1.

0 TITLE:
Production Technology on Non-Traditional Machining [Electrical Discharge Machining (EDM)]

2.0 OBJECTIVE:
-To design a basic NC program for Electrical Discharge Machining (EDM) wire cut.
- To cut a product using the Electrical Discharge Machining (EDM) wire cut.

3.0 INTRODUCTION:

Electrical discharge machining (EDM), sometimes colloquially also referred to as spark

machining, spark eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing
process whereby a desired shape is obtained using electrical discharges (sparks). Material is
removed from the workpiece by a series of rapidly recurring current discharges between
two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the
electrodes is called the tool-electrode, or simply the "tool" or "electrode", while the other is
called the workpiece-electrode, or "workpiece".
When the distance between the two electrodes is reduced, the intensity of the electric field in
the volume between the electrodes becomes greater than the strength of the dielectric (at least in
some point, which breaks, allowing current to flow between the two electrodes. This
phenomenon is the same as the breakdown of a capacitor (condenser) (see also breakdown
voltage). As a result, material is removed from both electrodes. Once the current stops (or is
stopped, depending on the type of generator), new liquid dielectric is usually conveyed into the
inter-electrode volume, enabling the solid particles (debris) to be carried away and the insulating
properties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode
volume is commonly referred to as "flushing". Also, after a current flow, the difference of
potential between the electrodes is restored to what it was before the breakdown, so that a new
liquid dielectric breakdown can occur.

Wire-cut EDM

The wire-cut type of machine arose in the 1960s for the purpose of making tools (dies)
from hardened steel. The tool electrode in wire EDM is simply a wire. To avoid the erosion of
material from the wire causing it to break, the wire is wound between two spools so that the
active part of the wire is constantly changing. The earliest numerical controlled(NC) machines
were conversions of punched-tape vertical milling machines. The first commercially available
NC machine built as a wire-cut EDM machine was manufactured in the USSR in 1967.
Machines that could optically follow lines on a master drawing were developed by David H.
Dulebohn's group in the 1960s at Andrew Engineering Company for milling and grinding
machines. Master drawings were later produced by computer numerical controlled (CNC)
plotters for greater accuracy. A wire-cut EDM machine using the CNC drawing plotter and
optical line follower techniques was produced in 1974. Dulebohn later used the same plotter
CNC program to directly control the EDM machine, and the first CNC EDM machine was
produced in 1976.

4.0 APPARATUS:
EDM wire cut Machine, Aluminium workpiece, NC Programming, copper wire electrode.

EDM Wire Cut Machine

4.1 INDUSTRIAL APPARATUS:

Wire Copper Electrode

1. Mitsubishi EDM Wire Cut

2. Electrochemical machine(ECM)

3. CNC Laser Cutting Machine

5.0 EXPERIMENTAL PROCEDURE:

1. Starting a CNC EDM wire cut machines.

2. Write a CNC program.
3. Prepare and display graphics using graph paper.
4. Coordinate offset coordinate position of the wire cutting and die on the
workpiece.
5. Programming and cutting operations on the machine.
6. Stop the machine CNC wire cut EDM

Safety precautions when handling EDM machines

1. Make sure there are no leaks in the tank dielectric liquid tank hose and pipe connections.
2. Make sure a fire extinguisher near the machine for use in emergencies.
3. Make sure the materials are installed in areas where the right job.
4. Make sure the electrodes are not touching the thing work.
5. Make sure the cutting wire is not touching things work.
6. Make sure each cable there is no leakage.
7. Clear oily liquid that is in place the working substance during the installation process.
8. Clean all dirt in the tank desk and storage tanks.
9. Wear appropriate clothing while using machines.

6.0 RESULTS:

NC PROGRAMMING
N100 G00 G21 G90;
N102 G92 X0. Y10. I15.;
N104 M60;
N106 M83;

N108 M81;
N110 S101 D1;
N112 G41 G1 X15. Y5.;
N114 G01 X10. Y5.;
N116 X5. Y10.;
N118 X15.;
N120 G03 X15. Y15. J2.5;
N122 G01 X10. Y15.;
N124 X10. Y20.;
N126 X15.;
N128 G03 X15. Y25. J2.5;
N130 G01 X5. Y25.;
N132 G01 X10. Y30.;
N134 X21. Y30.;
N136 G02 X15. Y5.;
N138 G01 X15. Y5.;
N140 G40 X0.;
N142 M50;
N144 M30;

7.0 DISCUSSION & ANALYSIS:

In the process of using Electrical- Discharge Machining (EDM) wire cut machine, we are
using copper wire of 0.2mm diameter to cut Aluminium plate which has thickness 5mm. At the
end of the process, we got the end product with the desire shape which is the shape above. The
process to cut the workpiece took about 15 minutes. After we get the real product, we do some

analysis regarding its dimensional. We have measure the output and get the same measure as the
drawing. Therefore, we know that EDM wire cut machine could produce accurate product base
on the drawing. As our product is small with 30mm x 30mm and the machine could cut it, so the
machine is capable to cut small and complex shape.
Wire EDM cutting, also known as electrical discharge machining, is a process that uses
an electrically energized thin wire to slice through metal. Wire EDM cutting uses rapid,
controlled, repetitive spark discharges from the wire to the work piece, thereby eroding the metal
away. The work piece must be electrically conductive. Wire EDM can cut material thickness
from only a few thousandths of an inch to several inches. Custom tooling is generally not
needed. Wire EDM cutting can provide high dimensional accuracy for close fitting parts. The process
can make sharp inside corners. The machine also can cut most any simple or complex 2D shape
including cutouts and thin walls, intricate openings and sharp inside corners. Cost optimization options
for wire EDM cutting include:

Reducing cut surface area

Stacking parts during cutting

Minimizing the number of holes and cutouts

Creating holes by providing a small gap connecting the hole to the outer edge.

Wire EDM Design Considerations

Edges are smooth but matte.

Typical surface finish is between 16 and 64 microinches.

The edges of the finished work piece will have virtually no burrs.

Kerf width typically ranges from 0.001" to 0.012".

Sharp internal corners will be slightly rounded (typically with radius ~.008").
7.1 Advantages and Disadvantages of Edm-Wire Cut

EDM-Wire Cut also has its own particular advantages. The machine capability is cutting
materials regardless of its hardness. EDM-Wire Cut is much faster than EDM. It can cuts
intricate shapes, narrow slots, small products and others. Furthermore no burrs generated during
the process. The wire electrodes used are much cheaper than shaped electrodes in EDM.
Nowadays, EDM-Wire Cut cables to cut tapered shape products.Electrical Discharge Machining
or EDM is a highly accurate method of part production. Wire EDM technology is essential for
higher tolerance parts and repeatable tooling. Tolerances are held to .0002" in our temperature
controlled facility. Achieving high accuracy and tighter tolerances is essential for many
industries such as aerospace, medical, injection molding and tool and die.
Besides that, EDM-Wire Cut also has disadvantages. The EDM-Wire Cut Machine more
expansive than other machine. High skills are required to handle the machine. The work piece
only conductors can be machine. EDM-wire cut have slow material removal rate (MRR) and less
flexible compared others machine.

8.0 CONCLUSION:

The desired objectives have been successfully implemented. Any guidance given by
lecturers is very useful and effective. We have been successfully using CNC EDM wire cut
machine with skill and know how to enter the program and run machine for the design of the
products made. In addition, we also know how to apply the program to form the G-code to get
the result as above. All that was taught to us was really helpful to our advantage as we go into the
working world later.

9.0 RECOMMENDATION:

One of the most important recommendations to buy EDM-Wire Cut is that due to the ability
to cut any material regardless of its hardness but only conductor materials. Besides that, the
absence of all-mechanical forces makes it possible to machine fragile parts without distortion. It
is so recommended due to its high accuracy thus producing a high quality product. Less labour is
required to operate but must be well trained. This will reduce overall production cost and
increase profit of the company.

10.0

REFFERENCES:

Krar, Stephen F. and Gill, Arthur R. (2003) Exploring Advanced Manufacturing Technologies, Industrial
Press Inc.

Jameson, E. C. (2001). Electrical Discharge Machining

www.thomasnet.com/articles/custom.../Wire-Cut-EDM
www.edmmachining.com/wire_edm.htm
Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994). Manufacturing Processes Reference Guide.
Industrial Press Inc.