1.

0 TITLE
Production Technology on Non-Traditional Machining (Electrical Discharge Machining)

2.0 OBJECTIVE
Our objectives in this experiment is :-

To design a basic NC program for Electrical Discharge Machining (EDM) wire cut.
To machine a product using the Electrical Discharge Machining (EDM) wire cut.

3.0 INTRODUCTION
Electrical Discharge Machining (EDM) is a machining method primarily used for hard
metals or those that would be impossible to machine with traditional techniques. The Electrical
Discharge Machining (EDM) process was invented by two Russian scientists, Dr. B.R.

Lazarenko and Dr. N.I. Lazarenko in 1943. The first numerically controlled Electrical Discharge
Machining (EDM) was invented by Makino in Japan. Electrical Discharge Machining (EDM)
can cut small or odd-shaped angles, intricate contours or cavities in pre-hardened steel without
the need for heat treatment to soften and re-harden them as well as exotic metals such as
titanium, hastelloy, kovar, and inconel. There are two main types of EDM machines; Sinker
EDM (also called Conventional EDM and Ram EDM) and Wire cut EDM.
During cutting, the wire doesnt touch the workpiece, so there is no cutting pressure or
mechanical stresses impartel on the workpiece compared to milling cutters and grinding wheels.
Also, very little clamping pressure is required to hold small, delicates, or thin fragiles parts, thus
preventing them from becoming distorted. The accuracy, surface finish and time required to
complete a job is extremely predictable; making the process much easier to quote EDM leaves
no residual burrs on the workpiece, eliminating secondary de-burring operations that save both
time and money. Additionally, EDM leaves no tooling marks, as the surface has uniform, random
pattern compared to marks that left by grinding and milling operations.
Electric 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 work piece 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 work piece-electrode, or work piece.

4.0 APPARATUS
4.01 EXPERIMENT APPARATUS
1.
2.
3.
4.

EDM wirecut machine

Workpiece material
NC programming
Wire diameter

4.02 INDUSTRIAL APPARATUS (EDM WIRECUT MACHINE)

1. AS 530S WIRECUT EDM

Features:

Specialized wire cut keyboard employs PC-compatible characters and numeric keys.

Optical mouse. RS-232C/100M Ethernet

Industrial grade master board with Pentium CPU/Windows for instant multi-task operation

system. USB disc interfacing.

5 axes AC servo high performance close-loop servo positioning systems.
Expert's system support permits searching for macro programs according to workpiece

material, wire diameter, thickness and quality etc.

High performance CAD/CAM editing functions permits easy editing.
Comprehensive G/M Code programs for grammar verifications and 2D/3D simulating

verifications.
Provide various taper cutting functions and various machining applications, such as same

angle at top and bottom, same radius and profile.

Perform servo type/constant speed type machining and round corner machining.
Instant trouble detection during operating. Machining processes and alarm history records.
Automatic control for water quality and temperature assures maximum stability of
machining.

2. DK77E CNC EDM WIRECUT MACHINE

Features:

CNC Wire Cut EDM is endowed with wire tightening system, "patent for its wire running sys
tem"

Parameter of multicutting (para of high frequency, wire running speed), once fixed, the
machine can be intelligently controlled.

The processing accuracy of the wire cut edm: Plus and minus 0.005mm

The best surface roughness:of the Wire Cut EDM: Ra1.2um

The max cutting speed of the EDM Wire Cut: 160mm2/min

The average speed of triple wire edm cutting is about 80mm2/min(one time cut, another two t
ime cuts for modification raising accuracy and reducing surface roughness of workpiece, surf
ace roughness 1.5uM)

The system of the CNC Wire Cut EDM adopts the cartography programing software, auto C
AD graphic in DXF format is compatible simultaneously.

The overall electricity contoller of the wire cut edm is a vertical contol box integrating in fun
ction of programming control, high frequency power electric parts, . The computer is the prof
esional computer for industrial use with 15'' liquid crystal screen enabled the
machine to easy for operation.

CNC Wire Cut EDM applies Nontouch point induction type direction switch. The wire runni
ng speed can be adjusted through frequency conversion.

CNC wire cut edm is suitable for processing mold and the components high in precision.

3. CNC WIRECUT MACHINE(DK7732C/DK 7732F)

Features:

The casting for the main machine bed, using high rigid HT250, which made by a famous
Japanese manufacturer. Integrated structure design, all casting parts are made with the
procedure of resin-send and twice heat treatment to improve the max load weight and keep

a good precision for long time and avoid the distortion.

Cantilever is symmetrical frame, which tension the electrode Molybdenum wire suitably to

reduce the rate of wire-broken.

The controller equipped the BMXP Intelligent software, which integrates the program and
control and based on Windows XP. This new designed BMXP software is the unique

software for WEDM running on the condition of windows XP.

Using the PCI slot controller card and the High-tech Industrial computer, which greatly

enhanced the stability of control and greatly reduced the computer the failure rate
To achieve a fast and convenient computer communication network, through network
technology, graphics, data and program transmission, can be directly controlled by the

technical design department since the first establishment of a program

Embedded Control system can be connected with many design software smoothly.
The search function of mechanical origin enable the transmission screw pitch
compensation, in order to greatly improve the positioning accuracy, especially in Servo
control system.

The control parameters of pulse power is directly by the software, in order to not only
improve anti-jamming capability in pulse power output, but also increase the roughness of

work piece.
Variety of pulse power can be chosen, which is suited for a number of processing

conditions to improve the cutting ability of the high precision parts.

With a large database storage capacity, which accumulated from many experiences. User
can choose the suitable parameter according to deferent working conditions. Users can
adjust machining parameters to establish a database at any time according to their own

experience
Three layer filters can prolong the using life of the working solution and improve the
finishing, with BAOMA series working solution can achieve a better performance and

PRO-environment.
Can be equipped with the close-loop control system, use the MITSUBISHI, YASKAWA

servo control system and servo motors.

The wire moving is controlled by EMERSON transducer, which adopts unlimited

adjustment.
The processing components involve godek mechanism, the best roughness Ra 1.5m (the

finishing can be improved greatly by using the BM working solution)

Customized extra-big machine can be manufactured in our company.

5.0 EXPERIMENTAL PROCEDURES

1. The information about Electrical Discharge Machine (EDM) wire cut was briefed clearly.
2. The specifications about coding like M code and G code were studied before the
machining process started

3. The shape of the product was design by using CATIA software. The design must be not
exceed 50mm x 50mm size.
4. The workpiece which was aluminium plate which 50mm x 50mm and 3mm thickness and
also 0.25mm wire diameter were prepared.
5. The value of H1, E and F were determined by referring to the manual.
6. After all the preparation were set, the NC program in EDM wire cut was set.
7. The NC program was transferred to the EDM wire cut machine based on the coordinate
of the design.
8. The 2D drawing was shown on the machines screen before the process started.
9. During this time, the design was checked to make sure no error occur during transferring
data.
10. Then the machine started to operate according to the complete data transferred.
11. The workpiece was cut following the desired design.
12. The product was ready.

9.0 RECOMMENDATION
High wire tension is necessary to maximize accuracy. In single pass cuts, high wire tension
will reduce corner error, belly, vibrations and deflections of the wire induced by flushing forces,
especially in tall work pieces. In skim cuts, high wire tension assures maximum precision.
Therefore, if the wire tension is lowered significantly thinner, less accurate jobs, we can apply
more power to the wire without breaking it.
The most significant factor in wire breakage is not the tensile load on the wire, but the flaws
created by the sparks which attack the wires cross section. It is common practice in tool design

to avoid sharp corners, since a crack will often radiate from a sharp corner leading to the failure
of the tool. Hence, the property of a material to resist failures caused by cracks is often called
fracture toughness. To avoid such occurrence, above practice it necessary.
Reliable unattended burning is always more productive than unreliable attended fast burning,
thus it is preferred that the operation should take sufficient time than being rushed to finish a
project to avoid any failure.

10.0 REFERENCES
1. Electrical

discharge

machining

(2011).

Retrieved

from

http://en.wikipedia.org/wiki/Electrical_discharge_machining on 18th December 2014.

2. Kalpakjian,

S.,

and

R.S.

Schmid,

(2000).

Automation

of

manufacturing

process:manufacturing engineering and technology, 4th. Edition, Prentice Hall.

3. Mikell P. Groover, (2011). Principles of modern manufacturing, 4th Edition, Wiley.

4. https://www.google.com/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF8#q=insdustrial%20apparatus%20for%20wire%20edm