings designed to help you ments of tool offsets
porate all that you have learned during this prepare, start up and terminate your step by step.
course. machining jobs. – Correctly prepare the
program, the elec-
We have created a working procedure for This procedure has been drawn up with the trodes and the part
machining which will facilitate your work aim of using PROGRAM-EXPERT and the (workpiece) so as to
preparation. measurement cycles available on Roboform start machining
machines. without overlooking
any item.
Working procedure – Apply the appropriate
maintenance
1) Programming of the machining job procedures after
The stages are the following : machining.
❑ Read the drawing and select a machining method (DOWN/ORB – EXPAN – VECT etc.)
and the position of the origin (FROM).
❑ Complete the three data input pages of PROGRAM-EXPERT.
❑ Select the priorities (speed – low wear – surface finish).
❑ Modify the results, if appropriate, and note the undersize values of the roughing and
finishing electrodes.
If your electrodes have already been made, validate their undersize with the “Block” key.
❑ Validate the results.
❑ Adjust the secondary parameters of the technology table generated by PROGRAM-EXPERT.
2) Preparation of electrodes
The stages are the following :
❑ Machine the electrodes with their respective undersizes, if possible directly in their
electrode holders (according to the results given by PROGRAM-EXPERT).
❑ De-burr the electrodes and check their quality and dimensions.
❑ Position the measuring tool and the electrodes on the tool changer of the machine.
Example : Measuring tool : posn. 1
Roughing electrode : posn. 2
Finishing electrode : posn. 3
3) Measurement of offsets
❑ Place the measuring sphere on the table or in the vice.
❑ Validate the radius of the measuring tool (RT) in the USER.OFS table.
❑ Call up the measuring tool with the command TCH and position it 10 mm above the
measuring sphere (in manual mode with the remote control).
❑ Activate the “Reference ball” cycle, insert the parameters R and ZF and press START.
❑ Call up your roughing electrode with the command TCH and position it above the
measuring sphere.
❑ Activate the “Tool offset” cycle, insert the parameters and press START.
❑ Execute this cycle for each electrode. The values of the offsets are loaded automatically in
the USER.OFS table.

3 . 47
4) Preparation of the part (workpiece) and clamping
❑ Clean the table, the part (workpiece) and the mountings.
❑ Place the part (workpiece) in the machine, on a flushing pot, on fixtures in a vice or
directly on the table. Align and clamp the part (workpiece).
Ensure that you position the part (workpiece) within the travel limits of the machine,
particularly with regard to Z, and check that the dielectric covers the part (workpiece)
during machining.
The flushing system can have an influence on clamping ! (injection pot, hoses and
connections, modification of mountings, etc.).
5) Adjustments
❑ Taking of references (edge, centering, etc.) with the measuring tool or an electrode.
❑ Verification of the status of parameters (MOF, BLK, etc.)
❑ Verification and dry run of the machining program(s)
❑ Correct positioning of the fume suction duct.
6) Starting up of machining
❑ Position the electrode or the measuring tool on the starting point (coordinates of FROM).
❑ Adjust the flushing nozzles (if lateral flushing)
❑ Note the starting coordinates (SEP,CP1 absolute system of axes)
❑ Set the clocks to zero with ZCL.
❑ Fill the work tank and adjust the level.
❑ Select the program in the “Program execution” page (EXE mode) with the RETURN key
and then start up machining with the START key.
PREP EXE INFO GRAPH

PROGRAM EXECUTION
ALEX
NONOS
.RBF
.RBF
512
512
05-09-92
05-09-92 Part prog : MEM:ESSAI
MEM:
.RBF
1/1
Cancelling of execution.
JUNKO
TEST
.RBF
.RBF
512
512
05-09-92
05-09-92
Machine mode : MACHINING
(Active only after
SQUARE .RBF
<FREE>
512
178345
05-09-92
pressing “stop machining”).
Stop machining
File (MEM): HELP
F1 F2 F3 DNCF4 FS F5 F6 F7
EXPERT DIEL. MEASURING MANUAL
EXECUTION PARAMETERS TABLES
CUT DRY RUN CHANGE
VERIFY DRAW SCREEN
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BACK
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F1 F2 F3 SPACE F4 1 2 F5 3 4 F6 5 6 F7 7 8 9 \
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PAGE
DOWN
1. Selection of program
2. Validation of program
3. START program

7) Machining
❑ Select the “Survey” page (INFO mode) to display the trend of efficiency.
❑ For an automatic optimization carried out by the machine, you can activate Pilot-Expert
with T = 0 in the “Generator parameters” page (EXE mode).
If you prefer to optimize your machining yourself, you can consult chapter 2 to find
solutions allowing it to be stabilized.
8) After machining
❑ Check the dimensions of the cavity before removing the part (if possible).
If there are corrections to be made to the dimensions, refer to chapter 4.
In the case of corrections, recommence the Working procedure from heading 6 (starting
up of machining).
❑ After removing the part, clean the table, mountings and work tank of the
machine.
❑ Clean and dry the removable units of the clamping system.
❑ Clean the keyboard with a cloth, and also the remote control.
❑ Switch off the screen with the “BLANK” function key (INFO mode).
Important remarks :
– When you start up a program, make sure you always reposition your electrode
correctly on the FROM coordinates.
– Always check the value of the parameter MOF to avoid having surprises with the tool
offsets. !
– Always end the PROFORM program with “TOOL/0” to put back the tool and cancel 1.*
the offsets.
– We strongly recommend that in the early stages you carry out simple machining jobs
in order to try to optimize by modifying the secondary parameters. Refer to section 2.
Exercises :
1) Where must you validate the radius of 3) What must be done before removing
the measurement tool ? the finished part ?
a. In the USER.PNT table a. Clean the part
b. In the USER.TEC table b. Stop all flushing
c. In the USER.OFS table c. Check the dimensions of the cavity
d. This radius is of no importance d. Note the number of working hours
needed to make the cavity
2) What is the first thing to do when start- Answers :
ing a new job ?
a. Prepare the electrodes 1) c.
b. Study the drawing
c. Write the program with 2) b.
PROGRAM-EXPERT
d. Define the flushing 3) c.

3 . 49
Description of technology curves
Programming :
Objectives :
general concepts
you should be able :
In the preceding chapters we have presented
various programming words, of which two
– To quote the two usual
are of special importance.
PROFORM words that
247.*
enable a program to
These are the words DOWN and ORB,
be carried out.
their special significance being found in
– To quote the two types
their combination.
of technology aids
available to you for
DOWN makes it possible to carry out
creating programs.
plunge cut machining, in which it performs
– To quote the 4 ele-
roughing with an energetic setting that
ments that can be de-
enables time to be saved.
termined by means of
the technology curves.
You will also discover that in nearly all

246.* applications you will need to do not just one
but several ORBs, carrying out a cascade of
settings allowing the grain (surface finish) to
be made finer at each stage.
The advantage of this combination is

to provide excellent efficiency and good
surface finishes with a minimum of electrodes
(usually 1 or 2).
We have seen that the syntax of our two

PROFORM words consisted of an “H”
defining the Gap and the “E” validating
ORB takes over from DOWN. The ORB the setting. The whole logic of programming
cycle, as we have seen, carries out a 45° is to be found in the finding of these two
translation, which gives us the dimension values.
we wish to obtain, independently of the
undersize of the electrode. Charmilles Technologies makes available
to you the following two means of
This is possible as long as the blocking programming :
of the plunge with the DOWN is correct, in
other words that the value of “H” corresponds – The technology curves
exactly with the radial undersize of the elec-
trode. – The “PROGRAM-EXPERT” software
PROGRAM-EXPERT has been presented in

this chapter.

3 . 51
Terminology concerning
technology curves
You will encounter these different key words Respect of electrode
in the course of your work with the curves, Not exceeding the current density limit.
or at a later stage when manipulating
PROGRAM-EXPERT. Frontal surface area
You should not hesitate to refer back to this Surface area of the front of the electrode
page if you have doubts. expressed in cm2.
CHe Material removal

Defines the roughing setting. Volume of material removed in a given time
(mm3/min).
CHf
Defines the final setting (final surface finish). Radial undersize (U/S)
Value in “microns” or “mm” enabling the
CHt size of an electrode to be determined.
Defines the setting for changing the
electrode.
Wear
Volume of wear on the electrode in relation
to the volume of material machined.
Notes :
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Technology curves
The technology curves reflect the technological developments carried out on ROBOFORM
machines. These curves are given in your pocket guide in material pairs, such as :
– Copper / Steel
– Graphite / Steel
– Copper tungsten / Carbide
Choix des sous-dimensions (radiales) Usinage planétaire, arrosage latéral en ébauche

Cuivre/Copper/Kupfer Selection of undersize (radial) Planetary machining, lateral flushing by roughing
Wahl der Untermasse (radial) Planetare bearbeitung, laterale Spülung in Schruppen
S
Sous-dimensions en microns (µm)/Undersize or in microns (µm)/Untermasse oder in Mikron (µm)
Acier/Steel/Stahl
1000
900 830
Usure volumétrique 800 Ebauche sécurité moy. 740
Enlèvement de matière ( arrosage intérieur ) % Volumetric wear (Down ébauche ou down finition)
Material removal rate ( internal flushing ) mm 3 / min Volumenverschleiss 700
Material Abtrag ( interne Spülung )
600
> 25 5 1 0.3 0.1 600
1000 500
P15/A13 500
461 482 420
Niveau d'intensité
600
P Intensity level 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
P14/A13 472 493
400
Stromstufe 441 452 360
400 432 463 483
443 350 310
Courant de pointe 473
I (A) Peak current 1 1.5 2 3 4 6 8 12 16 24 32 48 64 96 128 421 300
Spitzenstrom 453 P13/A13 250
200 P12/A12 250
412 433 220 Planétaire
434 (ORB intermédiaire)
391 402 414 200
100
P11/A11 170
372 P10/A10 140

383 150
394
60 331 352
373 P9/A10 125
110
40
384 100
100
90 85
291 312 P8/A10
20 323 80
280 Planétaire final
70
(ORB final)
271 293
334 60
282 303
10 P7/A9
50
262 314
6 251 273 40
241 P6/A9
4 232
35
221 242 294
30
31
220 P5/A8 25
2 253
20
200 264 20
1
P4/A8 15
180 15
0.6
201 212
0.4 191 223 11
140 10
192
120 181 202 8
0
234 0
0.2
100 213 -8
P3/A8
-10
0.1 224 -20
0.08 -20
P2/A8
0.06 CH 0 2 6 10 14 18 22 26 30 34 38 42 46 50
0.05 RA 0.1 0.12 0.2 0.32 0.5 0.8 1.26 2 3.2 5 8 12.6 20.2 µm
0.04
Ebauche sécurité moy. Mean safety roughing Schruppen mittlerer GAP
0.03 214
(Down, ébau. ou finition) (Down, roughing or finishing) (Down Schruppen oder schlichten)
P1/A8 Planétaire Planetary Planetar
0.02
(ORB intermédiaire) (intermediates ORB) (ORB Zwischenauslenkung)
Planétaire final Final planetary Letzte auslenkung
(ORB final) (final ORB) (End ORB)
0.01
CH 10 15 20 25 30 35 40 45 50
RA 0.32 0.56 1 1.8 3.2 5.6 10 18 µm
248.*
Curves of settings Curves of Gaps
These curves are made up of various lines and graphs which make it possible to determine :
– Wear
– The maximum roughing setting
– The machining settings
– The Gap values and undersize of electrodes
– The setting for changing electrodes

3 . 53
• Wear • Maximum roughing setting (CHe)
During machining the part (workpiece) is Every material has a physical reaction to the
eroded and the electrode becomes worn. passage of current. Some materials are non-
This is a normal and regular phenomenon conductors, whereas others accept a certain
and unfortunately cannot be avoided. density of current per unit of surface area,
Wear values during roughing are in a but there are limits :
range of 0 % to 2 %, and in finishing
between 2 % and 30 %. Copper ~20 Amperes/cm2 max.
Graphite ~15 Amperes/cm2 max.
These values may sound alarming, but they
are only relative to the volume of material If these limits are exceeded, the material will
removed from the part (workpiece). be destroyed. So it is important to define a
We see on the diagram below that wear on setting with a correct current density in rela-
the electrode has a direct relationship with tion to the frontal surface of the electrode.
the volume of material removed.
– If you respect the power limits, you will
spare your electrodes.
Roughing This is “respect of electrode”
– If you exceed the power limits, you are

likely to damage your electrodes.
This is “non-respect of electrode”
2% wear spread
over the electrode
250.*/ang
Roughing power is defined by the maximum
Volume of frontal surface area of your electrode and
material
removed the permissible current density.
2% of the volume For example :

of material removed An electrode in copper with a side of 5 mm
and a width of 65 mm will give us a sur-
face area of 325 mm2 or 3.35 cm2.
Finishing The maximum current density for copper is
;
20 A/cm2.
This gives us a peak current of 3.25 x 15,
i.e. approximately 48 A.
At the top of the “Settings curves” table it is

20% wear spread
over the electrode possible to define the maximum power P
according to the peak current determined
251.*/ang
previously.
Volume of
material
removed
Niveau d'intensité
P Intensity level 1 26 7 8 9 10 11 12 13 14 15
20% of the volume of Stromstufe
material removed
Courant de pointe
I (A) Peak current 6
1 1.5 8 12 16 24 32 48 64 96 128
Spitzenstrom
In finishing the percentage of wear is higher 252.*
but the volume of material machined is

lower. In the final analysis the volume of The result found in the table gives us a value
wear on the electrode is lower. of P12.
This value will select for us a curve of set-

tings in the table of Gaps, where it will be
possible for us to define the roughing setting
(“DOWN” setting).
In the example that follows we have

decided to take setting 453 (low wear).

• Machining settings
This table will enable you to define the machining settings by means of the two fundamental
parameters P (Power) and A (Pulse time), and will also allow you to estimate wear in %,
material removal in mm3/min and surface finish in CH or Ra.
Material pair
Volumetric wear
values corresponding
to iso-wear areas
pfer
er/Ku e
/Copp lumétriqu
Usure vo wear
Cuivre ic
Volumetr rschleiss
% ve
Volumen
S Stahl 0.1
Steel/ 0.3
Acier/ 1
5 P15/A13 482
eur ) 3 min 461 472 493
ge intéri mm /
( arrosa
ent de
matière ernal flu
shing ) > 25 P14/A13 452
Enlèvem rate ( int ülung ) 483
removal erne Sp
441 463
Material g ( int
473
Abtra 443
Material 13 14
15 432
11 12
7 8 9 10
421 P13/A13
1000 6 453
P12/A12
ité 4 5
3
d'intens l 1 2
Niveau leve 128 433
tensity 64 96 412
600 P In stufe 32 48
Strom 16 24 434
8 12
P11/A11
4 6
e 3 2 414
de point 1 1.5
2 391 40
400 Courant rrent
Peak cu
I (A)
Spitzen
strom P10/A10
372 383
394
200
352 373
P9/A10
331
384
100
P8/A10
60 312 323
Power
291
40 280
334
curves
293
271
282
303 P7/A9
20
314
262
273
P6/A9
10 251
241 294
6 232 242
221 P5/A8
4 220 253
264
2
200 P4/A8
Iso-wear
1 180
212 area
201 223
0.6 191
192 202
140
0.4 181 234
120 213 P3/A8
0.2 100 224
P2/A8
0.1
0.08
0.06
0.05 214
0.04 P1/A8 50
0.03 45 µm
40 18
35 10
0.02
30 5.6
25 3.2
20 1.8
0.01 15 1 249.*
CH 10 0.56
2
RA 0.3
Surface finish quality expressed in CH and RA
Material removal capacity of the settings
The large colored areas on the table are called “iso-wear” curves (equal wear in the same
area). They enable you to determine at a glance the rate of wear of a setting to be found in
one of the areas, ranging from 0.1 to over 25 % of volumetric wear.

3 . 55
A power curve is a group of settings of equal intensity P with variations of time A.
The three-digit numbers indicate the settings available in your technology table
(e.g. UCUAC.TEC).
352 (P8 / A8)

331
(P8 / A7) 373 (P8 / A9)
384
P8 / A10
253.*
After selecting the maximum roughing setting (CHe) you can choose settings for orbits
according to the priority that you have adopted. As a general rule you should go up in
increments of 1 or 2 CH in order to remain as long as possible in the desired iso-wear area.
Choice of settings with speed priority,

up to a final surface finish of CH 35 (CHf 35).
% 5 1 0.3 0.1 PN/EXAMPLE
AXE/ Z
FROM/ X,0,Y,0,Z,10
452
441 DOWN/ L,–20,E,453
432 463
443 ORB/ L,–20,E,443
421 473
ORB/ L,–20,E,432
453
ORB/ L,–20,E,412
412 433 ORB/ L,–20,E,402
402 434
ORB/ L,–20,E,391
391
414 ORB/ L,–20,E,372
372 ORB/ L,–20,E,352,RET
383
394
END
331 352
Settings selected
373 from the table.
They are situated
384 between 0.3 and
254.*/ang 1% wear.
Choice of settings with low wear priority,

up to a final surface finish of CH 35 (CHf 35).
% 5 1 0.3 0.1 PN/EXAMPLE 2

AXE/ Z
FROM/ X,0,Y,0,Z,10
452
441 DOWN/ L,–20,E,453
432 463
443 ORB/ L,–20,E,433
421 473
ORB/ L,–20,E,414
453
ORB/ L,–20,E,394
412 433 ORB/ L,–20,E,373
402 434
ORB/ L,–20,E,352,RET
391
414 END
372
383
These settings
are situated
394
331 352 between 0.1
373 and 0.3% wear.
384
255.*/ang

• Gap values and undersize of electrodes
For each setting selected there is a corresponding Gap value visible in the “Selection of
undersize” table.
The aim of this table is to define the Gaps of all the settings and the undersize of the
electrodes.
e
ébauch
latéral en ughing
arrosage ro
étaire, ing by n
ge pl an tera l flu sh Sc uppe
hr
s) Usina ning, la ülung in
(radiale y machi terale Sp
-d im ensions Planetar ar be itung, la
s so us e be 830
Choix de (radial) Planetar n (µm)
dersize in Mikro 740
n of un ial) se oder
asse (rad or in microns (µm)/U
ntermas
Selectio é moy.
e sécurit wn finition)
l de r Unterm ers ize Ebauch
che ou
do
Wah ns (µm
)/U nd
cro n ébau
(Dow
600
s en mi
mension
Sous-di
500
1000
900 420
800
360
700
600 310
ire
Gap
500 250 Planéta
220
(ORB int
ermédia
ire)
definition
400
350
curves
170
300
250 140
200 110 100
ire final
150 Planéta al)
85 (ORB fin
125
100
90
80
70
60
50
31
40
35
30 20
25
15
20
11
15
8
0
10 50
-8 46
42 µm
0 38 20.2
34 12.6
30 8
26 5
3.2 er GAP en)
-10
22
n mittler schlicht
Schruppe hruppen oder
18 2
-20 14 1.26
0.8 Sc
6
10
0.5 hing (Down
-20 2 0.32 fety roug ing) Plan et ar le nk un g)
Mean sa ughing or finish
0 us
0.2 ischena
CH 0.1 0.12
(Down,
ro (ORB Zw nkung
é moy. sle
RA e sécurit ) et ar y Letzte au )
Ebauch au. ou finition Plan
iates O
RB )
O RB
nd
(Down,
éb (intermed etary (E
re an
Planétai ire ) Final pl )
termédia O RB
(ORB in final (fi na l
re
Planétai )
al
(ORB fin 256.*/ang
Surface finish expressed

in RA and CH
Gap in
microns

3 . 57
• Undersize of electrodes
Radial undersize is defined on the yellow line called “Mean safety roughing” and the CHe
value.
If the CHe value is equal to 45, the radial undersize will be 0.7 mm.
This means that in order to machine a cavity with sides of 20 mm, our electrode must have
sides of 18.6 mm (20 – 2 x 0.7 mm).
1000
900 830
Mean safety roughing 740
800
(Down, roughing or finishing)
700
600
600
500
500
420
400 360
350 310
300
250
250
220
-20
45
CH 0 2 6 10 14 18 22 26 30 34 38 42 46 50
RA 0.1 0.12 0.2 0.32 0.5 0.8 1.26 2 3.2 5 8 12.6 20.2 µm
/
• Gaps for the orbits
The values of the Gaps will appear in the program with the “H” before the corresponding
setting.
All the Gaps are determined on the curve called “Planetary” except the one for the last orbit
which is defined on the “Final planetary” curve. (Below CH 14 there may be a need to
select up to 3 orbits on the “Final planetary” curve).
For a suitable selection of Gaps, you must follow the line that leads as directly as possible to
the CHf on the “Final planetary” line. If such a guide line does not exist, you must create one
that is parallel.
1000
900 830
800 Mean safety roughing 740
700
600 258.*/ang
600
500
500
420
400 360 PN/ EXAMPLE 2

350 310
300
275 250
AXE/ Z
250
220 Planetary
(intermediate ORB)
FROM/ X,0,Y,0,Z,10
200
170
DOWN/ L,–20,H,–0.700,E,453
150 140
125
ORB/ L,–20,H,–0.400,E,433
110
100
ORB/ L,–20,H,–0.350,E,414
100
90
80 ORB/ L,–20,H,–0.275,E,394
70 Final planetary
60
(final ORB) ORB/ L,–20,H,–0.150,E,373
50 ORB/ L,–20,H,–0.070,E,352,RET
40 END
35
30
31
25
Final ORB
20
20
15
intermediate ORB
U/S of the electrode
10
-10
-20
CH 26 30 34 38 42 46 50
RA 2 3.2 5 8 12.6 20.2 µm

• Setting for changing electrodes
It is possible to machine a cavity with one single electrode if a medium surface finish (≈ CH 35)
is desired, but if we wish to obtain a fine surface finish (CH<32) and guarantee good
geometry within our cavity, it is preferable to change electrodes before undertaking finishing.
To define how many electrodes we need and when we have to change them, the following
table can be used :
Copper / Steel technology Graphite / Steel technology
If CHf > 24 then CHt = CHf + 8 to 10 (CHe + CHf)

CHT =
2
If CHf > 24 then CHt = 32 for St > 5 cm2
CHt = 30 forr 3 <St ≤ 5 cm2 CHt min. recommended = 30
CHt = 28 for St ≤ 3 cm2
1 single electrode if CHf ≥ 30 or CHe ≤ 32 1 single electrode if CHf ≤ 34 or CHe > 34

or CHe – CHf ≤ 8 and CHe – CHf ≤ 8
In a situation where we need to use 2 electrodes, a setting for changing electrodes, called
CHt, will be defined.
This setting will enable us to find the undersize of the finishing electrode which is defined
on the “Mean safety roughing” line.
The example below shows you a specimen of a program with two electrodes.
1000
PN/EXAMPLE WITH TWO ELECTRODES 900 830
800 Mean safety roughing 740
AXE/Z 700
600
600
FROM/X,0,Y,0,Z,10 500
500
TOOL/1 420
400
DOWN/L,–20,H,–0.700,E,453 360
350 310
ORB/L,–20,H,–0.400,E,433 300
250
250
ORB/L,–20,H.–0.350,E,414 225
220 Planetary
(intermediate ORB)
200
ORB/L,–20,H,–0.275,E,394 170
155
ORB/L,–20,H,–0.230,E,373 150 140
125
ORB/L,–20,H,–0.200,E,352 110
100
ORB/L,–20,H,–0.155,E,323,RET 90 85
100
80
TOOL/2 70 Final planetary
(final ORB)
DOWN/L,–20,H,–0.225,E,323 60
50
ORB/L,–20,H,–0.155,E,323
40
ORB/L,–20,H,–0.100,E,303
35
ORB/L,–20,H,–0.080,E,294 30
31
ORB/L,–20,H,–0.050,E,273 25
ORB/L,–20,H,–0.040,E,262 20
20
ORB/L,–20,H,–0.030,E,251 15
15
ORB/L,–20,H,–0.020,E,241,RET
11
TOOL/0 10
8
END 0
-10
-20
259.*/ang
CH 22 26 30 32 34 38 42 46 50
RA 1.26 2 3.2 5 8 12.6 20.2 µm

3 . 59
Notes :
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Exercises :
1) What are the key words for a simple 3) The technology curves are the only
programming ? support for drawing up programs.
Answers : a. CONE – EXPAN a. True
b. VECT – ORB b. False
1) c. c. ORB – DOWN
d. DOWN – EXPAN
2) c.
2) What is the first stage for drawing up
3) False. There is also a program ?
PROGRAM-EXPERT 2 a. Defining the Gaps
which is a much more b. Defining the undersize of the electrodes
reliable aid for draw- c. Defining the maximum power
ing up your programs. d. Defining the gradation of settings

Command words and parameters
linked to programming
As we have already seen, the command
words enable us to give an order or start up SMA
SPA Objectives :
an operation, simply by typing a code on
the keyboard. We have also seen a fair
number of user parameters that allow us to These two command words enable you to
modify the machine’s behavior during define or redefine the origin of the part sys-
certain operations. tem and machine system of axes according
– Move the axes of the
to the current position of your electrode.
machine according to
We shall now show you some new
the part system of
command words and parameters that are – SMA defines the machine system of axes
axes, by means of the
relevant to the present chapter. – SPA defines the part system of axes
command words.
(same function as FROM)
– Carry out a
In chapter 4 we shall recapitulate all the
PROFORM program
command words and parameters in order
block by block.
to give you an overall view.
– Define new origins
with the command
words SMA and SPA.
Command words
MPA Y machine
MPR
Y part
20
You will no doubt recall the words MOV X part
and MVR, which make it possible to order
X,Y,Z and C movements on the machine 321.*/ang
system of axes. MPA and MPR have the same X machine

function, but on the part system of axes
established by the PROFORM word FROM
or the command word SPA. SPA,X0,Y-20,Z30
The syntax of this command will give the
– The movements are carried out in abso- electrode position in relation to the new
lute mode with MPA. origin that we wish to fix.
– The movements are carried out in relative The principle is identical to FROM in
mode with MPR. PROFORM language.
(MPR = MVR)

3 . 61
User parameters OSP
PREP EXE INFO

USER PARAMETERS
This validates or does not validate the STOP/
0
OPTIONAL instruction that can be inserted
BLK: 0 BLD:
CBC:
COE:
0
0
SIM:
TSIM:
0
1
INERTIE 2 into a PROFORM program.
OSP:
ENG:
0
0
ART:
TFE:
1
1
– If you type OSP,1 the stop will
VRF: 0 CHK: 1 be taken into account.
CLE: 0.000 TOL: 0.005 MTOL: 0.005 STOP – If you type OSP,0 the stop will
9.* not be taken into account.
Manual tool change position Z 245.000
Dry run Speed: 15.000 mm/s
Rotation Speed: 0 rpm
Measure Speed: 1 %
BLK :_ TSIM
In the “Program execution” page in the EXE

PARAMETERS EXPERT DIEL
EXECUTION TABLES
BLK CBC COE OSP ENG
mode, you can ask to carry out a dry run of
F1 F2 F3 F4 F5
a program. This simulation can be done in
two ways :
– With the simulation of tool changes,
Dry run speed TSIM,1
– Without the simulation of tool changes,
This determines the simulation TSIM,0 (by default).
20
speed of axis movements in
10.*
mm/sec.
The speed set by default is VRF
15 mm/sec.
BLK This parameter forces the verification of the

syntax of a machining program before its
execution.
Validation of the block by block (i.e. line by
line) reading or execution of a PROFORM – When VRF,0: no verification ;
program if you type BLK,1. machining is immediate. In cases of
This is useful for following up and checking programming errors, the machine will
a program path. stop at the defect and will display an
If you type BLK,0, the program will be car- error message.
ried out in a continuous manner (mode used – When VRF,1: verification of the pro-
by default). gram before machining.
Exercises :
1) Which are the command words that 3) What is the correct syntax for defining
enable you to move the machine’s axes an origin on the machine system of
according to the part system of axes ? axes ?
a. MOV and MVR a. SPA,X0,Y20,Z10
b. SMA and SPA b. SMA,X,10,Y,20,Z,5
c. MPR and MPA c. FROM/X,0,Y,0,Z,10
d. MPA and SMA d. SMA
Answers : 2) Which parameter makes it possible to

execute a program line by line, forcing
1) c. the operator to start the machine after
each operation ?
2) b. a. OSP
b. BLK
3) d. c. VRF
d. ART

Summary of chapter 3
In the course of this chapter you have discovered the PROFORM language, which makes it
easy for you to draw up machining programs on ROBOFORM machines.
You have seen how this language has a strict syntax that needs to be carefully complied with
in order to make your instructions clear to the machine.
There are a large number of PROFORM words, (roughly 40) making it possible to carry out :
– Movements with or without machining (VECT, GOTO...)

– Checking operations (FROM, AXE...)
– Modifications of geometry (ANGUL, SPIN...)
– Miscellaneous operations (FLUSH, AUXF...)
– Spatial machining (ORB3D,...)
While you are still relatively new to programming, the most important PROFORM words will be :
FROM – AXE – DOWN – ORB
Programming can be done in two ways, by means of :
– Technology curves
– PROGRAM-EXPERT
The technology curves enable us to determine the settings and Gaps necessary for programming.
These curves are very useful for comparing the percentage of wear and material removal for
a given setting, but are unfortunately not very practical for drawing up machining programs.
This is why PROGRAM-EXPERT has been created, in order to make your task easier and to
reduce the risk of errors. Besides being easy to use, this software deals with :
– Free form electrodes

– Respect of details
– Machining safety
– Machining priorities
– Management of electrodes and programs
– Creation of a technology adapted to the program
This programming tool is ideal both for beginners and experts, and will enable you to carry
out most of your applications quickly and with guaranteed results.
This chapter has also provided you with a working procedure for machining which lists step
by step what has to be done to carry out an application.
We strongly recommend that you use this working procedure until you have become
fully experienced.
In this chapter you have learned new command words and parameters linked to programming,
that make it possible to define a machine or part system of axes (SMA,SPA), or to make
movements on the part/workpiece system of axes (MPA,MPR). Block by block execution of a
program is possible by means of the parameter BLK. During simulation you can carry out
electrode changes with TSIM=1.
You are now in a position to answer the questionnaire on the following page of this chapter.

3 . 63
1) Correct the program below :
1:PN/TEST
2 :AUXF :22
3 :FLUSCH/LL,1,LR1
4 :FLI/1
5 :FROM/X10,Y0Z0
6 :AXE/X
7 :TCH/1
8 :DOWN/L,-15,H,-0.600,E432
9 :ORB/L,-15,H,-0.497,E,432
10:ORB/L,-15,H,-0.389,E,412
11:ORB/L,-15,H,0.280,E,402
12 :ORB/L,-15,H,-0.190,E,391
13 :ORB/L,-15,H,-0.115,E,372
14 :ORB/L,-15,H,-0.066,E,352,REP
15 :TCH/0
16 :FLUSCH/0
17 :END
After correction, type this program in the PROFORM editor and the verify it.
2) Indicate which of the following is correct. The word “FROM” allows you to fix the
.............. coordinates.
❑ a. PART
❑ b. MACHINE
❑ c. ABSOLUTE
❑ d. RELATIVE
3) Match the following PROFORM words with their corresponding functions :
VECT • • Plunge cut machining

PYR • • Defining the mode of coordinates
EXPAN • • Elementary machining on 4 axes
SPIN • • Movement without machining
ORB3D • • Machining along a pyramidal path
DOWN • • Rotation of the spindle
CONE • • Machining in conical mode
COORD • • Plane machining
GOTO • • Spatial machining
4) Which two tools are available that enable a machining program to be drawn up ?
❑ a. The text editor
❑ b. PROGRAM-EXPERT
❑ c. The technology files
❑ d. The technology curves
5) What can be done to eliminate electrode wear ?

❑ a. We can eliminate it by modifying the generator parameters
❑ b. We can eliminate it by selecting a material pair for the part (workpiece) and
electrode that involves no wear
❑ c. It is not possible to eliminate wear, but only to reduce it
❑ d. We can eliminate it by applying a surface treatment to the electrode

6) If we define an origin by means of SPA, which command word makes it possible to
make a movement according to the system of axes selected ?
❑ a. MOV
❑ b. MVR
❑ c. SMA
❑ d. MPA
7) While a program is being executed, your machine stops after each programming
line, and you have to press START to resume operation. What must be done to
avoid this ?
❑ a. Modify OSP
❑ b. Modify TSIM
❑ c. Modify BLK
❑ b. Modify ART in the “User parameters” page
8) fill in the following values as per the drawing below :
10 30
325.*
Electrode – part (workpiece) distance ....................................................................
Programmed depth :...........................................................................................
Depth of penetration ..........................................................................................

3 . 65
9) Give the ideal adjustment and also the programmed depth for the drawing below :
Z=0 30 –0.02
326.*
+0.03
0
20
Adjustment : ...........................................................................................................
Programmed depth : ................................................................................................
10) Using PROGRAM-EXPERT, draw up the program for the following machining job :
Final surface finish CHf = 18

Priority : Speed – Min. wear
Tolerance ± 0,02
Material pair : Copper / Steel
13
327.*
15
Roughing setting : ..............................
Roughing electrode undersize :.............
Finishing electrode undersize :..............
11) By means of PROGRAM-EXPERT, create the program for the following machining job :
Final surface finish CHf = 20

Priority : Min. wear - Surface finish
Tolerance +/– 0.02
Pair : Copper / Steel
Undersize for the two electrodes = 0,6 mm
2 45°
+
5
328.*
70
14
Ø 40
20
29
Ø 36
35
3°
20
10

Automation and machining
The command words and parameters

linked to command programs 4.3
Command words 4.3
User Parameters 4.5
Height of manual change Z 4.5
Creation of automation programs 4.7

Command programs 4.7
Program checking 4.9
The drawing parameters 4.9
Recapitulation of the most used words 4.11

Commands affecting the execution of programs 4.11
Commands affecting movements and auxiliary functions 4.11
Commands affecting tables and files 4.11
Commands affecting the parameters of the part-program 4.11
Measurement commands 4.11
Direct machining commands 4.12
Flushing commands 4.12
Miscellaneous commands 4.12
Dimensional corrections of cavities 4.13

A cavity not deep enough 4.13
A cavity that is too small 4.13
A cavity that is too small and not deep enough 4.14
Summary 4.15

4.1
General objectives of the chapter :
At the end of the chapter, you should be • Create a command program linking up
able to : several machining operations.
• Know, quote and use correctly 7 new • Simulate on the screen, thanks to the
command words linked to command graphic mode, a PROFORM program
programs and the execution of the and a command program.
programs.
• Correct a machining operation appro-
• Create a command program initializing priately so as to be within the tolerances.
the parameters of the machine.

The command words and parameters
linked to command programs
Command words STP
Objectives :
These command words supplement the list of
words that you have already learned in the Another very simple After reading this section
preceding chapters. We recapitulate these word in so far as it you should know :
words in this chapter. makes it possible to
impose an unconditional
STOP – The function of the
stop on the machine 7 command words
(changing of a part 9.* linked to the automa-
SPG tion of your machine.
(workpiece) to be done by the operator for
example). On reading this command, the – Which parameters
This command makes it possible to start up machine suspends operation, which allows have an influence on
execution of a part-program (PROFORM) the operator to carry out his task and then the running of a
from a command program. set machining in motion again. command program.
All that is needed is to specify the file name
and where it is located (peripheral, central
memory or diskette).
PAU
Example :
SPG,A : CAVITY.RBF
SPG,CAVITY.RBF (by default MEM :) This command causes a pause in the opera-
enables you to start the execution of the tion of the program. The pause is expressed
PROFORM program called CAVITY which in seconds or decimal fractions of a second.
is located on the disk drive A. At the end of the pause the execution starts
This command is one of the most often used up again automatically. The main applica-
ones in the automation language because tion of this pause is for programming
it makes it possible to start and link up any waiting periods to allow the dielectric to
desired program at any desired time. cool down in cases of very energetic ma-
chining (high P and A).
Another application is for programming a
reading pause between several messages
MSG
in a command program.
A very practical command word, which is For example :

used during an automation program to MSG, MACHINING
display warning, information or other PAU, 5
messages on screen (max. 36 characters). MSG, OF A PART ON
PAU,5
MSG, ROBOFORM
MSG, FINISHING MACHININ
COPY DELETE RENAME DISP
F1 F2 F3 F4
239.*/ang
Note : The message must be placed on

a programming line in front of the place
where it should appear.
Example :
•
•
MSG,FINISHING
SPG,CAVITY.RBF
• 331.*

4.3
LOOP
A command word which causes the return to the beginning of the command program under
way and does it the number of times fixed after the LOOP command ; for example LOOP,5
forces the re-execution of the program 5 times.
If we write LOOP without specifying the number of loops, the program will go on starting
again indefinitely.
This command comes in useful for repetitive series of machining jobs or in palletization
applications.
CCF
A word which allows you to call up a command sub-program that is external to the main
command program.
The CCF command only allows a sub-program to be called up one single time and only
allows one level of nesting.
PROGRAM PROGRAM
P.CMD SP.CMD
TCH,1
SPG,DEMO1.RBF TCH,3,M
TCH,2 SPG,DEMO2.RBF
MOV,X10 TCH,0,M
333.*/ang
CCF,SP.CMD
MOV,X20
TCH,4
SPG,DEMO3.RBF
TCH,0

User parameters
PREP EXE INFO GRAPH VPULS
USER PARAMETERS
BLK: 0 BLD: 0 AXO X 0.000

CBC: 0 SIM: 0 INERTIE 0 AXO Y 0.000
COE:
OSP:
0
0
TSIM:0
ART: 0
AXO
AXO
Z
C
0.000
0.000 This parameter fixes the speed of electrode
pulsation during machining (1 to 15 mm/s).
ENG: 0 TFE: 1
VRF: 0 CHK: 1
CLE: 0.000 TOL: 0 MTOL: 0.005
VPULS is very practical for deep narrow

Manual tool change position Z 111.000
Dry run speed 15 mm/s
Rotation speed 100 t/m
Measure speed 20% slots, since pulsation at high speed makes it
CBC:
possible to reduce contamination at the
PROGRAM
EXECUTION
USER
PARAMETERS
PILOT
EXPERT DIEL.
ACTIVE
TABLES MEASURING MANUAL
DNC FS
bottom of the cavity.
BLK CBC COE OSP ENG VRF CLE
F1 F2 F3 F4 F5 F6 F7
CBC
A parameter that allows execution of a

command program line by line, obliging the
operator to restart the machine after each
!
suspension (each line). 1.*
This parameter is to the command program In order for this parameter to come into
what BLK is to the ISO and Proform program. play during machining, you must of
necessity set the AUXF/29 function at
If we validate : the beginning of the part-program,
otherwise it will remain standard. This
CBC,0 the execution is done continuously is to prevent the risk of high speed
pulsation with a very large electrode.
CBC,1 the execution will be done line by
line (after each line press the
“Execution” button) Note : An automatic reset is performed by
the NC itself (AUXF/28) at the end of the
PROFORM program to return to the stan-
dard speed.
335.*
Height of manual change Z

The main interest of CBC lies in the check-
ing of command programs by the operator, Definition of the position of the Z axis
because it forces him to stay close to his (absolute system of axes) in cases of manual
machine and to be careful with regard to changing of the electrode (for bulky
operations being carried out (avoids the risk electrodes).
of collisions).

4.5
Notes :
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
Exercises :
1) What is the word that enables a part- 3) Block by Block execution of a

program to be started ? program is validated by means of
a. STP which parameter :
b. SPG
c. CCF ..................................................
d. GSP
Answers :
2) The command word LOOP is applied
1) b. particularly in the case of :
a. Palletization
2) a and b. b. Repetitive cycles
c. Measurement cycles
3) CBC. d. Rotation of the part (workpiece) axes

Creation of automation programs
Command programs
Objectives :
As you already know, it is possible to control your machine through command words, by
typing these words directly on the keyboard in EXE mode. After reading this section,
The problem is that to carry out a series of orders, you have to type the commands one after you should be able :
the other. This forces you to remain close to the machine so as to follow the operations as
they succeed each other. – To create a simple
Fortunately this drawback can be overcome thanks to command programs. command program
allowing you to start
These programs are able to link up the execution of several command words automatically. a machining program
This enables you to link up axis movements, tool changes, and execution of PROFORM – To know where to
programs without you having to intervene. type and how to
The programming logic is simple, you just have to give your orders line by line, following the check your command
sequence of operations, as follows : program
– To use the drawing
parameters and the
Orders to be carried out Command words graphic mode
Pick up the measurement electrode TCH,1

Measure the reference on the part (workpiece) CEN,X0,Y0
Pick up the machining electrode TCH,2
Move (10 mm) MOV,X10
Measure the Z reference on the part EDG,-Z,Z0
Fill the work tank AUX,22
Machine the cavity SPG,CAVITY.RBF
And so, with just a few words, you have created a command program. All you then need
to do is to enter it into the text editor, which you are already familiar with (see chapter 1),
creating a new file with an extension “CMD” (command).
PREP EXE INFO GRAPH

EDITOR
TCH,1
GOP,1
SPG,TEST.RBF
TCH,2
SPG,TEST.RBF
TCH,0
MSG,END
HELP
F1 F2 F3 F4 F5 F6 F7
! " # $ % & ' ( ) = ~ : _

BACK
0 - DELETE
<
SPACE
1 2 3 4 5 6 7 8 9 \
ESCAPE Q W E R T Y U I O P ' }] } DNC

]
@ FS
EDITOR + *. ?
RETURN
PROFORM *.VAR < > PAGE

F1 F2 F3 F4 F5 F6 F7
PAGE
337.*/ang DOWN

4.7
Example of a command program
The aim of this example is to show you how We have available to us two programs
to link up the machining of two cavities. drawn up with PROGRAM-EXPERT:
The “corner” measurement cycle has already
been executed as well as the tool offsets. A roughing program CAVEB.RBF
A finishing program CAVFI.RBF
Y MACHINE
40
X MACHINE
40
25
338.*
The command program is

Command programs are not only useful for
TCH,1 the command words but also for the
MOV,X25,Y40,Z10 parameters.
AUX,22
SPG,CAVEB.RBF It is also possible for you to create another
MVR,X40 small program that enables you to initialize
SPG,CAVEB.RBF the user parameters.
TCH,2
SPG,CAVFI.RBF
MVR,X-40 Initialization program
SPG,CAVFI.RBF
AUX,23 BLK,0
TCH,0 CBC,0
MSG,***MACHINING COMPLETED*** COE,0
OSP,0
ENG,0 (or 1 if you are working in INCHES)
MOF,3
BLD,0
TSIM,0
ART,1
TFE,1
CLE,0
TOL,0.005 (0.0002“)
MTOL,0.005 (0.0002“)
VRF,1
MSG, *** PARAMETERS INITIALIZED ***

Program checking The drawing parameters
This type of programming, although it has a EXE mode – Drawing parameters
simple structure, can nevertheless sometimes
become highly complex, as it can contain a PREP EXE INFO GRAPH
large number of different operations. DRAWING PARAMETERS
This is why various possibilities of program Machine

X
Y
0.000
0.000
Part
X
Y
0.000
0.000
verification have been provided. Z
C
r
0.000
0.000
0.000
Z
C
0.000
0.000
Mode Para View: XY

Scale: 1.000 Center sceen position X: 0.000
You can access these verification cycles in Start point:
Sectorization : 0
0 Y:
Z:
0.000
0.000
the EXE mode with the function “PROGRAM
EXECUTION”. Mode:
DNC FS
PROGRAM USER PIL DRAWING ACTIVER
PARAMETRES
EXECUTION PARAMETERS EXP MEASURING MANUAL
PARAMETERS
DESSIN TABLES
MODE VUE ECH ECRAN X ECRAN Y SCREEN Z STARTING
POINT
SCREEN X
F1 F2 F3 F4 F5 F6 F7
F4
File :
This page comprises many parameters
allowing modification of the display on the
PROGRAM USER PILOT
EXPERT DIEL.
graphic screen.
EXECUTION PARAMETERS
CUT DRY RUN VERIFY DRAW
SREEN
F1 F2 F3 F4
Mode
VERIFY
Auto : The numerical control will automatically
Allows the program syntax to be checked. select the best scale and position.
With “VRF,1” verification is done automatical- Para : This mode will enable you to select
ly as soon as the “CUT” function is selected. the position of the graphic view
according to the machine axes, and
DRY RUN to select the scale.
X,Y : Minimum scale used to enable you
Allows physical simulation of the machine to see the machine travel values and
operations (including changing the electrode the position of the execution.
by activating the parameter TSIM).
It is preferable to do this type of check com-
mand by command by setting the parameter View
CBC at 1.
Note : The two functions “VERIFY” and “DRY Makes it possible to select a view of the
RUN” are imperative in order to avoid errors X/Y, X/Z or Y/Z planes.
of syntax and/or positioning.
DRAW SCREEN Scale
Makes it possible to display graphically the Enables you to select the ideal scale for
movements and executions that the program looking at details or to have an overall view
will carry out. (valid in “Para” mode).
It is possible for you to modify the scale and
the views of the axes by defining the
drawing parameters which we shall see in Center screen position
greater detail later on in this course.
This function takes you automatically into the Position of display on X, Y and Z according
GRAPH mode. to the machine system of axes.
Please note that the functions mentioned

above are valid not only for command Sectorization
programs but also for PROFORM
programs. Enables you to display sectors where the
machining has been done (green color).
!
1.*

4.9
Let us now try to use these parameters with This gives us the following screen display :
a concrete example :
PREP EXE INFO GRAPH
If we wish to draw the detail of an orbital [mm] Part
machining operation according to an XY Y x 0.003
y -0.002
view so as to display the advance of

z 170.000
c 0.000
2.5
machining graphically, we just need to set

the following parameters : 0
-2.5
Mode :
Auto (to allow the numerical control to
-5
X
[mm]
select the position and the largest scale)

-5 0 5
DNC FS
341.*/ang
View :
XY (so as to display the orbit from above) During the graphic simulation, small icons
will appear, symbolizing the various
operations that are being simulated. Further
Center screen position : information is available in the NC manual.
Parameters automatically defined by the
numerical control
The common icons

Scale :
Parameter automatically defined by the ROM (Position from the part
numerical control (workpiece) center)
AXE (Choice of main axis)
TOOL (Tool change)
FLUSH (Flushing)
342.*
DELAY (Pause)
Exercises :
1) Creation of automation programs is 3) What graphic mode must you use

done by means of : when you wish to see the machine’s
a. The command editor travel values ?
b. Any word processing system
c. The faculty of memorization of each ......................................................
command typed on the keyboard ......................................................
d. The text editor
Answers : 2) If you wish to check just the syntax of
your program, what function should
1) d. you use ?
a. Dry run
2) b. b. Verify
c. Cut
3) X,Y mode. d. Graphic

Recapitulation of the most used words
Commands affecting the Commands affecting tables

Objectives :
execution of programs and files
SPG Execution of a part-program OFS Choice of an offset table you should be able to :
STP Suspension of a command TOF Loading of a stored offset into
program the table of offsets – Describe the 8 families
CBC Command after command TEC Selection of a technology table of command words of
execution RLD Loading of a setting or parame- your machine
MSG Displays on screen a message ters into the TEC table – Quote 3 command
of 36 characters max. REX Selection of a setting from the words per family and
LOOP Repetition of command program activated technology table use them properly
CCF Calling up of a command PNT Selection of a points table
sub-program
TSIM Simulation with change of
electrode Commands affecting
SIM Changeover from machining
to simulation (0 = machining the parameters of the
1 = simulation) part-program
CLS Clearing screen of the GRAPH
mode AXO Shifting of origin of the
MACHINE system of axes
MOF Activation of the tool offsets
BLK Block-by-block execution
OSP Execution of optional “STOPS”
Commands affecting COE Continuation of program in case
of errors
movements and auxiliary
functions
Measurement commands
MOV Simultaneous movement in
absolute mode in the MACHINE
system of axes MTOL Touch sensing accuracy in a
MVR Simultaneous movement in relative measurement cycle
mode in the MACHINE system EDG Seeks edge by an electrical
of axes touch in the given direction
MPA Movement in absolute mode in EDGT Carries out the search for a face
the PART (workpiece) system of along any vector
axes MTR Measures the position of the
MPR Movement in relative mode in reference ball useful for the
the PART (workpiece) system of measurement of offsets
axes MTO Measures the offsets of an
SEP Point storage electrode
GOP Movement to stored point CEN–CN2 Centering (0 – 45°)
AUX Activation of auxiliary M functions MPC Positioning at the corner of a
(ISO) part (workpiece)
TCH Change of electrode MPM Positioning at the center of a
SPA Updating of PART (workpiece) part (workpiece) by an external
coordinates centering
SMA Updating of MACHINE PAL Alignment of the face
coordinates of a part
AREF Automatic search for references TAL Angular positioning
(Roboform 30 · 31 · 40 · 41) of a tool

4.11
Direct machining commands Miscellaneous commands
DOWN Plunge cut machining ENG Selection of display units
VECT Vectorial machining ZCL Setting clocks to zero
ORB Orbital machining HELP Contextual help
EXPAN Plane machining
These commands are the ones that you will

most frequently meet when using your
Flushing commands machine. But there are more, which are
useful for advanced applications such as
contouring or palletization.
FLH Selection of flushing
ASP Suction You can find all these commands in the NC
FLI Injection pressure manual.
FLA Vacuum
Notes :
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................
Exercises :
1) The command word for updating the 3) The command word for setting the
machine axes is : flushing pressure is :
a. SMA a. FLA
b. SPA b. FLI
c. AXO c. FLH
d. FLA d. ASP
Answers :
2) The command word for centering in a
1) a.
hole is :
a. MTR
2) c. and d.
b. EDG
c. CEN
3) b.
d. CN2

Dimensional corrections of cavities
With any machining method it is necessary TOOL/2
to measure the part after machining, so as DOWN/L,L1,H,– 0.500,E,352 Objectives :
to check whether the dimension has been ORB/L,L1,H,– 0.113,E,352
obtained. ORB/L,L1,H,– 0.061,E,312 After reading this section,
ORB/L,L1,H,– 0.035,E,293,RET you should be able :
On a conventional machine it is easy to TOOL/0
make another pass to adjust a diameter or END – To correct a
the side of a prism by manipulating PROFORM program
verniers. With a numerical control machine to modify only the
it is also possible to re-work a dimension, depth of your cavity
but the machining program has to be – To correct a
modified. PROFORM program
A cavity that is too small to modify the sides of
On a ROBOFORM machine you may meet your cavity
several situations in which you will have to
19.97
modify your machining program, such as :
344.*
– A cavity not deep enough

10
– A cavity that is too small
20
– A cavity that is too small and not deep
enough
For this situation it is necessary to modify

These dimensional errors usually result from the parameter “H” of the 2 DOWN values
excessive electrode wear or an under-sizing that sets the under-sizing of the electrodes.
error. This will re-define the exact under-sizing of
the electrodes after machining, thus
compensating wear.
According to our diagram, the diameter is

A cavity not deep enough too small by 0.03 mm, i.e. a radius of
0.015 mm. So we must add this value to
the radial under-sizing of our electrode.
20
343.* If our old SDR was 0.5 mm, we need to
bring it up to 0.515 mm.
9.98 10
The corrected program is :
PN/CAVITY
This situation is easy to correct ; you only L1=–10
have to modify the parameter “L” of your FROM/X,0,Y,0,Z,10
Proform program : TOOL/1
DOWN/L,L1,H,– 0.515,E,414
The corrected program is : ORB/L,L1,H,– 0.311,E,391
ORB/L,L1,H,– 0.200,E,372
PN/CAVITY ORB/L,L1,H,– 0.125,E,352,RET
L1=–10,02 TOOL/2
FROM/X,0,Y,0,Z,10 DOWN/L,L1,H,– 0.515,E,352
TOOL/1 ORB/L,L1,H,– 0.113,E,352
DOWN/L,L1,H,– 0.500,E,414 ORB/L,L1,H,– 0.061,E,312
ORB/L,L1,H,– 0.311,E,391 ORB/L,L1,H,– 0.035,E,293,RET
ORB/L,L1,H,– 0.200,E,372 TOOL/0
ORB/L,L1,H,– 0.125,E,352,RET END

4.13
A cavity that is too small and Note:
not deep enough During execution, the modified program
will re-start machining from the start with
the roughing settings. If you want the fi-
! In this situation we have a combination of
the two types of error seen above. So we
nal surface finish of your cavity to be fine,
be careful to clean the micro-particles
1.* must correct the two defects at the same present in your machining environment,
time. since these particles are likely to create
arcing bridges with the energetic settings
Corrected program (according to the two and thus leave marks on your finished
previous diagrams) part.
PN/CAVITY In cases where there is only a small amount

L1= –10,02 of material removal (less than 0.05 mm) it
FROM/X,0,Y,0,Z,10 is possible to carry out only the second part
TOOL/1 of the program. It is easy to de-activate a
DOWN/L,L1,H,– 0.515,E,414 PROFORM line, without disturbing execu-
ORB/L,L1,H,– 0.311,E,391 tion, by means of the “;” sign.
ORB/L,L1,H,– 0.200,E,372
ORB/L,L1,H,– 0.125,E,352,RET
TOOL/2
DOWN/L,L1,H,– 0.515,E,352 The corrected program is :
ORB/L,L1,H,– 0.113,E,352
ORB/L,L1,H,– 0.061,E,312 Zone not executed by the machine
ORB/L,L1,H,– 0.035,E,293,RET
TOOL/0 PN/CAVITY
END L1= –10
FROM/X,0,Y.0,Z,10
;TOOL/1
;DOWN/L,L1,H,– 0.500,E,414
;ORB/L,L1,H,– 0.311,E,391
;ORB/L,L1,H,– 0.200,E,372
;ORB/L,L1,H,– 0.125,E,352,RET
TOOL/2
L1= –10.02
DOWN/L,L1,H,– 0.515,E,352
ORB/L,L1,H,– 0.113, E,352
ORB/L,L1,H,– 0.061, E,312
ORB/L,L1,H,– 0.035,E,293,RET
TOOL/0
END
Exercises :
1) You wish to machine a cavity of 2) You wish to machine a cavity with

15.5 mm depth. After measuring it sides of 43.4 mm. After measuring
you observe that it is only 15.46 mm them you observe that the value is
deep. How do you correct your only 43.28 mm. The under-sizing of
program ? your two electrodes are : SDR = 0.300
mm. How do you correct your pro-
Answers : a. Modify “L” as follows : L,-15.52 gram ?
b. Modify “L” as follows : L,-15.54
1) b. c. Modify “L” as follows : L,-15.46 a. Modify “H” as follows : H,0.360
d. Modify “L” as follows : L,-15.42 b. Modify “H” as follows : H,-0.240
2) c. c. Modify “H” as follows : H,-0.360
d. Modify “H” as follows : H,-0.260

Summary
In the course of this chapter, you have discovered some additional command words linked to
automation of your machine, adding to the long list of command words that you already
know (SPG,PAU,MSG, etc.).
You can use these words :
– Individually in the EXE mode, to give simple orders to your machine.
– Grouped together in a command program, so as to link up a series of orders enabling

you to automate your machine.
You are able to link up :
– Table and file management orders
– Parameter initialization orders
– Measurement cycles
– Movements
– Miscellaneous functions
– Execution of programs, etc.
You can create these programs by means of the text editor, by typing line by line the orders
that the machine must carry out. Once these programs have been created, you can check
them with the following functions :
– Verify
– Dry run
– Draw screen
During this chapter you learned how to correct the dimensions of a PROFORM program to
be able to touch up the bottom or the sides of a cavity.
This is easily done by modifying the parameter “L” if you wish to modify the depth, and with
the parameter “H” of the DOWN values if you wish to modify the sides of the cavity.
You can now answer the revision of knowledge questionnaire of chapter 4.

4.15
1) What is the purpose of the parameter VPULS ?

❑ a. To define the size of the electrode
❑ b. To set the pulsation speed of the machining axis
❑ c. To fix the sparking frequency
❑ d. To define the height of manual electrode changing
2) The command SPG cannot retrieve files stored on diskettes in the machine’s disk
drive.
❑ a. True
❑ b. False
3) Is it possible to execute a command program line by line ?

❑ a. Yes
❑ b. No
4) Match the following command words with their corresponding execution.

SEP • • Choice of flushing
EDG • • Execution of a part-program
SMA • • Activation of auxiliary functions
FLH • • Point storage
MVR • • Edge touch
ZCL • • Updating of machine coordinates
SPG • • Relative movement
AUX • • Setting clocks to zero
5) Describe in simple terms the stages of this command program :

TCH,1 ............................................................................................................
GOP,1............................................................................................................
CEN,X0,Y0 .....................................................................................................
MOV,Z10 .......................................................................................................
AUX,22 ..........................................................................................................
SPG,CAVEB.RBF ...............................................................................................
TCH,2 ............................................................................................................
SPG,CAVFI.RBF ................................................................................................
AUX,23 ..........................................................................................................
TCH,0 ............................................................................................................
6) In which mode can we start up a check of a command program or a PROFORM

program ?
❑ a. EXE
❑ b. PREP
❑ c. INFO
❑ d. GRAPH
7) In the “DRAWING PARAMETERS” page, which is the mode enabling us to see the
machine travel values and the execution at the same time ?
❑ a. Auto
❑ b. Para
❑ c. View
❑ d. X,Y

8) Mark the correct parameters to see the plunge cut in DOWN and ORB at a
maximum scale on the graphic screen (view from above).
Mode : Auto Para X,Y

View : XY YZ XZ
9) Correct the following program to enable this cavity to be touched up :
30
345.*
22.983 23
PN/CAVITY
FROM/X,0,Y,0,Z,10
TOOL/1
DOWN/L,-23,H,-0.400,E,414 L=................... H=.....................
ORB/L,-23,H,-0.311,E,391 L=...................
ORB/L,-23,H,-0.200,E,372 L=...................
ORB/L,-23,H,-0.125,E,352,RET L=...................
TOOL/2
DOWN/L,-23,H,-0.400,E,352 L=................... H=.....................
ORB/L,-23,H,-0.113,E,352 L=...................
ORB/L,-23,H,-0.061,E,312 L=...................
ORB/L,-23,H,-0.035,E,293,RET L=...................
TOOL/0
END
10) Create a small command program linking up roughing and finishing of the two
cavities, so as to produce the part shown below.
The external centering has already been done, as have the tool offsets.
There is no tool in the spindle.
A point has been stored at X0, Y0, Z10 (value of the FROM of the program)
The PROFORM programs do not carry any movements along X and Y.
The programs are :
CAVEB.RBF, for roughing
CAVFI.RBF, for finishing
Axe MACHINE
50
50
346.*

4.17
Alphabetical index
CHARMILLES TECHNOLOGIES 205 962 430/E/24.02.2000 5.1
Contact
Charmilles Technologies SA
rue du Pré-de-la-Fontaine 8-10
1217 Meyrin 1, Geneva/Switzerland
Tel. +41 (0)22 783 31 11
Fax +41 (0)22 783 35 29
www.charmilles.com
Agie Charmilles Group

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ROBOFORM 35• 2400•54/55•84

205 962 080/E/10.07.2001

2. The generator and the technology

3. Machine language and machining

Typesetting and production by Edipresse Imprimeries Réunies Lausanne s.a. /Renens

Our thanks for their collaboration go to : A. Favre, J.- M. Bosson,

CHARMILLES TECHNOLOGIES 205 962 130/E/24.02.2000 0.1

0.2 CHARMILLES TECHNOLOGIES 205 962 130/E/24.02.2000

Definition of electrical discharge machining (EDM) 3

Public health and safety regulations 9

CHARMILLES 205 962 180/E/10.07.2001

Definition of the process

CHARMILLES 205 962 180/E/10.07.2001

This breakdown voltage depends on :

At this stage, current can flow and the spark

At the same time a bubble of gas due to

CHARMILLES 205 962 180/E/10.07.2001

The erosion is called wear when it takes

The eroded material then re-solidifies in the

removed by the dielectric.

6 CHARMILLES 205 962 180/E/10.07.2001

Part Electrode Part

CHARMILLES 205 962 180/E/10.07.2001

8 CHARMILLES 205 962 180/E/10.07.2001

CHARMILLES 205 962 180/E/10.07.2001

10 CHARMILLES 205 962 180/E/10.07.2001

Emergency stop circuit

CHARMILLES 205 962 180/E/10.07.2001

For all interventions inside the generator

0 General nature of waste

12 CHARMILLES 205 962 180/E/10.07.2001

Braid Door seal

CHARMILLES 205 962 180/E/10.07.2001

14 CHARMILLES 205 962 180/E/10.07.2001

At this stage, current can flow and the spark

M2 – 2 4 990 670/E 11/93 4 990 670/E 11/93 M2 – 3

Zone 1 Zone 3 Zone 4

CHARMILLES 205 962 180/E/10.07.2001

The “Caution” sign

16 CHARMILLES 205 962 180/E/10.07.2001

In this manual, indicators at the bottom of Programming

the various units used.

one directory to another.

Changing of a unit is done before selecting a file (the file

COPY DELETE RENAME DISPLAY PRINT CAMBIO

cursor arrow keys

• Validate with RETURN

Indicator at bottom of page

CHARMILLES TECHNOLOGIES4 941 690/F/17.01.1995 4.2.3.1

CHARMILLES 205 962 180/E/10.07.2001

221 220 P5/A8

18 CHARMILLES 205 962 180/E/10.07.2001

Preventive maintenance : indicates to operators when maintenance operations need to be carried

Corrective maintenance, “troubleshooting”:

CHARMILLES 205 962 180/E/10.07.2001

General description of machines 1.3

Description of machine functions 1.13

Use of the screen and keyboard 1.33

Command words 1.47

Measurement cycles 1.51

Revision of knowledge of chapter 1 1.67

CHARMILLES TECHNOLOGIES 205 962 230/E/23.02.2000

CHARMILLES TECHNOLOGIES 205 962 230/E/23.02.2000

( * /