Title:

Work Instruction

DAITOH PRECISIONS, INC.

Process: EDM Machine : Linear Sodick, Makino, Sodick Epoc2
Customer :
Part name :
Model no. :
GENERIC
Drawing no. : Approved by Checked by

Process Step Illustration

1. POWER UP
1.3
1.1 Perform preventive maintenance inspection before starting the operation, refer to Preventive Maintenance Checksheet.
1.2 Open valve for air supply. Check air pressure gauge 0.6 Mpa ± 0.2
1.3 Turn ON the primary power source at the PPO panel breaker and the main power supply at the back of the machine.
1.4 Press the (source on) switch and (power on) switch.
1.5 Feed the axis to its travel limit.
2. RECEIVING OF DRAWING
2.1. Study and analyze the drawing from customer/requesting dept. ORIGIN Z+,X-,Y-
2.2. Check dimensional & visual appearance of the workpeice based on the drawing before to proceed the operation.
2.2. Refer to the drawing for the electrode design and initiate to EDM Electrode Request form ( MDM-002 ).
2.3. Submit the designed electrode ( EDM Electrode Request Form ) to supervisor for approval and fabrication
( wirecut / grinding / machining center process ).
3. TOOL PREPARATION
3.1. Allen wrench (1 set) 3.5. Open wrench (EDM 1 8mm, EDM 2 13mm) 3.8. Reference ball
3.2. Sine bar 3.6. Polishing stone 3.9. Pencil Stone
3.3. Lever type/Dial test indicator 3.7. Electrode holder 3.10. Copper/carbide electrode
3.4. Sine vise
4. MATERIAL PREPARATION AND MACHINE SETTING
4.1 Remove burrs and sludge from the workpiece using pencil stone before mounting it on the machine.
4.2. Clean the magnitec table using tissue, make sure table must free from oil and dirt before mounting the workpeice.
4.3 Mount/clamp the workpiece on magnetic table.
4.4 Adjust the parallelism max. of 0.002 microns of the workpiece using a lever type dial indicator. RECEIVING OF DRAWING PREPARATION OF TOOLS
4.5 Setting the x, y, z axis for reference
4.6 Remove burr and sludge from electrode before mounting.
4.7 Mounting the Electrode (see reference 2-d.1)
4.8 Adjust parallelism 0.001 microns of electrode using dial indicator.
4
4.9 Setting the die electric oil at least 80mm(3") above the workpiece, a flushing suction fixture, a clamp fixture etch
5. PROGRAMMING AND MACHINE OPERATION
5.1. Analyze the drawing for the Computation and movement of X, Y, Z axis.
5.2 LN asist programming
5.2.1. Click [EDIT], then [ASSIST] button from the screen.
5.2.2. Click [SHAPE],at the left of the screen.
5.2.3. Shape window appear, choose either (STANDARD, SOLID, SPECIAL) based on process needed.
5.2.4. Click [MACHINE PLAN] after you have selected from the 3 shape categories. then set the data following .
*DEPTH *LORAN PATTERN *ROUGHNESS
*MATERIAL *PROJECTED AREA *UNDERSIZE X & Y offset of the electrode
5.2.5. Click [NEXT] botton then the machine will automatically generate the conditioning parameters.
5.2.6 Click [NEXT] botton then the POSITION screen will appear. Choose from the POSITION screen
the corresponding categories for your machining process.
*1 HOLE *LATTICE *CIRCLE *CUSTOM
5.2.7 Click [NEXT] botton after you have selected the categories. Then an icon will appear for you ELECTRODE ALIGNING SETTING DIE ELECTRIC OIL
to input your desired file name then click [OK]. Then the program will be save in the hard drive.
You can check the program by clicking [EDIT] botton. If the program is ready you can click
[RUN] botton to start the machining process.
5.3 Parts checking after every process according to specs and tolerances.
6. DIMENSION CHECKING AND RECORDING
6.1. Check / Dimension the workpiece upon completing every process according to specification and tolerance.
1
6.2. Record the data to In-Process Inspection Result ( MDM-001 ).
6.3. Completely fill-up the Process Sheet
7. SHUTTING DOWN
7.1 Press manual in manual mode LN PROGRAMMING MACHINING
a.If axis travel or other operation are in progress, stop all the operation. SETTING DIE ELECTRIC OIL
1 b. Do not shut OFF the power supply while the program is being loaded or saved.
c. Do not shut OFF the power supply while the method is being switched from the setting mode to another mode
d. Shut OFF the power supply without switching to another mode when data restore operation is performed
in [SETTING] - [DISK] Submode.
d. Do not Shut OFF the Power Supply when using the U.T.Y mode.
7.2 Press the power OFF switch 7.5 Turn OFF the main power supply
7.3 Press the source OFF switch 7.6 Turn OFF the primary power source
Safety / Housekeeping
1. In case of non-conformance, inform the immediate superior.

2. Perform housekeeping and safety control in the entire production area before and after operation. DIMENSION CHECKING & RECORDING

R DATE REVISED ITEM IN-CHARGE DATE

E 04.09.11 Integrate dimension checking and recording of result and enhancement of process step 7.1. P. TAN
1
V

N
dpi Daitoh Precisions, Inc. Effective : 09-22-06 Rev. no. 1 Issue no. 1 DFAS no. F-029-06
 Page no.: 1/1

Document No.: DPI-C-WI-2085

c2 Revision No, : 1

Issue No. 1

Made by Originated Date: February 15, 2009

Standard Machining Parameters

CONDITION
Machine FINAL
ROUGHING SEMI-FINAL FINAL
ROUGHING

LINEAR SODICK C714 C008 C093 C032

513 512
MAKINO NA E04
N Z+,X-,Y-
800 420
SODICK EPOC 310 300

< 2.d.1 >

2.d.1.a To clamp the electrode, the following fixtures are
available :
HOLDER TYPE APPLICATION
*Threaded cut threads on the electrode and attach a rod-shaped shank
*Plate use a large size electrode
*Vise to secure plate or square shaped

*Drill Chuck, collet to secure round bar electrode

chuck

OOLS 2.d.1.b Adjusting Electrode Parallelism with Universal Holder

- Adjust the inclination of the front face of the electrode
Use adjusting screws (3) and (4)
- Adjust the inclination on the side face of the electrode.
Use adjusting screws (5) and (6)
- Adjust the parallelism in the electrode rotation direction
Use adjusting screws (1) and (2)
- Repeat the above steps and check the parallelism again

NOTE :
- Preventive Maintenance = Daily, Weekly and Monthly Preventive
Maintenance Checksheet
- EDM OIL : SODICK EPOC2 = CASTROL SE-180

OIL - GREASE : SODICK LINEAR = "KHS" Grease ( quarterly )

REVISED ITEM IN-CHARGE

DCC -041