CAM system for efficient generation of part-programs for wire-EDM

In the recent years wire-EDM became a necessity for many engineering applications, particularly in the dies making. Design of a good CAM system as an aid for making dies or other wire-EDM applications, became a challenging job with increased use of complex part geometry. In this paper a proposed CAM system is designed to overcome the limitations of the existing CAM systems. The proposed CAM provides automatic correction for maximum taper angle, and automatic creation of the programmed fixation stop. Programming time has been reduced using the automatic tool path creation, postprocessing, trace checking feature, and simulation check. Enhanced two-axis programming capabilities include, multiple operation automatic lead-in and :lead-out generation, automatic corner filleting for internal external, or all sharp intersections. One directional trim cut can be written as a main program which calls a separate sub-program NC file for each trim cut to reduce the NC program size. No-Core cut capabilities are also added to avoid the machine damage. Great saving in programming time, user effort, and the precision for all steps have been achieved.