Wire EDM Machine Operation Chapter 1
Copyright November, 98 Page 1-2 Sodick Inc.
.006 Diameter Wire (.17mm or .18mm wire guide)
.008 Diameter Wire (.21mm or .22mm wire guide)
.010 Diameter Wire (.26 mm or .27mm wire guide)
.012 Diameter Wire (.31 mm or .32mm wire guide)
NOTE: There are 2 wire guide sizes for each wire diameter. The first size listed is for
ultra-precise machining and the second size is for precise machining.
The upper and lower wire guides must match the wire diameter choice. When you change
wire diameters, you change the upper, and lower wire guides and also the pre-guide on
the threader.
AWT Upper Guide
On machines with AWT, the standard upper guide is made of sapphire and is a split
design. Sizes are etched in Japanese. When installing these guides, make sure the large
lead-in taper is facing up and the guide with the steel insert is the rear guide. There is also
available as an option a split diamond guide. The front half of these split guide moves in
and out to allow the AWT pipe to pass through the upper head when threading the wire.
The front half of this guide can be removed and reinstalled in the middle of a job and the
wire will still be vertical and in true location.
The lower wire guide is a one piece diamond guide. It is a self aligning screw on type
guide. This guide can be removed and reinstalled in the middle of a job and the wire will
still be vertical and in true location. Sizes are stamped in metric (see page 12-5).
WIRE TYPE
The second consideration is what type of wire to use. Sodick has developed the power
supply to cut at satisfactory speed with plain brass wire. Stratified and coated wires are
needed to cut at maximum speed . Hard brass wire works best for all general cutting
needs and for reliable AWT operation. Use half hard wire when taper cutting 10° to 15°,
and soft wire when cutting 16° or greater. Also look for a wire brand that stays straight
when unwound from the wire spool, this will give the best AWT operation.
Spool sizes the machine uses are the P-5, 11Lb or P-10, 22Lb.
RECOMMENDED WIRES
HARD BRASS WIRE
Sodick KHS Wire: Available from the Sodick Parts Dept.
Specialty Wires
Gisco Mega Cut D: Diffusion annealed speed cutting wire (up to 20%
faster than plain brass)
Gisco Mega Cut W: Very soft wire, use for 22° or larger taper cuts.
Gisco Mega Cut A: Use for .004” and .006” diameters
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