Abstract: An electrical discharge machine apparatus including a guide assembly for guiding a wire in cutting engagement with a workpiece and having a working end closest to the workpiece. The apparatus incorporates a bore-type or a barrel-type current pickup in sliding engagement with the wire for transferring current to or from the wire. A ring gear is provided on a flush cup coupled to gear teeth on the current pickup in a manner whereby turning of the flush cup causes turning of the pickup for exposing a new surface to the wire. A process is provided for indexing current pickups from the working end of the guide assembly. A process is also provided for removing and replacing guide assembly components from the working end of the guide assembly.

Abstract: An apparatus for transferring electrical current to or from a moving electrically conductive wire includes a rod-shaped electrically conductive member at an angle with a normal straight line of wire travel. The conductive member is received within a bore of a support body. A sleeve is located within the support body bore and between the rod-shaped conductive member and the bore wall. The sleeve includes a channel which is coplanar with the normal straight line of wire travel and communicating with the conductive member outer surface. The channel forms a wire passageway. The moving wire travels through the wire passageway and in contact with the conductive member circular outer surface. The conductive member is rotated about its longitudinal axis for exposing multiple surfaces to the wire and the sleeve is fixed to the support body to prevent movement thereof during such rotation of the conductive member. The sleeve can be made of a non-conductive material.

Abstract: An improved apparatus for placing current on a moving wire electrode traveling between two points and over a conductive member in the form of a rod. The rod is at an acute angle with respect to the normal straight line of wire travel and its circular outer surface is in contact with the moving wire. The improved apparatus provides a mechanism whereby the conductive member is turned about its longitudinal axis thereby exposing a plurality of different contact surfaces to the wire. An index mechanism is provided for stopping the conductive member at a plurality of positions. An indicator mechanism is also provided for indicating to an operator which contact surface is currently being used. The conductive member is loaded onto the support body from the working end.

Abstract: A multidirectional electrical discharge machine wire guide that is long-lasting and easily manufactured and, wherein the guide member thereof is not subject to dislodging. The guide member is made of a wear-resistant material, such as diamond or the like, and includes a wire hole for receiving a wire electrode therethrough and guiding the wire. A non-conductive member is provided and prevents electrical current flow between the wire electrode and the guide assembly at an area substantially near the guide member. The non-conductive member can surround and support the guide member on a wire guide body or, in the alternative, may be separate from the support member.

Abstract: A current pickup assembly for placing electrical current on a moving wire electrode in an electrical discharge machine apparatus and having a normal straight line of travel. The current pickup assembly includes a current pickup having a bore therethrough for receiving the wire electrode. The bore longitudinal axis is at an angle with respect to the normal straight line of wire travel and the moving wire electrode contacts the bore contact wall therein. A pivot means is provided for selectively pivoting the carbide pickup longitudinal axis at an angle with respect to the straight line of wire travel. A rotation means rotates the current pickup about the bore longitudinal axis. In the alternative, the current pickup is supported on a gimball means for selectively pivoting the pickup about two mutually perpendicular and intersecting axes of rotation intersecting at a point.

Abstract: A guide assembly for guiding an electrical discharge machine apparatus moving wire electrode through a workpiece. The guide assembly includes first, second, and third guide members, each having a bore for receiving the moving wire electrode and a current pickup is located between the second and third guide members. The first guide member is closest to the workpiece. The first and second guide members are mounted on a guide body at respective first and second openings communicating with one another through a wire passageway through the guide body. The guide body includes a threaded portion and a nut member is used for engaging the threaded portion and attaching the guide body to the support assembly. The nut member includes a housing defining a fluid passageway and an outlet bore for creating a threading fluid stream.