19.

1 Programming Methods
There are several methods available in which to create programs for
WEDM. The most efficient method to generate programs incorporates the use of
a specialized WEDM CAM system. These systems have built-in features that
can automatically generate part tabs and cut-off programs, create reverse cutting
programs, create 4-axis (X,Y,U,V) programs via two separate geometries, and
will ultimately provide the easiest and most flexible means to maximizing the
unattended machining time...which is a key objective of WEDM.
CAM programs are typically posted (generated) out as an all-inclusive
program, meaning that they contain all the necessary information to process
work. They include items such as a WCS callout, offset values, E-code callout,
and contain code for every thread and cut point of the wire. Since a CAMed
program is created fully complete off-line, there is no need for any further
programming or editing on the machine, and more time can be dedicated to
having the machine process work. All that an operator needs to do to process a
CAMed program is to set a part up in the machine, align the wire to the work
piece and set the applicable WCS, load the CAMed program, and begin machine
operation.
CAMed programs typically read and run in sequential order, and will
repeat the program geometry if processing multiple machining passes. CAMed
programs can contain sub-routines, but they are not that commonly used due to
easier and faster programming as direct serial (Type 1) programs. While many
WEDM CAM systems exist, the key differentiating factor is in the ability of their
post processors to properly generate code in the correct format for a particular
machine and or model. Other key differentiating elements of WEDM CAM
systems include the existence of a complete machine power settings (E-codes)
library, importable CAD data formats, and training/applications support.
Other methods of programming include the use of a milling CAM system
and hand written programs. While these methods will yield the same machining
results, they will however require a lengthier program generation time, have a
higher probability of program errors, and if generated as a Type 2 program, will
include further programming in the machine control to complete the program.
In general, WEDM programs are very small (kilobytes) when compared to
3-D milling programs (megabytes); the largest WEDM programs are typically
4-axis programs. Most WEDM programs are easily transferred into the machine
via a 3½” floppy disk, but other methods (RS232 & Network) are available.
Networking (via Ethernet card) has become more popular, and has played a key
role in data management. Many companies that are production orientated have
setup a system wherein no job program is left on the internal machine memory.
All programs are stored and then recalled and loaded into the machine from a
master source (network) each time a job batch/run is required. This type of data
management plays into several quality control systems, and is designed to
control errors by tracking any program and part changes or revisions.

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19.2 All G & M Codes
There are several different G & M codes that are available to use at any
time. The G & M codes covered in the Part 1training portion consists of the most
commonly used codes. Other codes exist, and each serves a specific function,
but their amount of use is purely dependant upon the combined factors of
application and programming ability. Below is a standard list of all G & M codes
with a brief description of its function. Please see the Programming Manual for
more information and examples of program format and callout for each function.

G Codes for MGW-S Control

G00 Rapid Traverse G77 Hole Center Positioning
G01 Linear Interpolation G78 Wire Vertical Adjustment
G02, 03 Circular Interpolation, CW & CCW G79 Corner Edge Pick-Up
G04 Dwell G80 Groove Width Center Positioning
Plate Width Center Positioning
G10 Change Set Data G81
(X Axis)
Plate Width Center Positioning
G22, 23 Work Limits G82
(Y Axis)
G24 Taper Corner Tangential Circle Insertion G83 Cylinder Center Measurement
Work Parallelism Measurement
G25 Spiral Interpolation G84, 85
(X & YAxis)
Automatic Measurement (machining)
G26 Rotation Copy G86, 87
Width
G27 Macro Call G89 Automatic Wire Threading
G28 Automatic Return to Reference Point G90 Absolute Command
G29 Return from Reference Point G91 Incremental Command
G30 Return to 2nd ~ 4th Reference Point G92 Coordinate System Setting
G40, 41, 42 Wire Radius Compensation G95 Z Axis Position Control
G43, 44 Corner Shape Control G130 Special Sub-Model Macro Codes
G45, 46 Corner Override G150 Parameter Output
G47, 48 Scaling G151 Machining Condition Output
G49 Maintain Top & Bottom Radius Same G152 Machining Time Output
G50, 51, 52 Taper Machining G153 Machining History Output
G53 Machine Absolute WCS G155 Screen Data Initialization
G54-G61 Work Coordinate System 1 – 8 G180 Program Master Initialization
M98 Restriction ON in Auto Scale
G500 ~ 515 Work Coordinate System Groups 1-16 G580
Mode
M98 Restriction OFF in Auto Scale
G65 Macro Call G581
Mode
M98 Call Restriction ON in Auto Scale
G68, 69 Rotation G582
Mode
M98 Call Restriction OFF in Auto
G70, 71 Mirror Image G583
Scale Mode
G72, 73 X/Y Axis Change
G75 C-Axis Centering (UH only)
G76 Work Edge Face Positioning

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M-Codes for MGW-S Control
M00 Program Stop M59 Work Tank Up
M01 Optional Stop M60 Index
M03 End of Program M62 Rotation Clamp
M05 Discharge Off M63 Rotation On
M06 Automatic Wire Threading M64 Rotation Unclamp
M07 Wire Automatic Cut Off M65 Rotation Off
M08 Remain Cut-Off M66 Auto Work Change
M16 Search Transfer M67 Work Load
M17 Machining On M68 Work Unload
M18 Machining Off M71 Approach
M20 Initial Hole Machining M72 Water Flow Rate Control
M28 Work Tank Fill ON M74 Process Skip
M29 Work Tank Fill OFF M75 Reference Hole Retry
M30 End of Program and Rewind M90 M08 Control
M40 Water Conductivity Check M98 Subprogram Call
M58 Work Tank Down M99 Subprogram End

Specialty G-Codes Functions for MGW-S Control

G121L19S0 Activates RWB Mode 0 (No RWB)
G121L19S1 Activates RWB Mode 1 (Continue after Max Failure)
G121L19S2 Activates RWB Mode 2 (Stop after Max Failure)

G121L21S0 Activates AWT Retry Mode 0 (Standard AWT- no sensor)

G121L21S1 Activates AWT Retry Mode 1 (Standard AWT- w/ sensor)
G121L21S2 Activates AWT Retry Mode 2 (Fine Hole AWT- annealer)
G121L21S3 Activates AWT Retry Mode 3 (High-Speed AWT)

G130 Codes Special Sub-Model Macro Programs (Must be loaded into machine memory)
G130E0 Grid Positioning Sub-Model
G130E1 Circular Positioning Sub-Model
G130E2 Die Circular Hole Machining Sub-Model
G130E3 Die Circular Hole Coreless Machining Sub-Model
G130E4 Die Circular Taper Coreless Machining Sub-Model
G130E5 Machining Start Timer Sub-Model
G130E6 Die Square Hole Coreless Machining Sub-Model

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 19.3 Programming Formats
There are two distinct programming methods (Type 1 & Type 2) which
were covered in detail in the Part 1 training. This section will break down the
programming G-code format further, and explain the sequence order of code to
process specific types of jobs. The following examples show program formats for
processing 2D geometry, offset call-out, tapers, and 4-axis programs.

Standard 2D Program:

Type 1 Program Type 2 Program

(2D Program Example) : Program Comments (2D Program Example) : Program Comments
G90 : Absolute Positioning N1 : Program Marker
M74 : Skip Machining Register Reset G90 : ABS Positioning
G500G54 : WCS Callout M17 : Machining Power On
G0X0.Y0.M6 M74L1 : Rapid to Start Pt., Thread, Mark M74 Pt. G41G1Y0.5 : Offset On
E1074D0.00765 : E-Condition & Direct Offset value G1X-0.375 : Geometry G-Code
N1 : Program Marker G3X-.0.5Y.375I-.1250.J0. : “
M17 : Turn Machining Power On G1 : “
G41G1Y0.5 : Offset On G3 : “
G1X-0.375 : Geometry G-Code G1 : “
G3X-.0.5Y.375I-.1250.J0. : “ G3 : “
G1 : “ G1 : “
G3 : “ G3 : “
G1 : “ G1 : “
G3 : “ G40Y0. : Offset Cancel
G1 : “ M99 : End Sub-routine
G3 : “
G1 : “
G40Y0. : Offset Cancel
M07 : Cut Wire
M30 : Program End

Offset Call-Out:
Offset values are used in WEDM much in the same manner as a
machining center. The offset values represent the tool or wire offset distance
from the center of the wire, and it is used in WEDM to accommodate the EDM
overburn of a particular power setting. Offset values can be defined by one of
two methods: Direct or Indirect. The machine operates and reads the offset
values as a working “D” register, and both offset callout methods assign values to
this register. A Direct Offset callout assigns the value to the machine working
“D” register as a direct decimal value, and is contained in the G-code program.
An Indirect Offset callout stores the offset value into a “D” register number, and
the D# register is called out in the G-code program. The “D” registers (D0 thru
D9) can be loaded either by hand on the Library page, or by assigning offset
values to the registers at the beginning of a G-code program. Benefits to using
the “D” offset registers in this manner enable the operator to only have to change
one offset value when making program adjustments.

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(Direct Offset Call-out) : Program Comments
G90 : Absolute Positioning
M74 : Skip Machining Register Reset
G500G54 : WCS Callout
G0X0.Y0.M6 M74L1 : Rapid to Start Pt., Thread, Mark M74 Pt.
E1074D0.00880 : E-Condition & Direct Offset value
M17 : Turn Machining Power On
N1 : Program Marker
G41G1Y0.5 : Offset On
G1X-0.375 : Geometry G-Code

(Indirect Offset Call-out) : Program Comments

#2001=0.00880 : Loads offset value into D1 register
G90 : Absolute Positioning
M74 : Skip Machining Register Reset
G500G54 : WCS Callout
G0X0.Y0.M6 M74L1 : Rapid to Start Pt., Thread, Mark M74 Pt.
E1074D1 : E-Condition & Direct Offset value
M17 : Turn Machining Power On
N1 : Program Marker
G41G1Y0.5 : Offset On
G1X-0.375 : Geometry G-Code

Taper Programs:
The machining and processing of tapers is not that much different than
processing straight wall parts. When comparing the G-code of straight wall
programs, taper G-code programs only contain 3 additional bits of information
(Taper Angle, Taper Direction, and Taper Plane Data). With this additional data,
the machine will know where the work piece sits within the machine, and how to
process and cut the taper. Beyond differences in the G-code programs, the
machine nozzles and cutting conditions (E-codes) used may be different when
processing tapers. Depending on the height or severity (high angle) of the taper,
less aggressive (lower) power settings and different nozzle types (allow for
greater clearance at high angles) will need to be used.

When processing tapers, it is best that the Taper button (located on the
Others page) is set to a 1, so that when the program is AutoScaled, both paths
(Program & Sub-Planes) of the program are displayed. When processing certain
taper or 4-axis programs, it may be advantageous to set the Taper button to a 2,
so that only the Program Plane is graphically drawn on the machine control.
This will speed up the graphic draw and may display a more recognizable
program part shape due to overlapping of the geometry.

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 (Taper Sample - 1)
(Ref 2.0 x 1.0 w.125r)
(Cuts 10.5 degree taper all around geometry)
G95 P0.0 Q1.5 Z#5015 (Sets Taper Data)
G90
G500G54
G0 X0. Y0. M06
M17
E1077 D0.00680
G41 G52 G1 Y.5 T10.5 (G52 & T turns Taper On)
X-.875
G3 X-1. Y.375 J-.125
G1 Y-.375
G3 X-.875 Y-.5 I.125
G1 X.875
G3 X1. Y-.375 J.125
G1 Y.375
G3 X.875 Y.5 I-.125
G1 X.1
M01
G1 X0.
G40 G50 Y0. T0. (G50 & T turns Taper Off)
M07
M30

(Taper Sample - 2)
(Ref 2.0 x 1.0 w.125r)
(Cuts different degree tapers)
G95 P0.0 Q1.5 Z#5015
G90
G500G54
G0 X0. Y0. M06
M17
E1077 D0.00680
G41 G52 G1 Y.5 T0.
X-.875
G3 X-1. Y.375 J-.125 G24 T5.0
G1 Y-.375
G3 X-.875 Y-.5 I.125 G24 T10.0
G1 X.875
G3 X1. Y-.375 J.125 G24 T15.0
G1 Y.375
G3 X.875 Y.5 I-.125 G24 T0.
G1 X.1
M01
G1 X0.
G40 G50 Y0. T0.
M07
M30

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(Taper Sample - 3)
(Lifter Pocket Sample 1)
(Size - 3.0 x 2.0)
(Cuts 2 tapered walls with sharp corners)
G95 P0.0 Q2.0 Z#5015
G90
G500G54
G0 X0. Y0. M06
M17
E1097 D0.00700
G42 G52 G1 Y1.0 T0.
G1 X 1.5
G1 Y-1.0 T10.
G1 X-1.5 T0.
G1 Y1.5 T-10.
G1 X0. T0.
G40 G50 Y0.
M07
M30

(Sample Taper - 4)
(Lifter Pocket Example 2)
(Size - 3.0 x 2.0 w/0.40r @ 15 Degrees)
(Cuts 2 tapered walls with constant corner radius)
G90
G95 P0. Q2.0 Z#5015
G500 G54
G0 X0. Y0. M06
M17
E1097 D0.00700
G41 G52 G1 Y1. T0.
X-1.46
G49 G3 X-1.5 Y.96 J-.04
G1 Y-.96 T15.
G49 G3 X-1.46 Y-1. I.04
G1 X1.46 T0.
G49 G3 X1.5 Y-.96 J.04
G1 Y.96 T-15.0
G49 G3 X1.46 Y1. I-.04
G1 X0. T0.
G40 G50 Y0.
M07
M30

234