One thing we do far too much of is turning round holes into square holes. Typical size is between 1/8" and 1/4", multiple parts stacked 1-3" high. We generally undersize the drill by ~20 thou and our 10 thou wire makes 3 passes around the square. However, the corners fall through and cause problems about 75% of the time.
We have read https://edmproud.com/the-most-effective-methods-for-holding-and-retaining-slugs/ but our parts and slugs are too small for glue, clamps or magnets. I am interested in the “Slug Ejection via Programmable Flushing” - Does anyone have any experience doing this on a Makino U3 or similar?
We have also tried roughing passes that make an X shape to cut into the corners first and remove material but it isn’t always successful either. Seems like dealing with “Backward movement exceeds limit during machining” errors is faster than any additional roughing passes.
Any other suggestions anyone? Thanks in advance!