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Plan the process

Process plan from a 3D model

Size the raw block, then plan wire cut, VMC or sparking one step at a time.

Open the workspace to keep the part, the electrodes, and the process choices on one screen.

Open a 3D model

STEP, STP, STE, IGES, IGS, SolidWorks SLDPRT, SLDASM, ASM or PRT, 3ds, 3dm, or an ASCII DXF with 3D faces. The file stays in this browser.

The picker lists every file.

Saved quotations

Each row stays in this browser. Download a Word file and edit it before you send it. Approve a row, then open that quotation as the process plan. Nothing is uploaded.

No quotation is saved yet. Finish the steps, then use Save quotation.

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How a quote starts from the raw block

Open the model, read the envelope, and set the raw material. A square part suggests a block. A round part suggests a round bar. A tube suggests a pipe. The suggestion adds 2 mm of stock. You can switch that suggestion to a block, a round bar, or a pipe, and choose the axis of the bar or pipe. The isometric view shows that material around a slightly see-through part, and each following step marks where that process is applied. Length is X, width is Y, and height is Z. The first two operations are on that stock: mill the outer, then grind the outer. Each one is confirmed before the next.

A profile that runs straight through the part, and leans at most 13° from the wire, is set as wire cut. The 1st setting runs the wire along Z, the way the model stands. The 2nd setting runs it along X. The 3rd setting runs it along Y. Those are the second and third fixture settings for a through linear profile. Click any other surface and choose VMC or sparking. That choice stays on the screen. Depth control is the VMC or the sparking machine. The planner does not pick that for you. A long straight inner corner is different: a milling cutter leaves its own radius there, so the slot would not be sharp. Those corners are suggested as sparking, and you still choose the process on that surface. A plate slot that does not run through the whole part can be wire cut when you select it. The reading shows the taper to set. The planner does not add a weld between separate discs. A round hole that runs through the middle is wire cut on its own, and that hole is a different step from the slots. The surface you choose stays marked: VMC in blue, and each sparking in its own color, so a second sparking is still visible. A dot and a line sit on the place itself. Select a surface to look at that place.

When every open surface has a process, the plan becomes a rough quotation. Wire-cut time is the cut area divided by a mid-range rate for an Electronica Hi-Tech or Fanuc machine in steel with brass wire. VMC time, including the outer milling, uses a mid-range Haas removal rate. Sparking asks you to choose graphite or copper, then prices the electrode blank and estimates the burn. Grinding is a light skim on a surface grinder. Change the rates to your shop. Pick the job metal before the stock is accepted. EN8 is one example, at an example price per kilogram you can change. The quotation includes that raw mass, the electrode blank, and a rough sparking time. Save the quotation in this browser. Download a Word file and edit it before you send it. An approved row in the saved list opens again as the process plan. Cutters and inspection are extra.

The reading comes from the triangles of the opened model. Touching regions can be read as one. Confirm every step on the part before the quote is sent. Nothing is uploaded. Measure a bore or a face in the CAD Viewer. Spark gap and skim stock are described in wire EDM allowance.

Frequently asked questions

When does the planner suggest wire cut?+

When a profile runs through the part and the walls lean at most 13° from the wire, and the section changes in one straight line. That opening is set as wire cut: the 1st setting along Z, the 2nd along X, or the 3rd along Y. A steeper through profile or a bulge is not set as wire cut. A plate slot that stops on a face can still be chosen as wire cut, and the planner shows the taper to set. Other surfaces are VMC or sparking.

What are the 1st, 2nd and 3rd settings?+

They are fixture settings for the wire. The 1st setting runs the wire along Z, upright as modeled. The 2nd setting runs it along X. The 3rd setting runs it along Y. A through linear profile within 13° of one of those axes is planned on that setting.

Why do milling and grinding come first?+

The quote starts from raw material around the part: a square block, a round bar when the part is round, or a pipe when the part is a tube. You can switch that suggestion to a block, a round bar, or a pipe. The outer is milled, then ground to the finished size. The isometric view marks that stock, then the outer, then each surface you select. VMC and each sparking stay marked on their own surface, so a second sparking remains visible. Through openings are already wire cut. Click any other surface and choose VMC or sparking. That choice stays on the screen.

Is the model uploaded?+

No. The file is read in the browser. The plan is a mesh reading for a quotation, so each step should be confirmed on the part before it is sent.

How are the wire, VMC, and sparking hours estimated?+

Wire-cut time divides the cut area by a mid-range rate for an Electronica Hi-Tech or Fanuc machine in steel with brass wire. VMC time, including milling the outer, divides the estimated metal removed by a mid-range Haas rate. Sparking asks for graphite or copper, then prices an electrode blank around that region and estimates the burn. A short setup allowance is added for each machine. Change the rates to your shop. A sharp inner corner is suggested as sparking because a cutter leaves a radius. You pick the job metal, for example EN8, and the raw mass is included with the electrode blank. Save the quotation in the browser or download a Word file. An approved quotation can be opened as the process plan. Cutters and inspection are extra, and the figure is a planning estimate from the display mesh.

Related engineering tools

CAD Viewer (opens STEP, IGES, SLDPRT, SLDASM, ASM, 3DS and Rhino), CAD Converter (writes STEP, IGES, or exact DXF edges), STEP file weight, metal weight, H7, tap drill, unit converter.

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