ElectrodeWorksUT.pdf

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ElectrodeWorks 2009 SP0User Guide and Tutorial

June 2009

PROPRIETARY RIGHTS NOTICE: All rights reserved. No part of this material may beproduced or transmitted in any form or by any means, electronic, mechanical, orotherwise, including photocopying and recording or in connection with any informationstorage or retrieval system, without the permission in writing from R&B.

The information in this document is subject change without notice and should not beconstrued as a commitment by R&B.R&B assumes no responsibility for any errors that may appear in this document.

The software described in this document is furnished under license and may be used orcopied only in accordance with the terms of such a license.

Copyright 2007-2009 by R&BAll rights reserved

R&B LTD.32 Shaham Str.

Petah Tikva 49170Israel


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0 Table of Contents

Chapter 1 1 Introduction 1-1

1.1 System Requirements ............................................................................1-3

1.2 Installing ElectrodeWorks.......................................................................1-4

1.3 Licensing ElectrodeWorks......................................................................1-5

Chapter 2 2 User Guide 2-1

2.1 ElectrodeWorks Property Page .....................................................2-2

2.1.1 Top Level .........................................................................................2-2

2.1.2 Electrode Level ................................................................................2-3

2.1.3 Clearance Level...............................................................................2-5

2.1.4 Spark Gap Level ..............................................................................2-6

2.1.5 Copy Level .......................................................................................2-7

2.2 Project Settings ...............................................................................2-8

2.3 Project Report .................................................................................2-9

2.4 Options ............................................................................................2-10

2.5 Add Electrode .................................................................................2-13

2.5.1 Positions ........................................................................................2-14

2.5.2 Settings...........................................................................................2-17

2.5.3 Holder Library Blanks ................................................................... 2-19

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2.6 Add Clearance ................................................................................2-20

2.7 Spark Gap .......................................................................................2-22

2.8

Copy Electrode ................................................................................2-24

2.9 Edit Electrode ..................................................................................2-25

2.10Edit Clearance........................................................................................2-26

2.11Edit Spark Gap .......................................................................................2-27

2.12Edit Copy................................................................................................2-28

2.13Electrode Data ................................................................................2-29

2.13.1 Data ...............................................................................................2-30

2.13.2 Properties ......................................................................................2-31

2.14Electrode Drawings .........................................................................2-32

2.15Multi Drawings .................................................................................2-33

2.16Creating User Electrode Blanks .............................................................2-34

2.16.1 SolidWorks Part.............................................................................2-34

2.16.2 Initial text file................................................................................. 2-35

2.16.3 BMP file......................................................................................... 2-36

Chapter 3 3 Tutorial 3-1

3.1 Create an electrode on the air holes......................................................3-2

3.2 Create an electrode on a boss ...............................................................3-7

3.3 Creating an electrode for the slot ...........................................................3-12

3.4 Settings/ Options/ Report/Technology ...................................................3-19

3.5 Drawings.................................................................................................3-21

3.6 Exact Face(s) and Multi-Electrodes .......................................................3-22

3.7 Copy Electrode.......................................................................................3-26

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1

1 Introduction

ElectrodeWorks automates all aspects of the extraction, design,management, documentation and manufacturing of EDM electrodes. Fullyintegrated into the SolidWorks environment ElectrodeWorks guides youthrough the electrode design and production process. You design theelectrode through a comprehensive yet easy to use user interface; theelectrode manufacturing and EDM positioning drawings, and the machiningfiles are created automatically.

Choose the holder and electrode blank shape from the standard, userextendable parametric shape library through theAdd Electrode environment

and select the burn faces. The electrode is automatically placed and sizedaccording to customizable factory setup parameters. Parameterand Position dialogues allow you to fine tune the electrode positioning and orientation. Onvalidation the electrode is then cut, showing clearly the burn faces.

Add Clearance enables you to create tangent, normal and draft offsets at theelectrode/part interface through integrated solid trim functionality, powered by ourease of use dialogue system.

Spark Gap creates a geometric spark gap on the burn faces according to a

given gap. The system creates a separate spark gap configuration of theelectrode.

Copy Electrode automatically looks for other areas on the part which are similarto the current burn area and copies the electrode to these areas.

Modification of the position and definition of the electrode and clearance isaccessed through the dedicated ElectrodeWorks Property Page.

Drawings are instantaneous and complete including sheets for electrode

manufacturing and EDM burn process.

Technology is defined through a dedicated dialogue which defines material andallows you to key-in the surface finish standards.

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Introduction

Process setup of the rough to finish spark gaps and the pattern method anddefinition are defined through the same dialogue, as well as safety z-levelpenetration.

Manufacturing information including the zero point for machine positioning andorientation as well as the previously defined technology is managed and storedwithin the electrode as an EXCEL report under the Design Binderfolder.

ElectrodeWorks Property Page

ElectrodeWorks has its own Property Page through which the menus anddata for the application are available (this is in addition to the menu system orthe icons on the toolbar). The property page is available when the product isloaded and is populated with ElectrodeWorks specific data when running theproduct. The data includes Electrodes and Clearances per electrode.

Accessing the menus through the Property Page is advantageous since thisautomatically populates the dialogue with the selected entity thereby saving amouse click.

ElectrodeWorks runs in assembly mode only.

1-2ElectrodeWorks 2009


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Introduction

1.1 System RequirementsElectrodeWorks is fully integrated under the SolidWorks environment thussystem requirements are similar to those of SolidWorks.

HardwareSince ElectrodeWorks creates relatively large assemblies we recommendusing the optimum hardware recommendations from SolidWorks.

Operating System

Windows XP /Vista(r) 32 or 64bit.

Networks

Windows XP /Vista(r) 32 or 64bit.

Required Software

ElectrodeWorks current version is ElectrodeWorks 2009.

SolidWorks current version is SolidWorks 2009.

Adobe Acrobat Reader 5.0 or higher.

Licensing

ElectrodeWorks is protected using a software license system FLEXlm(FLEXnet Publisher Licensing Module), which allows both an individualstandalone license (locked to a workstation) and floating licensing (across anetwork) without the need for a dongle.



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Introduction

1.2 Installing ElectrodeWorksA user must have administrator privileges to install ElectrodeWorks.

Make sure that SolidWorks is not running during the installation.

The ElectrodeWorks installation can be initiated from a CD or from anexecutable file downloaded from the R&B web site (www.RnBUSA.com)

Once the installation is completed, logon as the user and activate SolidWorks.You may have to add ElectrodeWorks to the SolidWorks add-ins using theSolidWorks > Tools > Add-ins menu.

http://www.rnbusa.com/http://www.rnbusa.com/


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Introduction

1.3 Licensing ElectrodeWorksR&B uses the FLEXlm (FLEXnet Publisher Licensing Module) licensemanager for all of its licensed products. This is a separate module allowing

licensing on a node locked or floating (server/client) basis.If this is an initial installation (i.e. the current ElectrodeWorks products havenever been installed on this workstation) a message box will pop up which allowsyou to make a license request by clicking on the Registerbutton. A licenserequest can also be made at any time through the ElectrodeWorks > LicenseRegistration menu or from the Start > R&B > License> R&B LicenseManager. Refer to the R&B License Guide for details on how to fill out andsend the license request.If you have no license or the license has less then 30 days left then a similarmessage box will appear as follows:



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2

2 User Guide

2-1


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User Guide

2.1 ElectrodeWorks Property PageThe ElectrodeWorks Property Page is available as soon as ElectrodeWorks

is checked in the SolidWorks add-ins dialogue, and an assembly document isopen.

This Property Page includes all the menus needed to run ElectrodeWorkswithout ever having to use the menu or icon system. In fact certain commandsexist ONLY under the Property Page.

2.1.1 Top Level

On the top level we have the assembly name.

The RHM button on this level opens the following set of menus:

- Project Settings

Initial settings

-Add Electrode

Create Electrode

- Project Report

Create Excel data sheet(s)

- Multi Drawings

Automatic drawing

- Options

Default dialogue options



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2.1.2 Electrode Level

Each electrode will have its own appearance according to its name as a folderin the ElectrodeWorks Property Page.

The RHM button on an electrode opens the following set of menus:

Add Clearance

Create clearances for the non-burn faces.

Spark Gap

Create geometric spark gap.

Edit Electrode

Modify initial electrode data.

Copy Electrode

Copy the electrode to similar burn areas.

Delete (only from the property page)

Delete this electrode.

Electrode Data

Add technological data to this electrode.

Show/Hide Electrode (only from the property page)

Toggle to display the complete electrode.

Show/Hide Holder(only from the property page)

Toggle to display the electrode holder.

Isolate (only from the property page)

Display only this electrode.



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Open Part (only from the property page)

Open this electrode.

Electrode Drawing

Draw EDM and/or manufacturing data of this electrode.



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2.1.3 Clearance Level

After adding a clearance to an electrode it will appear in the electrode folder.These menus are available only through the RHM button.

The RHM button on any clearance feature opens the following set of menus:

Edit Clearance (only from the property page)

Edit the specific clearance.


Delete the clearance (might create errors in theSolidWorks FeatureManagerif faces referred to byclearances, created after this clearance, are deleted as aresult of this action).

Suppress/Unsuppress (only from the property page)

Might also affect later created clearances as described for the Delete menu.

Rollback (only from the property page)

Might also affect later created clearances as described for the Delete menu.



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2.1.4 Spark Gap Level

After adding a spark gap to an electrode it will appear in the electrode folder.These menus are available only through the RHM button.

The RHM button on any spark gap feature opens the following set of menus:

Deactivate/Activate (only from the property page)

Deactivate the spark gap (i.e. return to the defaultelectrode configuration without gap).

Edit (only from the property page)

Edit the spark gap


Delete the spark gap



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User Guide

2.1.5 Copy Level

After copying an electrode it will appear in the electrode folder. These menusare available only through the RHM button.

The RHM button on the Copy feature opens the following set of menus:

Edit (only from the property page)

Edit the spark gap


Delete the spark gap

Hide/Show (only from the property page)

Toggle to hide or show the copied electrodes.



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User Guide

2.2 Project SettingsThis dialogue includes general data for the electrodes created in this project,

which will be used in subsequent dialogues and output files. It can be modifiedat any time during the process.

The ElectrodeWorks > Project Settings menu or relevant icon accessesthe initial electrode creation dialogue. This dialogue is also available byclicking the RHM button on the top level of the ElectrodeWorks PropertyPage.

The dialogue consists of a single section:

General

- Project name: key-in the specific project name.

- Designed by: key-in the specific designer name.- Date: defaults to todays date, can be modified.

- Description

This information is then transferred to the Project Report. It needs to becreated only once at any time during the project and the information istransferred to the property information for every electrode created. The data forspecific electrodes can be modified through a different menu.



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2.3 Project ReportThis menu provides an Excel file report of the electrode(s) selected. The report

is stored under the Design Binderof the assembly in the SolidWorksFeatureManager tree according to the Project Name. Each electrode willhave a separate sheet with the electrode name and its technological data.

The ElectrodeWorks > Project Report menu or relevant icon accesses theinitial electrode creation dialogue. This dialogue is also available by clickingthe RHM button on the top level of the ElectrodeWorks Property Page.

The dialogue has 2 sections:

General includes the information from the Project Settings dialogue and canbe modified at this time (refer to Project Settings for the explanation of theparameters)

Electrodes sectionisto select the electrodes to appear in the report.

- Reference part: select all the electrodes on this part.

- Electrode(s): select individual electrodes.



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2.4 OptionsThe Options dialogue allows you to define the default options for the naming,

display, technology and drawings.The ElectrodeWorks > Options menu or relevant icon accesses the initial



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electrode creation dialogue. This dialogue is also available from the RHMbutton on the top level of the Electrode Property Page. The dialogue iscomposed of 3 sections:

Electrode fordefault naming and coloring

- Name whichwill become the default name for all electrodes. (Or usethe default name which is dependent on the electrode holder nameselected). The Electrode name will be suffixed with _nn where nn is theindex.

- Prefix. Key-in a new Prefix.

- Suffix. Key-in a new Suffix.

- Burn faces color. Click on to change the color.

- Clearance faces color. Click on to change the color.

Blank Defaults is to set up the precision for the blankdimensions.


- Metric Round Value (Defaults to .1 mm)

- English Round Value (Defaults to .004inch)

Technology isto set up the default for the Electrode

Data dialogue.- Pattern Gap.

- Spark Gap.

- Total Gap (read-only).

- Surface finish

- EDM Z posi tion safety distance for the StartPosition calculation in Electrode Data.

Drawing dialogue defaults- Name whichwill become the default name for

all electrode drawings. (Or use the electrodename)

- Prefix. Key-in a new Prefix.

- Suffix. Key-in a new Suffix.


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- Manufacture drawing (default of the check).

- EDM drawing (default of the check mark).

- Multi Drawing Drawing per electrode/All electrodes in one drawing.

- Sheet size

- Display sheet format (default of the check mark).

Electrode Machine

- Machine Name toenter the name of the machine for which the outputmust be written.


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2.5 Add ElectrodeThis is the principle dialogue for creating an electrode. The electrode blank is

selected from a menu and placed on the part either by picking a point on thescreen or through the selection of burn faces. When using the latter methodthe electrode blank is estimated by the bounding box surrounding the selectedburn faces including user modifiable margins.

The ElectrodeWorks > Add Electrode menu or relevant icon accesses theinitial electrode creation dialogue. This dialogue is also available from the RHMbutton on the top level of the ElectrodeWorks Property Page.

Two tabs appear:

Positions (default).Define the Electrode, the Burn Area, the electrodePosition and the Holder and Base parameters. (The system brings upthe default holder library allowing you to select an electrode holder).

Settings. Modify and save the automatic sizing and positioningparameters of the electrode and optionally add a reference corner.

After creation of the electrode it will appear in the ElectrodeWorks PropertyPage under the name given. Clicking on the RHM button when selecting anelectrode will allow you access to the full range of menus which can be

activated on an electrode. These are:- Add Clearance

- Edit Electrode

- Delete

- Electrode Data

- Show/Hide Base (Toggle)

- Show/Hide Holder (Toggle)

- Isolate

- Open Part- Drawings



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2.5.1 Positions

This dialogue includes 4 sections:Electrode

In this section we define the electrode data including the blank, Electrodename, and the part on which the electrode is to be created.

- Selected blank accesses the Holder Library Blanks of standard aswell as user defined blanks (if exist), allowing you to choose anelectrode holder. This is automatically opened to the default holder forthe specific document unit.

- Electrode name defaults to the system default name for the specificelectrode or the name given in the Options menu.

- Part. Select the geometry on which the electrode will be created.

- Coordinate System. Select a coordinate system, defaults to the partorigin. All the Coordinate Systems (if any) in the part are selectableunder this drop down parameter box. This is used as the referencefrom which the electrodes are measured.

Burn Area

In this section we define the electrode direction and the burn area either byselecting faces or picking a point to place the electrode.

- Electrode work direction defines the direction of the electrode on thepart. Select an edge and optionally toggle the direction to definethe z direction of the electrode.

- Type can be Face(s), Exact Face(s) orPoint. It defines the way wecalculate and/or position the electrode.

o ForFace(s) we position the electrode around the selected facesaccording to a min max box enclosing them taking into accountx, y and z margins and a z depth as defined in the Settings tab.


o ForExact Face(s) the system creates the

electrode by projecting exactly the facesselected up to a plane of distance Bottomclearance (refer to the Setting dialogue)from the highest point of the selected faces.The system separates the different groupsof faces into multi electrodes (with oneholder). If there are holes in any group then the systemdisplays a


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warning. The user can either modify his selection to make surethat the group(s) are without holes or mark theAl low gapscheck box. The preview will update accordingly.

o ForPoint the system waits for a screen position to place theelectrode.

- Face(s)/Exact Face(s) orPick Point depends on the Type chosen.

o Face(s)/Exact Face(s) then the Faces selection box opens witha Calculate Electrode button underneath. Faces can beselected by identification or box select.

o Pick Point then a point selection box is displayed. Picking apoint displays the electrode at the specific point.

- Calculate Electrode (forFace(s) and Exact Face(s) only) will display

the electrode in the position as calculated once the faces have beenselected. Changes can be made to the selected faces or under theSettings tab and clicking on this button will recalculate the electrodesize and position according to the new parameters.

If the Face(s) or Exact Face(s) type is used then Calculate Electrode must be

pressed for an electrode to be created, although only clicking on willactually create the electrode.

Position

Modify the Electrode Coordinate System or position and rotation of theelectrode.

- There are 3 default Coordinate Systems created for the standardelectrode holders that come with the installation. For User ElectrodeHolders you can define as many as you need. The chosen CoordinateSystem will be used in the automatic EDM and Manufacturing drawingsas the reference coordinate system of the electrode relative to thedimensions and to the part.

- x/y/z/A parameters will dynamically move the electrode according tothe burned part coordinate system. If the burned part coordinate

system is not defined it will moved relative to SolidWorks coordinatesystem

Parameters

Modify the parameters of the Electrode Holder or the Base. If a User Holderhas been defined then the parameter are taken from the special .ini file definedalong with the electrode. These depend on the parameters and there names.



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- The Show Scheme buttonshows the meaning of the parameters. ForUser Electrodes, this can also be created.


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2.5.2 Settings

This dialogue has 2 sections:Estimation

In this section we define the margins of the electrode base pertaining to theautomatic electrode calculation when the Face(s) orExact Face(s) type isselected under the Position tab in the Burn Area section.

- Min. clearance (Face(s) type only)

o +X, -X, +Y, -Y and +Z are the dimensions of the margins in therelative directions (in the case of rectangular base)

o D and +Z are the margin dimensions for a cylindrical base.

- Bottom clearanceo ForFace(s) is the amount that the blank penetrates into the

material, relative to the lowest point (i.e. the lowest z value) of theselected faces on the Position tab.

o ForExact Face(s) it is the distance from the highest point of theselected groups of faces to the plane up to which the exact faceswill be projected.

- Save updates the default values to the current values.

- Show Scheme button will show the meaning of the parameters.

After these parameters have been modified the Calculate Electrode button onthe Burn Area section of the Position tab must be activated in order to takeinto account the new values, and update the electrode display.

Ref Corner

In this section we define the reference corner of the electrode and its type.This can only be done once the electrode is displayed. The different types are:

- None. No reference corner is created.

- Fillet. Create a fillet on the selected edgeo Radius of the fillet.

- Chamfer. Create a chamfer on the selected edge.

o Chamfer size.

o Chamfer angle.

In order to create a permanent chamfer or fillet, use the User Holder Library


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mechanism to create the electrode with the fillet (or chamfer).


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2.5.3 Holder Library Blanks

The Holder Library Blanks contains both standard blank libraries (3R andErowa) which cannot be deleted or modified and User Defined BlankLibraries (refer to section 2.12 to learn how to create your own ElectrodeBlank).

Clicking on the 3R (_mm or _inch) orErowa (_mm or _inch) folders opensthe libraries (folders) under which these standards are stored and you nowhave access to the different parts. Select the electrode you want and eitherdouble click or click OK.

Creating a User Holder Library

A User Holder Library is in fact a folder containing user electrodes. Click on the

Add folder icon in order to create a link to the folder,

The Pick A Folder dialogue opens. Click on to start browsing (upwardsat first) through the file structure until you reach the folder containing the user

electrode holders. Click to accept this folder which will then become partof your system.

You can add as many libraries as you need and each library or folder canhold as many electrode holders as is necessary.



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2.6 Add ClearanceThis menu becomes available once an electrode exists and its purpose is to

clear different areas of the electrode either to prevent electrode faces whichare not working from touching the surface or to clear away unwanted areas.

Activating it from the ElectrodeWorks Property Page will automatically selectthe electrode, while activating the menu from ElectrodeWorks > AddClearance or the relevant icon will request a selection of the specificelectrode.

This dialogue has 3 sections:

Electrode

- Select electrode necessary when the dialogue is opened from themenu or relevant icon.

Clearance Area

- Clearance direction is the direction that the clearance will be made.This can be an edge or a face. If its a face it cannot be a face which isto be moved (cleared).

- Face(s) are the faces to clear. The faces to clear can be any group of(disjointed) faces (usually normal or nearly normal to the clearance

direction)

- Preview plane is a check box to display the plane up to which theclearance will be made. This plane will be first created at the lowestpoint of the selected faces, and the distance entered in the Clearanceparameters will be from that point.



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Clearance Parameters

- Type of clearance.

o Tangent. The connecting faces will remain tangent.

o Normal. The connecting faces will be normal in the direction ofthe clearance.

o Draft. The connecting faces will be drafted in the direction of theclearance. In this case 2 extra parameters are displayed:

Angle of the draft.

Draft outward. Check box controlling the direction of thedraft.

- Length

o Blind enter a distance.o Through

o Up To Vertex select a point.

o Up To Surface select a face.

On validation ElectrodeWorks creates the clearances. Sometimes not all theclearances can be created and a message will notify the user of certainclearances which were not performed.

You can try to clear the material using different directions or parameters.

Once the clearance has been created it will appear in the ElectrodeWorksProperty Page under the name Clearance. Clicking on the RHM button whenselecting the clearance will allow you access the following menus relevant tothe clearance in question:

- Edit

- Delete

- Suppress/Unsuppress (Toggle)

- Rollback


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2.7 Spark GapThis menu becomes available once an electrode exists and its purpose is to

create a geometric offset on the electrode simulating the gap as a result of thespark and pattern gap. More then one spark gap can be created for anyelectrode. Each spark gap is represented by a new configuration in theelectrode part.

Activating it from the ElectrodeWorks Property Page will automatically selectthe electrode, while activating the menu from ElectrodeWorks > Spark Gapor the relevant icon will request a selection of the specific electrode.

This dialogue has 2 sections.

Total Gap

- Electrode selects the electrode on which to create the gap (default tothe current one when menu is activated through the RHM button).

- Gap defines the offset value (defaults according to the Technologysection of the Options dialogue).

Gap Face(s)

- Face(s) The system automatically selects all the burn faces which have

not been cleared through the clearance dialogue. You can delete oradd faces to this dialogue box.

On validation ElectrodeWorks creates the spark gap. A new configurationunder the electrode is created with the actual spark gap as its name.

Once the gap has been created it will appear in the ElectrodeWorks PropertyPage under the name Spark GapNN X.XXX where NN is the number andX.XXX is the actual gap.Clicking on the RHM button when selecting the sparkgap will allow you access the following menus relevant to the clearance in

question:- Deactivate

- Edit

- Delete



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2.8 Copy ElectrodeThis menu becomes available once an electrode exists and its purpose is to

find all the similar burn areas and preview an instance of the electrode on eachrecognized area. Each electrode is created as an instance and the electrodeoutput file will create the different positions for each instance. On the Electrodetree a new feature called Copy is created.

Activating it from the ElectrodeWorks Property Page will automatically selectthe electrode, while activating the menu from ElectrodeWorks > CopyElectrode or the relevant icon will request a selection of the specificelectrode.

This dialogue has 2 sections.

Electrode

- Electrode Name selects the electrode whose burn faces we analyze inorder to find similar faces in the part.

Instance(s)

- New Posit ions The system displays a reference face for every similararea and previews the electrode. You can delete instances by deleting

the reference face in this dialogue

On validation ElectrodeWorks creates an instance for each copied electrodein the SolidWorks FeatureManager tree and a Copy feature in theElectrodeWorks feature tree.Clicking on the RHM button when selecting theCopy feature will allow you access the following menus relevant to theclearance in question:

- Edit

- Delete

- Hide



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2.9 Edit ElectrodeThis menu allows you to modify the initial data from which the electrode was

created. The Selected blank, Electrode name and Part on which theelectrode was created CANNOT be modified.

Clearances which have been added to the electrode will not be modified andtherefore may become incomplete or irrelevant, which might create errors inthe SolidWorksFeatureManager.

Access this menu by selecting the electrode from the ElectrodeWorksProperty Page and clicking on the RHM button or the ElectrodeWorks > Edit> Edit Electrode menu or relevant icon. You can also select the electrodefrom the screen and click on the menu or icon.

The dialogue which appears reflects the same information as was initially usedto create the electrode including the Burn Area, Position and Parameterssections, filled in with the relevant parameters and data.

The Settings tab including the Estimation and Ref. Cornersections will alsobe updated according to the electrode being edited.

For further information regarding the parameters please check the AddElectrode menu.



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2.10 Edit ClearanceThis menu allows you to edit the clearance data for a specific clearance on anelectrode.

Clearances which have been added to the electrode appearing before thisclearance will not be modified and therefore may become incomplete orirrelevant, which might create errors in the SolidWorksFeatureManager.

This menu can be accessed ONLY by selecting a clearance under anelectrode from the ElectrodeWorks Property Page and clicking on the RHMbutton.

The dialogue which appears reflects the same information as was initially usedto create the clearance including the Clearance Direction, Face(s) andClearance Parameters filled in with the relevant parameters and data.

For further information regarding the parameters please check theAddClearance menu.


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2.11 Edit Spark GapThis menu allows you to edit the specific spark gap on an electrode.

This menu can be accessed ONLY by selecting a spark gap under anelectrode from the ElectrodeWorks Property Page and clicking on the RHMbutton.

The dialogue which appears reflects the same information as was initially usedto create the spark gap including the Face(s) and Gap Parameters filled inwith the relevant parameters and data.

For further information regarding the parameters please check the Spark Gapmenu.


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2.12 Edit CopyThis menu allows you to edit the copy feature of an electrode.

This menu can be accessed ONLY by selecting the copy feature under anelectrode from the ElectrodeWorks Property Page and clicking on the RHMbutton.

The dialogue which appears reflects the same information as was initially usedto create the copy feature including the Instance(s) sectionfilled in with therelevant reference faces of the copies electrodes.

For further information regarding the parameters please check the CopyElectrode menu.


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2.13 Electrode DataHere we allow you to add metadata pertaining to the method in which the

electrode burns the part. This data will be saved with the electrode in theSummary Information dialogue under the Custom tab and outputted to anExcel file in the current folder. The Summary Information dialogue can beaccessed it through the standard SolidWorksFile > Properties menu in thePart Document. The data is also outputted through the Project Report menu.

Access this menu by selecting the electrode from the ElectrodeWorksProperty Page and clicking on the RHM button or the ElectrodeWorks > EditElectrode menu or relevant icon. You can also select the electrode from thescreen and click on the menu or icon.

This dialogue contains 2 tabs: Data

Properties



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2.13.1 Data

Under this tab there are 2 sections, Position and Technology.

- Position of the electrode during theburn phase includes

o Start Position calculated as theEnd posit ion Max depth EDM Z position safetydistance (from the Optionsdialogue). This parameter maybe modified.

o End position (read-only) of theelectrode

o Max depth (read-only),calculated from the highest pointof the burn faces to the bottomof the electrode.

o When an electrode hasbeen copied these arrowsappear in order to page through

the different instances.



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- Technology describing the method used toburn the pockets.

o Electrode Configuration per sparkgap (for each spark gap or default ifnone)

o Electrode Technology for defaultwe include 3 technologies; RoughPre-Finish and Finish. For a SparkGap we include only the Roughtechnology.You can add technologies by using

the , delete using the andchange the order in which they

appear by using the andarrows. Each technology has a setof parameters which can be defined.

o Electrode Burn Method(Simple/Cylindrical/Spherical)

o Pattern Gap

o Spark Gap

o Total Gap (by default = the actualSpark Gap). This value is constant(can be modified); changing thePattern gap changes the Spark gapand visa versa.

o Surface finish

o Quantity of electrodes to be created.

o Material (graphite/Copper/Infiltrated Graphite/CopperTungsten/Tungsten)

2.13.2 Properties

This tab contains general information (Electrode name, Electrode folder,Source part and Source part folder) about the electrode and the part on whichit has been created. The information contained here is read-only.

.



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User Guide

2.14 Electrode DrawingsThis menu automatically creates an EDM and/or manufacturing drawing of the

selected electrode.The ElectrodeWorks > Drawings > Single Drawing menu or relevant iconaccesses the electrode drawing dialogue. This dialogue is also available fromthe RHM button on the top level of the Electrode Property Page.

The dialogue is composed of 2 sections:

Electrode section defines the information and drawing types.

- Electrode: select the electrode.

- Drawing filename: defaults to the electrode name unless modified

through the 2.1 dialogue.

- EDM drawing check box to create EDM drawing.

- Manufacturing drawing check box to create manufacturing drawing.

Sheet Format/Size section is similar to the dialogue when creating a newSolidWorks drawing.



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2.15 Multi DrawingsThis menu automatically creates EDM and/or manufacturing drawings of the

selected electrode(s).The ElectrodeWorks > Drawings > Multi Drawing menu or relevant iconaccesses the multi drawing dialogue. This dialogue is also available from theRHM button on the top level of the Electrode Property Page.

The dialogue is composed of 2 sections:

Electrode/Part section defines the information and drawing types.

- Reference part: select all the electrodes on this part.

- Electrode(s): select individual electrodes.

- Drawing filename: defaults to the electrode name unless modifiedthrough the 2.1 dialogue.

- EDM drawing check box to create EDM drawing.

o Separate drawing/One drawing. Either a separate drawing foreach electrode including the part is created or one drawing withall the electrodes and the part. In the latter each electrode (withreference dimensions) will be colored differently.

- Manufacturing drawing check box to create manufacturing drawing.

Sheet Format/Size section is similar to the dialogue when creating a newSolidWorks drawing.



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2.16 Creating User Electrode BlanksIn order to create a user electrode blanks we suggest that you look at one ofthe standard electrodes in the Blanks folder under the ElectrodeWorksinstallation path.

There are 3 files needed to define a User Electrode Blank.1. SolidWorks Part file that contains two solid bodies called Holderand

Electrode (the base of the electrode)2. An initial text file with .ini suffix that define the blank parameters.3. BMP file (optional) which is a bitmap with a drawing of the holder and

parameters.These 3 file must have the same name, and must be saved in the same folderi.e.

2.16.1 SolidWorks Part

This part contains:

Holderas drawn from the catalog you are working with. Use standardSolidWorks dimensions, relations and equations as needed.

Electrode is a rectangular or cylindrical body:

- The rectangular body should have the following dimensions: length,width, thickness and centering dimensions in the length and widthdirections.

- The cylindrical body needs only the diameterand thickness dimensions.

The electrode coordinate system is defined using the SolidWorks coordinatesystem feature. More then one coordinate system can be defined.



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2.16.2 Init ial text f ile

This text file contains the parameters of the blank as they are to appear in theparameter menu. It contains 4 sections; each section has a section header namein square parentheses:

1. Electrode Parameters - this section defines the Electrode base parameters.On the left side of the equation are the parameter names referring to the lengthAthe length center dimensionA2 the width B the width center dimension B2 andthe thickness dimension Thickness for the rectangular base; and S_Dia andThickness for the cylindrical base. The parameter names must appear aswritten. On the right side of the equation are the actual SolidWorks dimension

names as they appear in the part document and they will be the names which willappear in the Parametersection underElectrode Base of theAdd Electrodedialog.

For example a typical 1st section will look like this:

[Electrode Parameters]A=Q1A2=Q2B=T1

B2=T2

Thickness=R

Q1, Q2, T1, T2 and R are the parameter names from the SolidWorks document.In the case where the electrode base has 2 steps, then use the names DX, DYand S_Thickness for the larger step where DX and DY are the relative width andlengths of the step and S_Thickness is the thickness. Check theEDM_Holder_1 Step.SLDPRT under the 3R folder.

2. Holder Parameters - this section defines the Holder parameters.On the left side of the equation are the parameter names and on the right sidethe names of the relevant dimension in the SolidWorks part (same as before).You can add as many parameters as needed (Param1Param4, Param5 etc)The names will be used in the Parameters section underElectrode HolderoftheAdd Electrode dialog.



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For example a typical 2nd section will look like this:

[Holder Parameters]

Param1=XParam2=YParam3=ZParam4=.....

Here X, Y and Z would be the relevant SolidWorks dimension names and alsoappear in the menu.

3. Electrode Type - this section defines the Electrode type to be Box orCylinder.A typical 3rd section for a rectangular electrode base looks like this:

[Type]Type=Box

4. Coordinate Systems - this section defines the number of coordinate systemsin the blank and their names in the SolidWorks part, you can have as many

coordinate systems as you need.These names are used in the Position section of theAdd Electrode dialog.A typical 4th section looks like this:

[Coordinate Systems]CoordinateSys1=Default originCoordinateSys2=option 2CoordinateSys3=option 3

Here again the names Default origin, option 2 will appear in the Position

section (underElectrode Coordinate) of theAdd Electrode dialog.

2.16.3 BMP file

Bitmap with a drawing of the blank and its parameters (not mandatory) This BMPwill be displayed when the Show Scheme button is pressed under theParameters section of the Add Electrode dialog.


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3

3 Tutorial

The files here can be found in the Car Handle folder under theElectrodeWorks\Example Files directory.

3-1


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3.1 Create an electrode on the air holes Open HandleHousing.SLDASM from the Example Files\Car Handle

folder.

Select HandleHousing from the top level of the ElectrodeWorksFeatureManagertree and click on the RHM button and selectAddElectrode

(Or Select the ElectrodeWorks > Add Electrode menu or relevant icon

( ). The electrode library automatically opens.

At this stage you should see the standard ElectrodeWorks blanks library (withthe locks on them), and perhaps some user defined ones as well.

Choose EDM_Holder_1Step from the 3R_mm library.

Select the core as the Part.

The Burn Area section of the dialogue expands to allow you to select theElectrode work di rection.

Select an edge on the core as shown below


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3-3

Notice that the arrow must be in the z direction and that the coordinate

system points that way as well. Select the burn faces by selecting a rectangle encompassing the bosses

on the top. (If this doesnt work - depending on which SolidWorks version -then select each boss top face individually and skip to CalculateElectrode)

ElectrodeWorks 2009


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This selection automatically selects/unselects faces, which are picked orrectangle selected. Obviously we dont want to include the big top face.

Select the top face again to unselect it from the Face(s) select box.

Click on the Calculate Electrode button.

The Electrode will be placed around the faces, with a certain margin and depthas dictated in the Settings tab.

Click on the Settings tab and open the Estimation section.

Key-in the values as shown above.


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Click Show Scheme to see the meaning of the parameters. Click again tohide the scheme,

Click Save to save these values permanently.

Click Calculate Electrodefrom the Positiontabto update the electrode.

Click to create the electrode.

A feature called EDM-Holder_1 Step1-n will be created under theElectrodeWorks FeatureManager tree.

Select the feature and click on the RHM button to see the following menu.


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These are all the commands which relate to a single electrode.

Click on Isolate.

We have added the Isolate command from the standard SolidWorks menu,

since it is useful especially when creating clearances.


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3.2 Create an electrode on a bossHere we will demonstrate adding clearances

SelectHandleHousing from the ElectrodeWorks FeatureManagertree

and clickAdd Elect rode from the RHM button. Choose EDM_Holder_2Step from the 3R_mm library.

Select the core.

Select an edge on the core as before.

Select the faces as shown below.

You can alter the selection colors through the standard SolidWorks > Tools >Options dialogue, we use the Selected Item 2 and Selected Item 3colors.


The holder is too short.

Open the Parameters section and click on Show Scheme to get help on

the parameters which are divided into Electrode Base and ElectrodeHolder.

Scroll the thickness parameter to 47mm.

Click to create the electrode. The new electrode appears in theElectrodeWorks FeatureManagertree.


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Select this electrode and click on Isolate.

Next we are going to add some clearance.

Select this electrode and click onAdd Clearance

The following dialogue appears:

Select a face in the clearance direction BUT NOT a face which is to be


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cleared.

Check the direction of the clearance arrow and make sure that it points

upward, if not click on the .

Select the clearance faces as shown below. (pay attention to the smallface)

Open the Clearance Parameters section. Notice that a plane is displayed


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at the point (on the selected surfaces) of maximum distance in the directionof the clearance.

Scroll the D parameter to 5mm .

Click .

Exit the Isolate.

Now you can see the clearance in relation to the core. The Clearance alsoappears as a sort of feature under the electrode in the ElectrodeWorksFeatureManagertree.

Select the Clearance and click on the RHM button to see the menus


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related to the clearances.


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3.3 Creating an electrode for the slotHere we will show adding clearances, editing of the electrode and adding aspark gap.

SelectHandleHousing from the ElectrodeWorks FeatureManagertreeand clickAdd Elect rode from the RHM button.

Choose ER-010063 from the Erowa_mm library.

Select the core.

Select an edge on the core as before to indicate the electrode direction.



Click .


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Select this electrode and click on Isolate.

Select this electrode and click onAdd Clearance

Define the clearance parameters as shown below. (Length is Through)


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Add clearance to the other side in the same manner. You can pin this dialogueso that it becomes modal.

Now we need to do some clearance work on the top, the problem is that wehave not left enough space. In order to solve this we will edit the electrode.

Select the electrode from the ElectrodeWorks FeatureManagertree, clickon the RHM button and select Edit Electrode

Scroll the thickness parameter in the Parameters section to 54.00mm.

Click .

Now we can add more clearances.

Select the electrode and click onAdd Clearance

Define the clearance parameters as shown below.


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Now we will add to the electrode a normal clearance.

Select the electrode and click onAdd Clearance

Define the clearance parameters as shown below.


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Click .

Notice the difference between a tangent clearance and the normal clearance.

Also notice the different Clearance icon.


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Now well add a spark gap.

Select the electrode and click on Spark Gap

The following dialogue box appears.

Notice that only the burnt faces are selected.

Scroll the Gap to .2.

Click .

Zoom to bottom of the electrode to see the gap.

Select ER010063_2-1 from the ElectrodeWorks FeatureManagertree,


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click on the RHM button and selectOpen Part

ElectrodeWorks has created a new configuration called Spark Gap 0.2000 inthe electrode part.

Close the Part.


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3.4 Settings/ Options/ Report/TechnologyProject setup should be done before creating the electrodes; however, you cando it anytime afterwards as well. If you want to change the electrode names

and prefixes this must be done before creating the electrodes (or the drawings)in the Options dialogue.

We set up a project:

SelectHandleHousing from the ElectrodeWorks FeatureManagertreeand clickProject Settings from the RHM button. The date isautomatically defined (according to the locale on your OS).

Key-in Tutorial forProject name:

Key-in your name forDesigned by:

Key-in Creating electrodes on Car Handle forDescription:

Next we add Electrode Data to one of the electrodes. SelectER010063 Step_2-1 from the ElectrodeWorks FeatureManager

tree and clickElectrode Data from the RHM button.

Notice that there is only a Rough gap according to the spark gap that wecreated (i.e. .2). (Total gap is ,2 as well).

Key-in .1 for the Pattern gap automatically the Spark gap becomes .1.


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The Total gap stays the same. In fact what we call the Spark gap in thegeometric dialogue is actually the Total gap.

Select Cylindrical from the drop down box forthe Electrodeburnmethod.

Key-inPolish and then clickon to add it to the list.

Select the Polish and key-in .19 for the Pattern gap and .01 for the Sparkgap.

Select Cylindrical from the drop down box forthe Electrodeburnmethod.

Click .

Now we will create the Project Report.

SelectHandleHousing from the ElectrodeWorks FeatureManagertreeand clickProject Report from the RHM button.

Select the core as the Reference part to get a report on all the electrodesdefined on it.

Click .

An excel file report has been created by the name ofTutorial.xls and can befound in the SolidWorks FeatureManagertree under the Design Binderaswell as in the current active folder.

Each electrode has its own work sheet.


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3.5 DrawingsElectrodeWorks outputs two types of drawings (EDM and Manufacturing).The EDM includes the part and shows the positioning of the electrode and can

be outputted separately for each electrode or all on one sheet.Any group of electrodes may be selected to be drafted together.

SelectHandleHousing from the ElectrodeWorks FeatureManagertreeand clickMulti Drawings from the RHM button.

Select the CoreInsert_1 as the Reference part and check theManufacturing Drawing and EDM Drawing.

Check One drawing.

Select C-Landscape for the Sheet Format/Size.

Click .

Below is an example of the EDM drawing on one

sheet.


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3.6 Exact Face(s) and Multi-ElectrodesIn this section we will demonstrate the capability of creating electrodes exactlyon the faces selected (which partly eliminates the need for clearances) and

includes the ability to create groups of electrodes with a single holder. Open AbdeckForElectrodes.SLDASM from the Example

Files\AbdeckFinal folder.

Hide everything except CoreInsert part.

SelectAbdeckForElect rodes from the ElectrodeWorks FeatureManagertree and ClickAdd Elect rode from the RHM button menu.

Choose ER-010063 Step from the Erowa_mm library.

Select CoreInsert.

Select an edge on the core (-z direction).

SelectExact face(s) from the Type drop down list.


Click on Calculate Electrode.


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The height of the plane above the highest face selected isaccording to the Bottom clearance parameter on the Settingspage.

Modify this parameter to 15mm.

Click on Calculate Electrode from the Position page again.

Click .

The electrode is created with a single holder above a group of disjointed faces.In the next electrode we will show what happens when a group of faces have


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3-24

hole(s).

ClickAdd Electrode from the RHM button at the top of theElectrodeWorks feature manager.

Choose ER-010063 from the Erowa_mm library.

Select CoreInsert.

Select an edge on the core (-z direction).

SelectExact face(s) from the Type drop down list.

Select the faces as shown below. (Leaving the gap around the boss).

Click on Calculate Electrode. The following dialogue appears.

ElectrodeWorks 2009


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ClickOK.

Mark theAl low gaps check box.

The system shows the following preview (including gaps).

Click .


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3.7 Copy Electrode Open HandleHousing.SLDASM from the Example Files\Car Handle

folder (again)

Select HandleHousing from the top level of the ElectrodeWorksFeatureManagertree and click on the RHM button and selectAddElectrode

(Or Select the ElectrodeWorks > Add Electrode menu or relevant icon

( ). The electrode library automatically opens.

At this stage you should see the standard ElectrodeWorks blanks library (withthe locks on them), and perhaps some user defined ones as well.

Choose EDM_Holder_2Step from the 3R_mm library.

Select the core as the Part.

The Burn Area section of the dialogue expands to allow you to select theElectrode work di rection.

Select an edge in the z direction as before.

Select the four faces as shown below and change the Type to Exactface(s).


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Click .

Click withRHM button on this newly created electrode from theElectrodeWorks feature tree and selectCopy Electrode

The system analyzes the part and previews copies of the electrode (one copyin this case) allowing you to delete some of them if you wish.

Click the system creates an instance of the electrode in theSolidWorks FeatureManager tree as well as a new feature in theElectrodeWorks feature tree called Copy.

If you click on the RHM button on this new feature you can Edit, Delete or


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Hide/Show the copies of the electrode.

ElectrodeWorksUT.pdf

Documents

Transcript of ElectrodeWorksUT.pdf