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If you're not going to buy punches and do it right, at least use something that is through hardened like a drill or reamer blank.

You realize you can build the die in sections too right?

".030" soft aluminum"

Not good enough ... what grade and T#?

You may get away with 4140PH ... or you may have to use A2 @ 58/60 Rc.

Check with EDM Network, they used to be very good helping us with the refurbished HS-300 we bought from them.

It's been a few years, but can't hurt to ask.

Not sure what components you are using, but the guides in our Drill-20 are about 20x larger than the guides in our Robofil and CUT wire-edm's.

More than that, how do you intend to mount them so...

Don't forget to allow for your lead-in either.

Hastelloy B, C, X?

Never had a problem with sheet or bar stock in our Charmilles and Brother machines.

Suspect you may have dirty and/or oddly shaped castings that are the source of you...

Don't know about your Fanucs, but I've seen it happen several times on our Brother HS-70A's.

You have to be very careful greasing the Z-axis.

Over vigorous application will pop the seals, and...

You need to give us some more information to work with here.

What make/model jet?

What hp pump/intensifier are you running?

What pressure should it be running at? (45k seems kind of low to...

Die Sets - Custom Die Sets, Standard Die Sets, Cast Die Sets - Anchor Danly

The problem is going to be finding a die set that will handle 8" deep channel that will fit in your 5 ton kick press ......

I am not familiar with your machine but:

In cutting any kind of taper via wedm it is critical the machine "know" where the program (X/Y) plane is.

When doing 4-axis cutting it is also critical...

Sounds like you got it fixed then ... ?

Good job.

From your description it seems to more resemble the Robofil machines.

They are non-submerged machines so turning on contact wetting for the...

If you took the upper head apart and didn't see any fragments that's good.

Check your unspooling pulley, the aluminum one @ the green belt, for an excessive groove.

If .01" wire has grooved...

I'm not familiar with the 240CC but, just to be sure:

Did you also change to .004" guides?

Did you put new pinch rollers, contacts, and belts on?

Did you make sure the correct .WIR and .TEC...

Machine: make, model?

Material: type, thickness, state?

Mode of failure: won't cut with low pressure, won't switch to low pressure, etc.?

Please provide more information ...

Not sure about your area but in some places they consider the used garnet hazardous waste because of the metal content, better look into that.

If your going to do a lot of cutting ... that tank...

Absolutely, if you are cutting the same profile one combination will make your part to the correct dimensions and the other will make it under/over size by twice your kerf width.

Just remember to...

(Sorry for the delay, Friday was very busy and I was not well Saturday.)

OK, I'm not familiar at all with Pronest but it looks very similar to the Flow software.

If that is the case either the...

1. You say you are trying to grind a c'sink, then list a variety of carbide tools you have tried to use. Which is it ... grind or cut?

2. You say the material is "very hard". How hard is it?

3....

While your lead-in line generally determines which side of the profile/toolpath your kerf will be on, whether it is "to the left" or "to the right" is dependent on which direction you are cutting.
...

That's going t depend a lot on just what it is you are trying to do, and what you are trying to do it in ...

Here's a good place to start:

Harvey Tool - Coating Chart for Ferrous and...

Kerf is the width of the slot cut by the jet.

What you really want to know about is "offset" which determines which side of the tool-path the jet cuts on, the left or the right, and how far off...

... I thought slavery was outlawed in Switzerland.

Do you, perhaps, mean surfboard?

Where does one surf in Switzerland anyway?

Stop threatening and sue them already.

Which direction(s) are you cutting on your passes?

I always had better results climbing the roughs and doing conventional on the springs.

Sometimes I would have to do one spring climbing and...

We're talking about a die here ...

An acceptable finish will never be achieved turning or milling through an interrupted cut.

Rough turn or mill and grind, as already suggested, is the solution...

If you can still read the original floppies on your PC try this ...

Instead of copying the files, image the diskette and then copy the image back to a new floppy.

Not familiar with Sodick.

How old are your machines?

What format disc do they require?

Some older machines will not read the "new" 1.44 MB floppy discs.

Have you tried formatting them as...

OK, that's a start.

Have you called ONA?

I have no experience with ONA machines but ...

We have experienced a similar problem on our Charmilles machines.

The culprit was a stuck key on...

Make?
Model?
Year?

Please rephrase your question.

We cannot help if we cannot understand what you are asking.

Also, please tell us if you have the Charmilles or the Fanuc controller.