Titivating a Wire EDM Machine

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stvy:
Andrew,

Am enjoying this thread..... I have to admit I really like these re-build threads with these "above garden shed sized" machines.

One thing that this thread got me wondering is if this machine is the perfect tool to make a block of blank multifix tool holders..... Do you have a project in mind for it?

Steve

awemawson:
Steve,

There is no definite object in mind. Today I've been doodling various gear profiles, just as a test piece. I'm loathe to start using it with water until I've finished one or two cosmetic changes. Several years ago I bent up replacements for several of the panels that were missing. Having now sorted that sliding cover it's time the tin work got a coat of paint ! I ordered up a RAL colour chart, and now it's arrived went to trying to match the grey it's mainly painted, but various bits are different greys :bang: I brought in the heavy guns and got the wife to decide (RAL 7044 silk grey) and placed a paint order today. It all needs etch primer as most is galvanised sheet with some aluminium.

I've been spending my time trying to sort out my 'DNC' issues - DNC refers to the coupling of the machine to a PC via (usually) RS232.

Firstly physically: up until now I've have cables trailing over the floor - I've installed conduit uprights to take the cable up into the gods and thence wired back to my desk avoiding walk ways.

Secondly software wise. I have three CNC machines and was hoping to use a single serial port on the PC via a switch box. However the DNC software, which holds configurations for each machine (which have widely different configs) insists that each have a separate COM port number.

Rather unwillingly, as the software vendors are not answering queries, I've bought a 'USB to four Serial Port' adaptor 'Hydra Cable'. Installing it proved a nightmare with ports ending up with silly numbers. I solved that (hidden previously installed USB things needed purging) only to find that it's operation was inconsistent to say the least, with ports sometimes working and other times not.

http://www.ebay.co.uk/itm/330820909340?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

The 'Hydra Cable' is on it's way back to the supplier and a (hopefully) more professional version ordered:

http://www.ebay.co.uk/itm/361060354571?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Time only will tell :bugeye:

Back to your question - Yes I'm sure that the profile of a Multifix holder could be cut relatively easily - It would be a very slow way of doing it - presumably they only need to be EN8 or some such decent engineering steel that could be cut on a CNC mill. Now if you needed it in tool steel in the hardened state it would be a good choice

AdeV:
Multiple COM ports always were a nightmare on PCs. COM1-4 were typically available in the BIOS, but COM1 & 3, and 2& 4 used to share interrupts, so realistically you could only reliably use 2 at a time anyway...

It _used_ to be possible to buy add-on cards with additional COM ports attached (with their own interrupts & memory addresses), but try find one that goes in a modern PCIe slot. Assuming you've even got a computer with a PCIe slot these days - most laptops certainly don't have room for such things.

Q: Wouldn't you be better off running 3 salvaged laptops (=cheap on fleabay), and a KVM splitter? That's what I'd do. If you want a KVM splitter, I've got an 8-port PS/2/VGA one I no longer use going begging. Good quality Adder one too.

awemawson:
Ade,

I'd initially intended to have a small form factor Compac (as I have a pile of them!) at each CNC machine, and whiz files around by Ethernet only using RS232 for the final link to the machine - but it's a space issue at the machines, so I decided to concentrate everything on one desk top (another HP / Compac SFF) actually at my desk.

We'll see how the replacement USB -> 4 x serial works :med:

AdeV:
What expansion port(s) do you have in those SFF machines? If they'll take PCI cards, you can fit one (or two) of these: http://www.ebay.co.uk/itm/261083309079

And then you've got 4-6 serial ports (including the 2 on the machine)....

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