INSTRUCTIONS FOR WIRE EDM MACHINING OF SOMMA RESHARPENABLE QUICK CHANGE INSERTS 3/8" THICK FOR USE IN RQCMS-2 AND RQCMS-3 SHAVE TOOL HOLDERS

ALSO INSERTS MUST BE A PARALLELOGRAM FORM, THEREFORE, BACK SURFACE MUST ALSO BE AT 0 DEGREES PARALLEL TO FORMED FACE.

INSERTS ARE OVERSIZE ON LENGTH AND WIDTH TO ALLOW FOR EDM WIRE THICKNESS AND ARE RECESSED ON BACK END FOR MOUNTING IN THE GRINDING FIXTURE SO THAT BACK EDGES CAN BE MACHINED AT THE SAME TIME AS FORMED SURFACE WITHOUT REMOVING FROM FIXTURE.

FIXTURE IS SUPPLIED WITH TWO WEDGE CLAMPS:
CLAMP MARKED "4" IS USED WHEN HOLDING 3 INSERTS AND 1 SPACER.
CLAMP MARKED "3" IS USED WHEN HOLDING 3 INSERTS ONLY.

INSERTS SHOULD BE CAREFULLY MOUNTED IN FIXTURE WITH APPROPRIATE CLAMP AND TIGHTENED SECURELY WITH CLAMP SCREW. BE CERTAIN THAT INSERTS ARE FULLY SEATED IN BOTTOM BASE OF FIXTURE. THIS IS IMPORTANT BECAUSE IF FACE ANGLES ARE NOT EXACTLY 0 DEGREES, THERE MAY BE DIAMETRAL DIFFERENCE ERRORS IN THE WORKPIECE.

ALSO, INSERTS SHOULD BE IN ALIGNMENT WITH EACH OTHER AND CLEARANCE ANGLE CUTOUT IN INSERT SHOULD BE CENTERED ON FIXTURE WITH EQUAL SPACE ON BOTH SIDES OF FIXTURE BODY.

WHEN WIRE EDMing, WE RECOMMEND PLACING THE SPACER IN THE MIDDLE POSITION AND MACHINING ALL THE WAY AROUND THE FORM STARTING ON THE LEFT SIDE IN THE SPACE BETWEEN THE FIXTURE AND THE RECESS IN THE INSERT AND ENDING IN THE GROOVE ON THE OPPOSITE SIDE (SEE SAMPLE PRINT ATTACHED). THIS GROOVE PREVENTS OUTER SHELL FROM BREAKING OFF AND JAMMING WIRE. SHELL SHOULD BE BROKEN OFF MANUALLY AND ANY REMAINDER GROUND AWAY SO THAT IT DOES NOT INTERFERE WITH SEATING OF INSERT IN HOLDER.

FOR RQCMS-2 HOLDERS:
IN ORDER TO SIMPLIFY ADJUSTMENT OF THE INSERT SLIDE WHEN CHANGING OVER FROM JOB TO JOB, HOLDERS ARE DESIGNED SO THAT A 1.125" LONG INSERT WILL CUT TO 1/8" DIAMETER (.125" BASE DIAMETER). THEREFORE, ALL INSERTS SHOULD BE DESIGNED USING .125" AS THE BASE DIAMETER. THIS WILL CAUSE THE INSERT TO BE CORRESPONDINGLY SHORTER FOR ALL OTHER DIAMETERS, OR SLIGHTLY LONGER IF FORMING A DIAMETER SMALLER THAN .125".