DESIGN AND DEVELOPMENT OF ROTATING

WORKPIECE HOLDING MECHNAISM IN

ELECTRIC DISCHARGE MACHINING

DISSERTATION
SUBMITTED IN PARTIAL FULFILMENT OF THE
REQUIREMENT FOR THE AWARD OF THE DEGREE OF
Integrated Dual Degree
in
Mechanical Engineering
(Production Engineering)
Submitted by:
Sahil Dev
Under the Supervision of
Dr. U.S. Rao
DEPARTMENT OF MECHANICAL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY
(BANARAS HINDU UNIVERSITY)
VARANASI 221005

Roll No. : 10406EN016

Enrolment No. : 322603

DEPARTMENT OF MECHANICAL ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY
(BANARAS HINDU UNIVERSITY)
VARANASI - 221005

CERTIFICATE
This is to certify that the dissertation entitled, DESIGN AND DEVELOPMENT OF
ROTATING WORKPIECE HOLDING MECHANISM IN ELECTRIC DISCHARGE
MACHINING, submitted by MR. SAHIL DEV in partial fulfilment of the requirements
for the award of Integrated Dual Degree (B.Tech + M.Tech) in Mechanical Engineering
(Production Technology) of IIT (BHU) Varanasi is a bona fide work carried out by him under
my supervision and guidance.
The matter embodied in this dissertation has not been submitted in part or in full to this
institute or to other institutes for the award of any other degree or diploma. If accused of any
involvement in plagiarism activities, Mr Sahil Dev will be responsible as the supervisor has
no facility to check the same. Mr Sahil Dev has accepted to this.

Dr. U.S. Rao

Dr. A. K. Agrawal

Supervisor, Assistant Professor

Professor and Head of department

Department of Mechanical Engineering

Department of Mechanical Engineering

IIT (BHU) Varanasi - 221005

IIT (BHU) Varanasi 221005

DECLARATION
This is to certify that the dissertation entitled, DESIGN AND DEVELOPMENT OF
ROTATING WORKPIECE HOLDING MECHANISM IN ELECTRIC DISCHARGE
MECHANISM, submitted to Department of Mechanical Engineering, IIT(BHU) Varanasi
in partial fulfilment of the requirement for the award of the Integrated Dual Degree in
Mechanical Engineering (Production Technology) of IIT (BHU) Varanasi, is the result of
research work done by me under the supervision of Dr. U.S. Rao, Department of Mechanical
Engineering, IIT (BHU), Varanasi. I have not submitted the same earlier to this or any other
institute for the award of any degree.

Place : Varanasi, India

Date : 21 June 2016

Sahil Dev
10406EN016

ACKNOWLEDGEMENT
I have a great pleasure and distinct privilege in expressing my deep sense of gratitude and
indebtedness to Dr. U.S. Rao, Assistant Professor, Department of Mechanical Engineering, Indian
Institute of Technology (Banaras Hindu University), Varanasi for his inspiring guidance, invaluable
discussions and for giving me utmost freedom and flexibility throughout the progress of this
dissertation work.

I am indebted to Dr. A.K. Agarwal, Professor and Head of Department of Mechanical

Engineering, Indian Institute of Technology (Banaras Hindu University), Varanasi for
providing the necessary conductive atmosphere and departmental facilities that lead to the
partial completion of the present work.
I am very much grateful to my parents for their beloved blessings for the completion of this
project in a most beautiful way. Last but not least, I thank the almighty for his grace and also
helping me in numerous ways to complete this project in this grand manner.

Sahil Dev
10406EN016

ABSTRACT
Electrical discharge machining (EDM) process is one of most popular amongst the non-traditional
material removal techniques with applications in a broad variety of industries such as die and mold
making, aerospace, automotive, and medical and other industrial applications. The machining
process involves controlled erosion of electrically conductive materials by the initiation of repetitive
electrical spark discharge between the tool and the work piece separated by dielectric fluid. A spark
gap is maintained in between the tool and the work piece to cause the spark discharge.
In the present study we designed, developed and fabricated a mechanism to provide a rotating motion
to the workpiece. The design of the setup is done considering the all mechanical and electrical forces,
which will be acting on the setup and their possible failure condition. Experiments has been done to
compare the machinability of the conventional Electrical Discharge Machining with the rotatory
aspect of the workpiece. In our experiments we studied that in convention EDP process with increase
in current, increase in Material Removal Rate and Tool Wear Rate is obtained and with increase in
Ton Time, increase in Material Removal Rate and decrease in Tool Wear Rate is obtained. Taper in
the tool shape is studied by considering the data obtained from the experiment for tool wear for
copper tool, used for machining of AISI H13 in EDM. However there has been a major setback i.e.
our inability show the actual working of the setup on EDM machine in the production lab.

ii

PREFACE
Electrical-discharge machining (EDM) is extensively used for high strength materials. A major
advantage of EDM is that the tool and the workpiece do not come into contact, thus eliminating
chatter and vibration problems and allowing small or thin components to be machined without
mechanical force. The efficiency of the EDM process depends the process parameters such as pulse
on-time, pulse off-time, spark gap, electrode material, supply current and voltage. Material removal
rate and tool wear are two parameters to check the efficiency of EDM process. In this present study,
an analysis of workpiece rotation on the process parameters is made.
Here, the work is completed in 7 parts:

Part A: Introduction The chapter mainly gives an overview of Electric Discharge Machining
Process, its difference from conventional machining process, various advantages over conventional
process of machining with respect to cost, strength, ability to offer complicated profiles etc.

Part B: Literature Survey Under literature survey detailed discussion is made on the
previous work done on EDM process. A detail study of process parameters effects on the machining
efficiency, tool wear rate and material removal rate has been done in this section.

Part C: Design & Developments The chapter covers the design of whole setup. In this
chapter all the calculation has been shown for the each components of setup which includes spur
gear selection, selection of DC motor, shear force analysis for the dielectric, torque calculation for
the DC motor, failure condition for the base rods and the mounting plate and selection of collar
bearing. This chapter also include the material selection for the each component.

Part D: Fabrication of various parts This chapter includes the fabrication of the whole
setup. All the machining process which is used to fabricate the setup is been shown in this chapter.
The various machine used to perform different machining process is also mentioned in this chapter.
Due to manufacturing limitations the original design has been modified while fabricating.

iii

Part E: Experimental Analysis In this chapter experiments is been carried out to find out
the effect of process parameters on the material removal rate and tool wear rate. Also, experiment is
done find out the change in the cylindricity of the circular tool with high depth to tool diameter ratio
or drill machining.

Part F: Result and Discussion In this chapter a comparative study is been made how pulse
current and pulse on-time affects the machinability of the Electrical Discharge Machining process.
Also, studied the taper problem in work tool in high aspect ratio machining.

Part G: Conclusion and scope for future work Based on the fabricated setup, literature
survey and experimental analysis the conclusions made are represented here. Further scope of work
in this subject and the application of fabricated setup is also mentioned.

iv

NOMENCLATURE
DP

Pitch diameter

No. of teeth

Minimum bore radius

RPM

Module

Spur gear thickness

Modulus of elasticity

Area moment of inertia

le

Effective length

d1, d2

Diameter of base rods

l1, l2

Length of base rods

Viscous shear stress

Dynamics viscosity of dielectric

Angular velocity of spur gear

Torque

Ton

Pulse on-Time

Pulse Current

LIST OF FIGURES
Fig. A.1.2a: Spark occurs within a column of ionized dielectric fluid.
Fig. A.1.2b: Thermal energy of the spark.
Fig. A.1.3: Spark on, workpiece and tool material vaporized
Fig. A.2.1: Die sinker sparking from electrode end.
Fig. A.2.2: Wire cut sparking from electrode end.
Fig. C: Design of whole setup made in Solidswork package.
Fig. C.2.1: Spur gear design made in Solidswork package.
Fig. C.2.2: Design of base rods made in Solidswork package.
Fig. C.2.3: Planetary geared motor 175RPM 24V 100W.
Fig. C.2.4: Workpiece holder design made in Solidswork package.
Fig. C.2.5: Gear hub design made in Solidswork package.
Fig. C.2.6: Gear mounting plate design made in Solidswork package.
Fig. C.2.7: Motor mounting plate design made in Solidswork package.
Fig. C.2.8a: Technical specification of single row radial ball bearing.
Fig. C.2.8b: Design of collar bearing made in Solidswork package
Fig. C.2.9: Design of base made in Solidswork package.
Fig. D.1: Fabrication of spur gear.
Fig. D.2: Fabrication of base rods.
Fig. D.3: Fabrication of workpiece holder.
Fig. D.4: Fabrication of gear hub.
Fig. D.5: Fabrication of gear mounting plate.
Fig. D.6: Fabrication of motor mounting plate.

vi

Fig. D.7: Fabrication of base.

Fig. E.1a: Mechanical and physical properties of mild steel.
Fig. E.1b: Mechanical and physical properties of copper.
Fig. E.2.3: Stereo zoom microscope.
Fig. E.3.3a: Taper measurement in circular tool.
Fig. F.1a: Material removal rate vs current graph.
Fig. F.1b: Tool wear rate vs current graph.
Fig. F.2a: Material removal rate vs Ton time graph.
Fig. F.2b: Tool wear rate vs Ton time graph.
Fig. F.3: Taper vs depth of cut graph.

vii

LIST OF TABLES
Table C.1: Bill of materials.
Table C.2.1: Spur gear specifications.
Table E.3.1a: Observation table for MRR vs current.
Table E.3.1a: Observation table for TWR vs current.
Table E.3.2a: Observation table for MRR vs Ton time.
Table E.3.2b: Observation table for TWR vs Ton time.
Table E.3.3a: Observation table for depth of cut vs machining time.
Table F.3: Observation table for depth of cut vs taper.

viii

CONTENTS
PART A: INTRODUCTION

1-10

A.1: Overview 2-8

A.1.1: Principle of Operation 3
A.1.2: Spark Initiation... 3-5
A.1.3: Metal Removal Mechanism 5-6
A.1.4: Dielectric 6-7
A.1.5: Tool Electrodes..

7-8

A.2: Types.. 8-10

A.3: Performance Measures... 10

PART B: LITERATURE SURVEY

11-14

PART C: DESIGN & DEVELOPMENTS

15-27

C.1: Bill of Materials.. 16

C.2: Design of Components ... 17-27
C.2.1: Selection of Spur Gear 18
C.2.2: Design of Base Rods..

19-20

C.2.3: Selection of DC Motor 20-23

C.2.4: Design of Workpiece Holder.. 23-24
C.2.5: Design of Gear Hub 24-25
C.2.6: Design of Gear Mounting Plate.. 25
C.2.7: Design of Motor Mounting Plate 26
C.2.8: Design of Collar Bearing 26-27
C.2.9: Design of Base 27

ix

PART D: FABRICATION OF PARTS

28-36

D.1: Fabrication of Spur Gear 29-30

D.2: Fabrication of Base Rods........ 30-31
D.3: Fabrication of Workpiece Holder... 31-32
D.4: Fabrication of Gear Hub. 33
D.5: Fabrication of Gear Mounting Plate 34-35
D.6: Fabrication of Motor Mounting Plate. 35-36
D.7: Fabrication of Base. 36

PART E: EXPERIMENTAL ANALYSIS

37-46

E.1: Mechanical Properties of Workpiece and Tool.. 38

E.2: Equipment Used.

38-40

E.3: Experiment.

41-46

E.3.1: Experiment-1.. 41-42

E.3.2: Experiment-2.. 43-44
E.3.3: Experiment-3.. 45-46

PART F: RESULT AND DISCUSSIONS

47-53

F.1: Effect of Pulse Current on Machining Process..

48-49

F.2: Effect of Pulse on-Time on Machining Process.

50-51

F.3: Effect of High Aspect Ratio on Tool Cylindricity.

52

F.4: Rotating Workpiece Holder Mechanism

53

PART G: CONCLUSION AND SCOPE FOR FUTURE WORK

54-57

PART A
INTRODUCTION

A.1: Electric Discharge Machining: An overview

Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove
metal by means of electric spark erosion. In this process an electric spark is used as the cutting tool
to cut (erode) the workpiece to produce the finished part to the desired shape. The metal-removal
process is performed by applying a pulsating (ON/OFF) electrical charge of high-frequency current
through the electrode to the workpiece. This removes (erodes) very tiny pieces of metal from the
workpiece at a controlled rate.
The traditional machining processes remove material by chip formation, abrasion or micro chipping.
There are situations, however, where these processes are not satisfactory, economical or even
possible because of following reason:

The hardness and strength of the material is very high (typical above 400 HB) or the material
is too brittle.
The work piece is too flexible, slender or delicate to withstand the cutting or grinding forces,
or the parts are difficult to fixture i.e. to clamp in the work holding devices.
The shape of the part is complex, including such features as internal and external profiles or
small diameter holes in fuel injection nozzles.
Surface finish and dimensional tolerance requirements are more rigorous than those obtained
by other processes.
Temperature rise and residual stresses in the workpiece are not desirable or acceptable.

These requirements led to the development of chemical, electrical, laser and other means of material
removal. Beginning in the 1940s, these advanced methods, these in the past have been called nontraditional or unconventional machining. When selected and applied properly, these advanced
machining processes offer major technical and economic advantages over traditional machining
methods.
Electrical discharge machining (EDM), also called electro discharge or spark erosion machining is
based on the erosion of metals by spark discharges. We know that when two current conducting
wires are allowed to touch each other, an arc is produced. If we look closely at the point of contact
between the two wires, we note that a small portion of the metal has been eroded away, leaving a
small crater.
This phenomenon of erosion was discovered by Joseph Priestly, in 1770s. But, during the World
War 2, two Russian scientists were tasked in 1943 to investigate ways to prevent the erosion of
tungsten electrical contacts due to sparking. They failed in this task but found that the erosion was
more precisely controlled if the electrodes were immersed in a dielectric fluid. This led them to
invent EDM machine. Simultaneously, but independently, an American team, Harold Stark, Victor
2

Harding and Jack Beaver, developed an EDM machine for removing broken drills and taps from
aluminium castings [1].

A.1.1: Principle of Operation

The basic EDM system consists of a shaped tool (electrode) and the workpiece, connected to a dc
power supply and placed in a dielectric (electrically non-conducting) fluid. When the potential
difference between the tool and the workpiece is sufficiently high, a transient spark discharges
through the fluid, removing a very small amount of metal from the workpiece surface. The capacitor
discharge is repeated at rates between 50 kHz and 500 kHz, with voltages usually ranging between
50V and 380V and currents from 0.1A and 500A.
EDM differs from most chip-making machining operations in that the electrode does not make
physical contact with the workpiece for material removal. Since the electrode does not contact the
workpiece, EDM has no tool force. The electrode must always be spaced away from the workpiece
by the distance required for sparking, known as the sparking gap. Should the electrode contact the
workpiece, sparking will cease and no material will be removed. There are some EDM machines
that do allow the electrode to contact the workpiece. These machines are used primarily for removing
broken taps and drills and are not considered die-sinker or wire-cut types of EDM machines [1].

A.1.2: Spark Initiation

The tool and the work material are immersed in a dielectric medium. Generally kerosene or deionised
water is used as the dielectric medium. A gap is maintained between the tool and the workpiece.
Depending upon the applied potential difference and the gap between the tool and workpiece, an
electric field would be established [Fig. A.1.2a].

Fig. A.1.2a: Spark occurs within a column of ionized dielectric fluid [Ref. 1].

Generally the tool is connected to the negative terminal of the generator and the workpiece is
connected to positive terminal. As the electric field is established between the tool and the job, the
free electrons on the tool are subjected to electrostatic forces. If the work function or the bonding
energy of the electrons is less, electrons would be emitted from the tool (assuming it to be connected
to the negative terminal). Such emission of electrons are called or termed as cold emission. The cold
emitted electrons are then accelerated towards the job through the dielectric medium. As they gain
velocity and energy, and start moving towards the job, there would be collisions between the
electrons and dielectric molecules. Such collision may result in ionisation of the dielectric molecule
depending upon the work function or ionisation energy of the dielectric molecule and the energy of
the electron. Thus, as the electrons get accelerated, more positive ions and electrons would get
generated due to collisions. This cyclic process would increase the concentration of electrons and
ions in the dielectric medium between the tool and the job at the spark gap. The concentration would
be so high that the matter existing in that channel could be characterised as plasma. The electrical
resistance of such plasma channel would be very less. Thus all of a sudden, a large number of
electrons will flow from the tool to the job and ions from the job to the tool. This is called avalanche
4

motion of electrons. Such movement of electrons and ions can be visually seen as a spark. Thus the
electrical energy is dissipated as the thermal energy of the spark [Fig. A.1.2b].

Fig. A.1.2b: Thermal energy of the spark [Ref. 2].

Another basic fundamental of the process is that only one spark occurs at any instant. Sparking
occurs in a frequency range from 2,000 to 500,000 sparks per second causing it to appear that many
sparks are occurring simultaneously. In normal EDM, the sparks move from one point on the
electrode to another as sparking takes place. The spark removes material from both the electrode and
workpiece, which increases the distance between the electrode and the workpiece at that point. This
causes the next spark to occur at the next-closest points between the electrode and workpiece [1-2].

A.1.3: Metal Removal Mechanism

The high speed electrons then impinge on the job and ions on the tool. The kinetic energy of the
electrons and ions on impact with the surface of the job and tool respectively would be converted
into thermal energy or heat flux. Such intense localised heat flux leads to extreme instantaneous
o

confined rise in temperature which would be in excess of 10,000 C. Such localised extreme rise in
temperature leads to material removal. Material removal occurs due to instant vaporisation of the
material as well as due to melting. The molten metal is not removed completely but only partially.
As the potential difference is withdrawn, the plasma channel is no longer sustained. As the plasma
channel collapse, it generates pressure or shock waves, which evacuates the molten material forming
a crater of removed material around the site of the spark.

Thus to summarise, the material removal in EDM mainly occurs due to formation of shock waves as
the plasma channel collapse owing to discontinuation of applied potential difference. This is the
Thermal model of metal removal.
Singh and Ghosh gave a thermo-electrical model of metal removal. They re-connected the removal
of material from the electrode to the presence of an electrical force on the surface of the electrode
that would be able to mechanically remove material and create the craters. They proposed thermoelectric model as a general method of calculating the electrostatic force on the surface of the cathode
and the stress distribution inside the metal during the discharge. The result obtained for the stress
distribution deep inside the metal, where the surface stress acts as a point force, can be extended for
any kind of discharge. The model can explain the experimental results for short pulses. The model
proposes that the electrostatic forces are the major cause of metal removal for short pulses and
melting becomes the dominant phenomenon for long pulses. The model explains the reason for
constant crater depth with varying discharge duration, for short pulses [1].

Fig. A.1.3: Spark on, workpiece and tool material vaporized [Ref. 1]

A.1.4: Dielectric
As thermal processing is required to be carried out in absence of oxygen so that the process can be
controlled and oxidation avoided. Oxidation often leads to poor surface conductivity (electrical) of
the workpiece hindering further machining. Hence, dielectric fluid should provide an oxygen free
machining environment. The main characteristic of dielectric fluid is that it is an electrical insulator
until enough electrical voltage is applied to cause it to change into an electrical conductor. The
dielectric fluids used for EDM machining are able to remain electrical insulators except at the closest
6

points between the electrode and the workpiece. At these points, sparking voltage causes the
dielectric fluid to change from an insulator to a conductor and the spark occurs. The time at which
the fluid changes into an electrical conductor is known as the ionization point. When the spark is
turned off, the dielectric fluid deionizes and the fluid returns to being an electrical insulator. This
change of the dielectric fluid from an insulator to a conductor, and then back to an insulator, happens
for each spark. Dielectric fluid used in EDM machines provides important functions in the EDM
process. These are:

Controlling the sparking-gap spacing between the electrode and workpiece.

Cooling the heated material to form the EDM chip.
Removing EDM chips from the sparking area.

The area heated by each spark is very small so the dielectric fluid quickly cools the vaporized
material and the electrode and workpiece surfaces. However, it is possible for metallurgical changes
to occur from the spark heating the workpiece surface [1].

A.1.5: Tool Electrodes

Electrode material should be such that it would not undergo much tool wear when it is impinged by
positive ions. Thus the localised temperature rise has to be less by tailoring or properly choosing its
properties or even when temperature increases, there would be less melting. Further, the tool should
be easily workable as intricate shaped geometric features are machined in EDM. Thus the basic
characteristics of electrode materials are:
High electrical conductivity electrons are cold emitted more easily and there is less bulk electrical
heating

High thermal conductivity for the same heat load, the local temperature rise would be less
due to faster heat conducted to the bulk of the tool and thus less tool wear
Higher density for the same heat load and same tool wear by weight there would be less
volume removal or tool wear and thus less dimensional loss or inaccuracy
High melting point high melting point leads to less tool wear due to less tool material
melting for the same heat load
Easy manufacturability
Cost cheap

The followings are the different electrode materials which are used commonly in the industry:

Graphite
7

Electrolytic oxygen free copper

Tellurium copper 99% Cu + 0.5% tellurium
Brass

The tool electrodes are shaped by forming, casting, powder metallurgy or machining techniques.
Electrodes as small as 0.1mm in diameter have been used and the depth-to-hole diameter ratios can
range up to 400:1.
Tool wear is an important factor because it affects dimensional accuracy and the shape produced.
Tool wear is related to the melting points of the materials involved: lower the melting point, higher
the wear rate. Consequently, graphite electrodes have the highest wear resistance. Tool wear can be
minimised by reversing the polarity and using copper tools, a process called no-wear EDM [1].

A.2: Types
There are two main types of EDMs: the ram (die sinker) and the wire-cut. Each are used to produce
very small and accurate parts as well as large items like automotive stamping dies and aircraft body
components. The largest single use of EDM is in die making.
In ram EDM, the electrode/tool is attached to the ram which is connected to one pole, usually the
positive pole, of a pulsed power supply.
The wire EDM process uses a consumable, electrically charged wire to effect very fine and intricate
cuts. The process is particularly useful in cutting fine details in pre-hardened stamping and blanking
dies. A wire drive system constantly presents fresh wire to the work so electrode wear is not a
problem. Typical wire diameters range from .002 to .013 inches. These wires will produce a kerf
slightly larger than their own diameter. A 0.012 wire will leave a 0.015 wide cut, just .003 inches
larger. Wire EDMs can run for long periods without operator attention.

Difference between the two types:

Dielectric fluid
Die-sinker EDM machines use hydrocarbon oil and submerse the workpiece and spark in the fluid.
Wire-cut EDM machines normally use deionized water and contain only the sparking area in the
fluid.

Applications
Die-sinker EDM machines are normally used for producing three dimensional shapes.
These shapes utilize either cavity-type machining or through-hole machining.
Wire-cut EDM machines are always used for through-hole machining, since the electrode wire
must pass through the workpiece being machined.

DIE-SINKER AND WIRE-CUT SPARKING:

Die-sinker machines produce sparks that occur between the electrode end and the workpiece. Diesinker sparking occurs across the end surface and from the corners of the electrode. Spark length is
set by the machine controls. Sparks occur from the electrode corners, producing a clearance between
the electrode corner and the sidewalls of the workpiece [Fig. A.2.1].
Wire-cut machines produce sparks that occur between the electrode-side surface and the workpiece.
Spark length is set by the machine controls. The sparking area consists of only the front 180 of the
electrode diameter as it progresses into the cut [Fig. A.2.2] [1-2].

Fig. A.2.1: Die sinker sparking from electrode end [Ref. 1].

Fig. A.2.2: Wire cut sparking from electrode end [Ref. 1].

A.3: Performance Measures

Typically, there are two performance measures:

Metal Removal Rate (MRR) - we try to increase it.

Tool Wear Rate (TWR) - we try to decrease it.
According to various researches, the MRR can be improved byHollow tube electrodes and electrodes with eccentric drilling results in better MRR due to
improved flushing condition.
Best tool shape for higher MRR and lower TWR is circular in shape, followed by triangular,
rectangular and square.
Higher voltage setting results in higher spark gap, again improving flushing conditions.
Using powder mixed dielectric, which has reduced insulation, thus again increasing the spark
gap.
Using multiple electrodes for multiple sparks, this also lowers the power

10

PART B
LITERATURE SURVEY

11

Literature Survey

Although a considerable amount of work has recently been reported on the various technological
aspects of industrial application of Electric Discharge Machining, so far less attempt has been made
to check the rotating aspect of workpiece on the various parameter of the EDM process. In order to
understand rotating aspect of EDM process and machining parameter a brief account of the literature
survey done for this project is presented here:
Ali Ozgedik and Can Cogun [3] studied the effect of machining parameter on the machining
performance outputs. Experiments were conducted using steel workpiece and round copper tools
with a kerosene dielectric under different dielectric flushing conditions (injection, suction and static),
discharge currents and pulse durations. It is found experimentally that increasing discharge current
increases the workpiece removal rate, tool wear rate, relative wear, front-surface wear rate and
average surface roughness. The workpiece removal rate increases with increasing pulse duration.
The relative wear decreases with increasing pulse duration since the workpiece removal rate
increases at a faster rate than the tool wear rate.

Y.H. Guu and H. Hocheng [4] conducted experiment to study the effects or workpiece rotation on
machinability during EDM process. An experimental analysis was carried out on an AISI D2 tool
steel with a copper electrode. The effects of machining parameters such as pulsed current, pulse ontime and workpiece rotation on MRR and surface roughness were analysed. Experimental results
indicated that the centrifugal force in rotary EDM improved gap flushing and machining efficiency.
The MRR in rotary EDM was up to twice that of conventional EDM. The value of surface roughness
decreased with increasing rotation speed. Workpiece rotation reduced the formation of micro voids
and defects on the machined surface.

Chinmaya P. Mohanty, Jambeswar Sahu and S.S.Mahapatra [5] presented a thermal-structural model
to analyze the process parameters and their effect on three important responses such as material
removal rate, tool wear rate and residual stresses on work piece in EDM process. A coupled thermostructural FEM analysis has also been done to know how the extreme temperature gradient generated
between tool and work piece affects the surface integrity of the machined surface. The proposed
model can be used for selecting ideal process states to improve EDM process efficiency and finishing
capability.
12

Mohammadreza Shabgard, Mirsadegh Seyedzavvar and Samad Nadimi Bavil Oliaei [6] investigated
the effect of machining parameters on EDM process characteristics. An experimental analysis carried
out on an AISI H13 tool steel with copper as electrode. Experimental result indicated the increase in
pulse on-time leads to an increase in the material removal rate, surface roughness, as well the white
layer thickness and depth of heat affected zone while the increase in pulse current leads to a sharp
increase in the material removal rate and surface roughness. The tool wear ratio decreased by the
increase of pulse on-time, and increased by the increase in the pulse current. It also indicated that by
constant level of discharge energy, high pulse current and low pulse on-time leads to a reduction in
the white layer thickness and depth of heat affected zone on the surface of EDMed workpiece.

Shankar Singh [7] et al., (2004) performed investigations into the electric discharge machining of
hardened tool steel using different electrode materials and observed that for the EN-31 work material,
copper and aluminium electrodes offer higher MRR, Copper and coppertungsten electrodes offer
comparatively low electrode wear for the tested work material, and aluminium electrode also shows
good results while brass wears the most, of all the tested electrodes. Lonardo .P.M, Bruzzone
[8].A.A, (1999) studied the effect of Flushing and Electrode Material on Die Sinking EDM and
observed that the electrode material has significant influence in finishing operations on wear and
height roughness parameters. When copper electrodes are used wear is larger and surface height is
smaller and that flushing in roughing operations increases both MRR and electrode wear. In finishing
operations flushing influences the form parameters. Lauwers .B [9] et al.,(2004) investigated the
material removal mechanisms in EDM of composite ceramic materials and points out that besides
the typical EDM material removal mechanisms, such as melting /evaporation and spalling, other
mechanisms can occur such as the oxidation and decomposition of the base material.

Han-Ming Chow et al., (2000) performed [10] a study of added powder in kerosene for the microslit machining of titanium alloy using electro-discharge machining. Manoj Mathew and Rajendra
Kumar .P.K, (2011) studied [11] the optimization of process parameters of boro-carburized low
carbon steel for tensile strength by Taquchi method with grey relational analysis and observed that
the optimal process parameters and their levels for pre-carburized AISI 1015 steel are carbon content
0.45% at 950 C temperature and 4 h process duration. The results revealed that process time, case
carbon content and process temperature influenced the yield strength and % elongation. The ultimate
13

strength is influenced by the process temperature, process time and carbon content. The process
temperature was the most influential control factor that affects the tensile strength properties. George
.P.M et al., (2004) performed [12] EDM machining of carboncarbon compositea Taguchi
approach and observed that the process variables affecting electrode wear rate and MRR, according
to their relative significance, are Vg, Ip and Ton, respectively and, Ton is insignificant.

Ahmet Hascalk and Ulas Caydasin [13] studied the electrical discharge machining (EDM) of
titanium alloy (Ti6Al4V) with different electrode materials namely, graphite, electrolytic copper
and aluminium and process parameters such as, pulse current and pulse duration were performed to
explore the influence of EDM parameters on various aspects of the surface integrity of Ti6Al4V.
Scanning electron microscopy (SEM), X-ray diffraction (XRD), energy dispersive spectrograph
(EDS) and hardness analysis were performed. The experimental results reveal that the value of
material removal rate, surface roughness, electrode wear and average white layer thickness are
tendency of increase with increasing current density and pulse duration. However, extremely longpulse durations such as 200ms led to decrease MRR and surface roughness. Furthermore, the surface
hardness is increasing due to the Ti24C15 carbides formed on the surface and obvious cracks are always
evident in re-solidified layer when machining copper electrode. The surface crack densities and
critical crack lines were determined for the tested material. The graphite electrode is beneficial on
material removal rate, electrode wear and surface crack density but relatively poorer surface finish.

14

PART C
DESIGN & DEVELOPMENTS

15

We have tried to design a rotating workpiece holding mechanism which can easily rotate the
workpiece inside the die-electric. The design constitutes of set of spur gears which are designed to
transmit angular motion and power between parallel shafts, gear hold support to hold the gear the
horizontally, a workpiece holder to hold the EDM workpiece, a motor support plate to support the
motor on the top outside of die electric and a collar bearing setup to rotate the spur gear smoothly.
The details of the design have been shown in the following pages using 3-D drawings prepared using
the Solid works Software package. While fabricating the setup we optimized the design according
to available manufacturing process [Fig. C].

Fig. C: 3d model of the whole setup made in Solidswork package.

16

C.1: Bill of Materials

Material used in fabrication of the setup is listed below with their mechanical properties [Table C.1]:
Component

Material

Mechanical Property

Spur Gear x 2

AL-5052

Gear Base Rod x 6

A-36 Mild Steel

Gear Mounting Plate x 2

A-36 Mild Steel

Workpiece Holder x 1

A-36 Mild Steel

Motor Mounting Plate x 1

A-36 Mild Steel

Motor Base Rod x 4

A-36 Mild Steel

Base x 1

A-36 Mild Steel

Collar Bearing x 2

A-36 Mild Steel

UTS = 228 MPa

YS = 193 MPa
UTS = 399.8 MPa
YS = 250.2 MPa
UTS = 399.8 MPa
YS = 250.2 MPa
UTS = 399.8 MPa
YS = 250.2 MPa
UTS = 399.8 MPa
YS = 250.2 MPa
UTS = 399.8 MPa
YS = 250.2 MPa
UTS = 399.8 MPa
YS = 250.2 MPa
UTS = 399.8 MPa
YS = 250.2 MPa

Table C.1: Bill of materials.

NOTE: The quantities listed above are per one setup.

Material Properties
A 36 Mild Steel

AL-5052

C = 0.9 1.2 %

Mg = 2.2%-2.8%

Mn = 0.3 0.75 %

Cr = 0.15%-0.35%

Si = 0.14 0.35 %

Cu = 0.1%

S = 0.4 %

Fe = 0.4%

P = 0.4 %

Mn = 0.1%
Si = 0.25%

17

C.2: Design of Components

C.2.1: Selection of Spur Gear
Since in Electric Discharge Machining there is no direct contact between tool and workpiece so there
is no mechanical force will induce on the workpiece by the tool during machining. In order to provide
rotatory motion to workpiece, the rotatory mechanism should overcome the shear friction acting on
the surface of the workpiece and the workpiece holder. In this setup a standard spur gear with module
2.0 is been used [Fig. C.2.1].

Fig. C.2.1: Spur gear design made in Solidswork package.

No. of

Pitch

Min

Max

Outside

Module

Diametrical

Thickness

Teeth

Diameter

Bore (d)

Bore

Diameter

(m)

Pitch (P)

(k)

(z)

(Dp)

80

160mm

2.0

0.5

20mm

(D)
20mm

98mm

164mm

Table C.2.1: Spur gear specifications.

18

C.2.2: Design of Base Rod

Base rods are used to support the gear and to the motor also. These base rod will be subjected to
vertical compression force due the weight of motor and gear mechanism, they may only fail under
the mode of crushing or buckling. As the ratio of length vs lateral width is nearly equal to the 10 so
Eulers theory is applied to find out the maximum allowable load which they can carry [Fig. C.2.2].

Fig. C.2.2: Design of base rods made in Solidswork package.

According to Eulers theory:

2
2

Where,
F = maximum allowable load
E = modulus of elasticity
I = area moment of inertia

= effective length
As base rod are fix at one end and free at other end, = 2
19

Calculation for Gear Base Rod

Length of the rod (l1) = 180mm
Diameter of the rod (d1) = 20mm
Modulus of elasticity (E) = 215GPa
Area moment of inertia for circular cross section,

4
64

3.142 215 106 3.14 (20 103 )4

=

4 64 (180 103 )2
= 1.28 105

Calculation for Motor Base Rod

Length of the rod (l2) = 235mm
Diameter of the rod (d2) = 16mm
Modulus of elasticity (E) = 215GPa
Area moment of inertia for circular cross section, I =

d4
64

3.142 215 106 3.14 (16 103 )4

4 64 (235 103 )2

= 3.08 104

C.2.3: Selection of DC Motor

In this setup we setup we used a DC motor to provide the rotation to the spur gear which is in contact
with another spur gear via simple spur gear train. The main function of DC motor is to provide the
rotation minimum up to 100RPM by overcoming the friction force which is acting on the surface of
spur gear by the dielectric fluid. Considering the dielectric as Newtonian fluid we can apply the
Newtons law of viscous friction to find out shear stress acting on the spur gear surface by dielectric.

20

Shear Force Calculation

Using Newtons law of viscous friction which states that the shear stress is directly proportional to
the rate of shear strain or velocity gradient (du/dy).
=

Where,
t = shear stress
w = angular velocity of spur gear
k = thickness of the spur gear
= dynamic viscosity of dielectric
() = .
=

. . . 2.

2. . . 3
=

3
=
Kinematic viscosity of dielectric = 2.010-6 m2/s
Density of dielectric = 0.790kg/m3
Dynamic viscosity () = 1.610-6 N-s/m2
Thickness of spur gear (k) = 20mm
Pitch diameter (DP) = 160mm
Angular velocity (w) = 10.5rad/s
=

2 3.14 1.6 106 10.5 (160 103 )3

20 103
3

F = 7.1810-6 N

21

Torque Calculation
Since, =

1
2

Mass of spur gear = 1.1 kg

Pitch diameter (DP) = 160mm
2

(160 103 )
1
= 1.1
. 2
2
4

= 3.45 103 . 2
() =

= 10.5 / 2
= 3.45 103 10.5 .
= 0.036 .
() = .
= 0.036 10.5
= 0.3768
So, on the basis of calculated viscous shear stress and required torque to rotate the setup we selected
a planetary encoder gear 24V 175RPM 100W DC motor with given specifications:
Specifications:

Hardened shaft diameter: 10mm

Shaft Length: 23mm
Mounting PCB of 40mm x 4 holes.
Motor Diameter: 60mm
Motor Length without Shaft: 154mm
Motor Weight: 1450 grams
Rated Torque: 142kgcm
Stall Torque: 344kgcm
No load speed: 175RPM
Base Motor speed: 6000RPM
Base Motor count: 2000ppr
Geared Motor count: 72000ppr
Replaceable Carbon Brushes
22

Fig. C.2.3: Planetary geared motor 175RPM 24V 100W.

24V 100W planetary geared motor with rated torque of 142kgcm comes with a 2000 PPR Base motor
optical encoder with quadrature outputs for increment and decrement counting. This Motor is an
Industrial grade motor with replaceable carbon brushes and hardened shaft. The 0.18 degree
resolution optical encoder with quadrature outputs for increment and decrement counting. It will
give 2000 transitions per base motor rotation between outputs A and B. A quadrature decoder is
required to convert the pulses to an up or down count. The Encoder is built to Industrial grade [Fig.
C.2.3].

C.2.4: Design of Workpiece Holder

Workpiece holder is designed to hold the EDM workpiece in the center with work tool and also to
provide the rotation to workpiece. In EDM process no mechanical force acts on the workpiece so
there is no possibility of mechanical failure. We used bolts to fix the workpiece in the center and to
attach it with the spur gear horizontally. Workpiece up to 25mm diameter & of 20mm thickness can

23

be easily fitted in the extruded cut. On the perimeter of the bottom plate 3 hole is provided to attach
it with the gear using bolts [Fig. C.2.4].

Fig. C.2.4: Workpiece holder design made in Solidswork package.

C.2.5: Design of Gear Hub

On the top of the driving gear an extruded gear hub is provided to fix the shaft of the DC motor with
the spur gear. A horizontal hole is cut to fix the shaft of DC motor in the gear hub using bolt. Gear
hub is 40mm long with 10mm bore. A 5mm diameter grove is provided to lock the motor shaft into
the gear hub [Fig. C.2.5].

24

Fig. C.2.5: Gear hub design made in Solidswork package.

C.2.6: Design of Gear Mounting Plate

The mounting plate is provide support to the spur gear and keep it horizontally stable. This plate is
fix on the base rod using bolts and there is also space provide for the collar bearing which is attached
with the spur gear to provide a smooth rotation. Its only function is to hold the spur gear so only a
single vertical weight is acting on it. The diameter of plate is taken as 150mm and the thickness of
the plate is taken as 5mm. The extruded cylindrical part is of length of 40mm and 5mm thickness
[Fig C.2.6].

Fig. C.2.6: Gear mounting plate design made in Solidswork package.

25

C.2.7: Design of Motor Mounting Plate

A mounting plate is used to place the DC motor. The length of the plate is taken as 197mm and width
65mm. The thickness of the plate is 5mm. This plate is placed on the base rods. A 30mm hole is
provided for placing the DC motor which is fixed on the plate by bolts of 5mm diameter. To fix this
plate on the base rods 10mm hole is provided on the both end [Fig. C.2.7].

Fig. C.2.7: Motor mounting plate design made in Solidswork package.

C.2.8: Design of Collar Bearing

To provide spur gear a smooth rotation and to support it horizontally a collar bearing is been used in
this setup. Two radial ball bearing used on the both end of 10mm diameter shaft. The selection of
ball bearing is done on the basis of the rotational speed, working load, frictional losses and the
lubrication. Specification of the ball bearing is given below [Fig. C.2.8]:

Fig. C.2.8a: Technical specification of single row radial ball bearing.

26

Fig. C.2.8b: Design of collar bearing made in Solidswork package.

C.2.9: Design of Base

Base is designed to fix the assembly. The base is 360mm in length, 250mm in width and 2mm in
thickness. To keep the base above the ground a 25mm thick strip is attached around its parameter
[Fig. C.2.9].

Fig. C.2.9: Design of base made in Solidswork package.

27

PART D
FABRICATION OF PARTS

28

D.1: Fabrication of Spur Gear

Fig. D.1: Fabrication of spur gear.

29

Material used: Aluminium 5052

Machining process employed: Milling, grinding, hobbing, broaching, casting and forging.
Modifications in the original design: The dimension of the fabricated spur gear is taken from the
standard gear size which is different from the model design and to reduce the material cost we
modified the design with grooves on it.

D.2: Fabrication of Base Rods

Fig. D.2: Fabrication of base rods.

30

Material used: A-36 Mild Steel

Machining process employed: Facing, turning, cutting, centering, drilling and thread cutting.
Modifications in the original design: None

D.3: Fabrication of Workpiece Holder

31

Fig. D.3: Fabrication of workpiece holder.

Material used: A-36 Mild Steel

Machining process employed: Facing, turning, cutting, centering, cut-off, boring, drilling, reaming
and grinding.
Modifications in the original design: None

32

D.4: Fabrication of Gear Hub

Fig. D.4: Fabrication of gear hub.

Material used: A-36 Mild Steel

Machining process employed: Facing, turning, cutting, centering, cut-off and drilling.
Modifications in the original design: None

33

D.5: Fabrication of Gear Mounting Plate

Fig. D.5: Fabrication of gear mounting plate.

34

Material used: A-36 Mild Steel

Machining process employed: Facing, turning, cutting, centering, boring, drilling and grinding.
Modifications in the original design: None

D.6: Fabrication of Motor Mounting Plate

Fig. D.6: Fabrication of motor mounting plate.

35

Material used: A-36 Mild Steel

Machining process employed: Shaping, centering, drilling and grinding.
Modifications in the original design: To reduce the material wastage we modified the mounting as
rectangular plate instead of using square plate as we made in the 3d model.

D.7: Fabrication of Base

Fig. D.7: Fabrication of base.

Material used: A-36 Mild Steel

Machining process employed: Shaping, cutting and grinding.
Modifications in the original design: None

36

PART E
EXPERIMENTAL ANALYSIS

37

To find out the problem associated with the DIE Sinking EDM and provide a corrective procedure
to overcome these problems through literature and experimental data.

E.1: Mechanical properties of the workpiece and tool material

Fig. E.1: Mechanical and physical properties of mild steel.

Fig. E.1: Mechanical and physical properties of copper.

E.2: Equipment Used

E.2.1: SMART ZNC Electric Discharge Machine
Technical Data
Height

2220 mm

Width

1280 mm

Depth

1350 mm

Net weight of machine tool

1150 kg

E.2.1a: Machine Base

The machine base, which is of welded construction, carries the worktable. Four levelling screws at
the foot of the machine base are provided for the levelling of the machine.

38

E.2.1b: Machine Column

The machine column is bolted to the bottom slide and carries the work head.
Travel of the quill

250 mm

Reading accuracy of the Dial gauge

0.01mm

Depth of throat

360 mm

Maximum load Lifting Capacity

30 kg

E.2.1c: Co-ordinate table

Mounting surface (length x width)

550 mm x 350 mm

Maximum workspace height

250 mm

Max. job weight

300 kg

X axis travel

300 mm

Y axis travel

200 mm

Least count of hand wheel with Vernier scale

0.02 mm

Maximum table-quill distance

515 mm

Minimum table-quill distance

265 mm

Width of work tank

800 mm

Depth of work tank

500 mm

Height of work tank

350 mm

E.2.2: Weighing Machine

It has been used to find out the amount of wear in the tool and the amount of material removed
from the work piece in grams. Least count = 0.0001 gm

E.2.3: Stereo Zoom Microscope

It has been used to find out the amount of taper in the hole machined in the work piece and to study
the wear profile of the tool after machining [Fig. E.2.3].

39

Fig. E.2.3: Stereo zoom microscope.

E.2.4: Clamp
A customize clamp has been used to hold the work piece vertically to perform the high aspect ratio
machining.

40

E.3.1: Experiment-1
To find out the effect of current on Material Removal Rate and Tool Wear Rate in Die Sinker EDM
process.
Experiment Data:
Thickness of work piece

8mm

Cross section of tool

10x10mm2

Ton time

30s

Machining time

15min

Voltage

10v

Density of copper

8.96gm/cm3

Density of mild steel

7.85gm/cm3

Material Removal Rate/Tool Wear Rate =

m/ (m x machining time)

m = change in the mass of tool/work piece

m = density of tool/work piece

Observation table for workpiece

Serial

Current (A)

No.

Initial Mass

Final Mass

Change in mass

Material

mi (g)

mf (g)

m (g)

Removal Rate
(cm3/s)

42.7557

42.5284

0.2273

3.20x10-5

42.5284

42.2664

0.2620

3.70x10-5

42.2664

41.9304

0.3360

4.75x10-5

41.9304

41.5606

0.3698

5.23x10-5

Table E.3.1a: Observation table for MRR vs current.

In this chart given below, corresponding to current 4A, 5A, 6A and 7A at 10v and 30s, MRR was
noted.

41

Observation table for tool

Serial

Current

Initial Mass

Final Mass

Change in

Tool Wear Rate

No.

(A)

mi (g)

mf (g)

mass m (g)

(cm3/s)

13.5876

13.5848

0.0028

3.47x10-7

13.5848

13.5793

0.0055

6.82x10-7

13.5793

13.5697

0.0116

14.3x10-7

13.5697

13.5468

0.0209

25.9x10-7

Table E.3.1b: Observation table for TWR vs current.

In this chart given below, corresponding to current 4A, 5A, 6A and 7A at 10v and 30s, TWR was
noted.

42

E.3.2: Experiment-2
To find out the effect of Ton time on Material Removal Rate and Tool Wear Rate in Die Sinker EDM
process.
Experiment Data
Thickness of work piece

8mm

Cross section of tool

10x10mm2

Current

10A

Machining time

10min

Voltage

40v

Density of copper

8.96gm/cm3

Density of mild steel

7.85gm/cm3

Material Removal Rate/Tool Wear Rate =

m/ (m x machining time)

m = change in the mass of tool/work piece

m = density of tool/work piece

Observation table for workpiece

Serial

Ton time

Initial Mass

Final Mass

Change in

Material Removal

No.

(s)

mi (g)

mf (g)

mass m (g)

Rate (cm3/s)

10

43.8924

43.7991

0.0933

1.98x10-5

50

43.7991

43.4318

0.3676

7.80x10-5

100

43.4318

43.0342

0.3976

8.44x10-5

200

43.0342

42.6786

0.3556

7.55x10-5

Table E.3.2a: Observation table for MRR vs Ton time.

In this chart given below, corresponding to Ton time 10s, 50s, 100s, 200s at 40v and 10A,
MRR was noted.

43

Observation table for tool

Serial

Ton time

Initial Mass

Final Mass

Change in

Tool Wear Rate

No.

(s)

mi (g)

mf (g)

mass m (g)

(cm3/s)

10

13.6625

13.6219

0.0406

7.55x10-6

50

13.6219

13.6020

0.0199

3.7x10-6

100

13.6020

13.5978

0.0042

0.78x10-6

200

13.5978

13.5944

0.0340

0.63x10-6

Table E.3.2b: Observation table for TWR vs Ton time.

In this chart given below, corresponding to Ton time 10s, 50s, 100s, 200s at 40v and 10A,
MRR was noted.

44

E.3.3: Experiment-3
To find out the change in the cylindricity of the circular tool with high depth to tool diameter ratio
or drill machining.
Experiment Data
Length of the tool

35mm

Diameter of the tool

3mm

Current

20A

Ton Time

150s

Voltage

60v

Density of copper

8.96gm/cm3

Density of mild steel

7.85gm/cm3

Initial weight of tool = 25.3071g

Weight of tool after machining = 25.1411g
Initial weight of work piece = 83.0293g
Weight of work piece after machining = 81.2779g

Observation Table
Serial No.

Depth of cut (mm)

Machining time (sec)

2.50

448

1.50*

270

2.51

349

2.51

287

2.51

224

2.50

227

2.51

194

2.50

198

2.51

220

10

2.50

252
45

11

2.52

210

12

2.51

222

13

0.85*

133

= 29.93

= 3234

Table E.3.3a: Observation table depth for cut vs machining time.

Procedure
First, on given parameter, increasing the depth of cut (2.50 in each step) machining time was noted.
After machining with the help of stereo zoom microscope photographs of different region of tool
was taken. With the help of Adobe Acrobat taper in different region of tool was calculated [Fig.
E.3.3a].

Fig. E.3.3a: Taper Measurement in Circular Tool

46

PART F
RESULT AND DISCUSSION

47

F.1 Effect of Pulse Current on Machining Process

Heat generation is directly proportional to current supplied, so on increasing the current the quantity
of heat generated also increases. As a result utilized energy in melting and vaporizing the workpiece
and tool material also increases. So that on increasing the current at constant Ton time and voltage,
increase in the Material Removal Rate and Tool Wear rate is obtained [Fig. F.1].

MRR vs Current
6
5.23

4.75

MRR x 10-5 (cm3/s)

3.7

4
3.2
3

0
4

Current (A)

Fig. F.1a: Material removal rate vs current.

48

TWR vs Current
30
25.9

TWR x 10-7 (cm3/s)

25

20
14.3

15

10
6.82
5

3.47

Current (A)

Fig. F.1b: Tool wear rate vs current.

49

F.2 Effect of Pulse on-Time on Machining Process

At constant current and voltage with increase in Ton Time increase in MRR and decrease in TWR is
obtained. On increaseing Ton time, period of tranferring energy to the workpiece increases and leads
to formation of bigger molten metal crater but after a peak value due to resolidification MRR begins
to decrease. Increasing Ton time increases the dimension of the plasma channel and increasing the
amount of heat transferred from the plasma channel to the electrodes, the plasma channel efficiency
in removing molten material from the molten crater at the end of each pulse decreases, while the
dimensions of the molten crater on the electrodes increases so that TWR decreases [Fig F.2].

MRR vs Ton Time

9

8.44
7.8

7.55

MRR x 10-5 (cm3/s)

7
6
5
4
3

1.98
2
1
0

10

50

100

200

Ton Time (s)

Fig. F.2a: Material removal rate vs Ton time.

50

TWR vs Ton Time

8

7.55

TWR x 10-6 (cm3/s)

6
5
3.7

4
3
2
1

0.78

0.63

100

200

0
10

50

Ton Time (s)

Fig. F.2b: Tool wear rate vs Ton time

51

F.3 Effect of High Aspect Ratio Tool on Tool Cylindricity

For high aspect ratio or drill machining with EDM process, on increasing the depth tool side wear
increase. This occurs due to spark initiation from the sides of the tool and as a result taper is obtained
in the tool profile [Fig. F.3].
Depth of Hole (mm)

Taper (m per mm)

4.13

12

5.69

18

7.65

25

9.25
Table F.3: Depth of cut vs taper.

10

9.25

9
7.65

Taper (m/mm)

7
5.69

6
5
4.13
4
3
2
1
0
5

12

18

25

Depth of cut (mm)

Fig. F.3: Taper vs depth of cut.

52

F.4 Rotating Workpiece Holder Mechanism

Rotating workpiece holding mechanism is tested on DC power supply and it is able to provide a
rotatory motion to workpiece up to 175RPM. In this setup workpiece will be fixed in the center of
workpiece holder by using bolts. This workpiece holder is attached on the top of a spur gear which
is connected to another spur gear by simple gear train. On the top of driving gear a DC motor is been
fixed by using mounting plates. By providing the electricity supply DC motor will cause the spur
gear to rotate. The whole setup is fixed on the base by using base rods. As, base rods and base are
made of mild steel, the workpiece will be on positive polarity and tool will be on negative polarity
and that would provide a ideal condition for Electrical Discharge Machining. Other than DC motor
whole setup will be submerged in the dielectric. It will avoid the chances of DC motor failure.

53

PART G
CONCLUSION AND SCOPE FOR
FUTURE WORK

54

We studied that with increase in current, increase in Material Removal Rate and Tool Wear
Rate is obtained.

With increase in Ton Time, increase in Material Removal Rate and decrease in Tool Wear
Rate is obtained.

Taper in the tool shape is studied by considering the data obtained from the experiment for
tool wear for copper tool, used for machining of AISI H13 in EDM.

The major objective of our M.Tech project has been successfully completed. The design,
development, modification and fabrication of the rotating workpiece holding mechanism has
been completed successfully taking into consideration various parameters involved in the
Electric Discharge Machining process. However there has been a major setback i.e. our
inability show the actual working of the setup on EDM machine in the production lab.

Scope for Future Work

Workpiece rotation could be very effective in EDM process in compare to conventional EDM. The
centrifugal force due to workpiece rotation could improve the gap flushing and machining efficiency.
For future scope this study can be carried out to study the surface roughness, formation of micro
voids and defects in the machined surface. Also, to check performance measurement of the process
from the rotating aspect. A rotary motion may be studied for taper problem of work tool in high
aspect ratio machining because it will provide a symmetric and uniform tool wear rate.

55

REFERENCES
1.

Electrical Discharge Machining by Society of manufacturing Engineers-www.sme.org.

2.

Electrical Discharge Machining By Steve Krar.

3.

Ali Ozgedik and Can Cogun (2006). An experimental investigation of tool wear in electric
discharge machining, The International Journal of Advanced Manufacturing Technology,
Vol. 27, 488500.

4.

Y. H. Guu and H. Hocheng (2001), Effects of workpiece rotation on machinability during

Electrical Discharge Machining, Material and Manufacturing Process, Vol. 16, No. 1, 91101.

5.

Chinmaya P. Mohanty, Jambeswar Sahu and S.S.Mahapatra (2013). Thermal-structural

Analysis of Electrical Discharge Machining Process, Procedia Engineering, Vol. 51, 508
513.

6.

Mohammadreza Shabgard, Mirsadegh Seyedzavvar and Samad Nadimi Bavil Oliaei (2011).
Influence of Input Parameters on the Characteristics of the EDM Process, Journal of
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