1.

0 INTRODUCTION

Electrical discharge machining is one of the most accurate manufacturing

processes available for creating complex or simple shapes and geometries within parts
and assemblies.EDM works by eroding material in the path of electrical discharges that
form an arc between an electrode tool and workpiece. The EDM consist of a shape
tools or wire cathode, and the part the part is associated with a power supply..
Sometimes to create a potential difference between the workpiece and tool, the
workpiece is immersed in dielectric conducting fluid which is circulated to flush away
debris.

The cutting pattern is usually CNC controlled. Various EDM machine cathodes
can pivot two-three rotate thinking about cutting of internal cavities. This makes EDM a
significantly capable assembling process.

EDM comes in two basic types wire and probe. Wire EDM is usually primarily for
shapes cut shapes through a selected part or assembly. With a wire EDM machine, if a
set pattern should be made, an underlying opening must first be bored in the material,
then the wire can be bolstered through the gap to finish the machining. Sinker EDM are
generally used for complex geometries where the EDM machine uses a machined
graphite or copper electrode to erode the desired shape into the part or assembly.
Sinker EDM can cut a hole into the part without having a hole pre-drilled for the
electrode.

Electric discharge machining is accompanied by acoustic emission signals, that

can be used monitoring, diagnostics, and control of the process. electric discharge
machining may be accompanied by phenomena impairing the products surface quality
and even damaging the machine tool, such as short circuiting, which may harm the
surface; mobility of the part at separation, with the appearance of burring; variability of
the charged particle fluxes (due to contamination of the working medium by erosion
products), with increase in surface roughness; and breakaway of the tool electrode.

In electric discharge machining, the workpiece is completely immersed in

dielectric, and the machining zone is small and so far from the surface that automated

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monitoring of the numerically controlled machine tool is difficult In existing electric
discharge equipment, deviant checking of the electrical parameters related with the
discharge heartbeats in the deterioration gap is commonly used.. The parameters
monitored may be, for example, the pulse efficiency, the amplitude of the discharge
voltage, the resistance of the erosion gap in the interval between pulses, and the
discharge current . Such monitoring calls for relatively complex circuitry. Regularly, the
measuring interims must be expanded with a specific end goal to acquire data; that
builds the latency of the control framework.

Advantages of Electrical Discharge Machining

Creates complex shapes that would otherwise be difficult to produce with

conventional cutting tools.

Cuts extremely hard, challenging and exotic materials to very close tolerances for
high precision mechanical components.

Suits very small work pieces, where conventional cutting tools may damage the
part from excess cutting tool pressure.

There is no direct contact between tool and work piece. Therefore, delicate
sections and weak materials can be machined without any distortion.

No burrs.

Little or no polishing is required after the process is complete.

Disadvantages of Electrical Discharge Machining

The slow rate of material removal.

The additional time and cost used for creating electrodes for Ram/Sink EDM.

Reproducing sharp corners on the work piece is difficult due to electrode wear

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2.0 LIST OF SENSOR INVOLVED IN MONITORING PROCESS OF ELECTRICAL
DISCHARGED MACHINING

1-voltage probe mounted on machine

2-current sensor

3-sensor monitoring

4-3d sensor

2.1 FUNCTION OF THE SENSOR IN THE PROCESS MONITORING

1- VOLTAGE PROBE MOUNTED ON MACHINE

The objective of this sensor type is to Measure the voltage in the gap between wire
electrode and workpiece. The gap voltage sensor in the power supply and control the
infeed of the electrode or workpiece to precisely match the rate of material removal. If
the gap voltage sensor system determnine that a piece of electrically conductive
material has btidged the gap between the electrode and workpiece, Figure 1 below
show a wiring diagram for a gap voltage sensor in electrical discharge machining

Figure 1: wiring diagram for a gap voltage snesor.

The power supply is an important part of any EDM system. It transform the alternating
current from the main utility electrical supply into the pulsed direct current required to
produce the spark discharges at the machining gap.EDM power supplies convert input

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power into usable pulses in a similar manner.First, the input power is converted into
continuous DC power by conventional solid state rectifiers. A small percentage of this
DC power is used to generate a square- wave signal via a digital multi vibrator oscillator
circuit.The oscillator is usually crystal controlled to maintain a timing precision of
approximately 0.01% of the set values. This precision signal is used to trigger a bank of
power transistor. the power transistor act as high speed switches to control the flow of
the remaining DC power. This high powered, pulsed output is the delivers to the
workstation to create the sparks responsible for material removal. Sensing the voltage
between the electrode and workpiece is an additional function if the EDM power
supply.Because a direct relationship exist between this voltage and the electrode
workpiece gap this signal is used to control the servosystem enabling it to maintain a
constant gap distance throughout the EDM cycle.

2-CURRENT SENSOR

Bearing currents cannot be measured directly by placing the current sensor into the
bearing. Therefore, motor needs insulated bearings and bypass bridge around the
insulation in figure 2, which makes the measurement possible. However, insulation
sleeve and bypass bridge change the initial electrical conditions in the bearing-current
circuit.

Figure 2

The shunt resistor as a current sensor was analyzed regarding appropriateness for
measurement of high-frequency bearing currents. The circuit model of electric discharge
machining currents circuit was built to determine the influence of insulation sleeves and
bypass bridge to the initial system. Parameters of the model were estimated with

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simplex algorithm. The measurements and investigations of bearing-currents trend line
were performed.
Bearing currents are parasitic phenomena, especially prominent in electric motors,
supplied by inverters, like brush-less direct-current (BLDC) motors. Bearing life could be
significantly reduced due to flow of electric current. Inverter-induced bearing currents
can be divided into four groups, namely capacitive currents, electric discharge
machining (EDM) currents, high-frequency circulating currents and bearing currents,
due to currents between the motor and the load [1]. In low-power motors EDM currents
are especially prominent, therefore this paper focuses on them.

Current sensing is a vital task in electrical sector, where the current

information is required for monitoring and control purposes. The measurement of
current ranges from Pico amps to several hundreds of amps depending upon the
application in which the current is being measured and differentiated from one another
based on required specifications such as the measurement of peak to peak value, RMS
value, accuracy, bandwidth, robustness, cost, isolation or size and many different
current measurement methods have been developed to satisfy these demands
The sensor works when the current conductor passes through a magnetically
permeable core that concentrates the conductor's magnetic field. The Hall effect device,
which is mounted within the core, is at a right angle to the concentrated magnetic field
and a constant current (in one plane) excites the Hall device. The energized Hall device
is then exposed to a magnetic field from the core and it produces a potential difference
that can be measured and amplified into process level signals such as 4-20mA or a
contact closure.
Inductive- Inductive sensors use a coil through which a current-carrying wire passes.
This causes power to flow in the coil that is proportional to the current. This happens
because of the magnetic field produced by flowing current. Inductive sensors are used
for AC currents. The sensor has a wire-wound core and a signal conditioner. As the
current conductor passes through the core, it becomes magnified by the conductor's
magnetic field. Since AC current is constantly changing potential from negative to
positive (general rate of 50 to 60 Hz) and therefore creating an expanding and

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collapsing magnetic field, a current is induced in the windings. The secondary current is
converted to a voltage and conditioned to output process; signals such as 4-20mA or
contact closures.
Magnetoresistive- The magnetoresistive effect is the property of certain materials to
change the value of its resistance as a function of a magnetic field applied to it. If
magnetic flux is not applied, the current flows straight through the plate. If magnetic flux
is applied, a Lorentz force proportional to the magnetic flux density will deflect the
current path. As the current path is deflected, the current flows through the plate for a
longer distance, causing the resistance to be increased.

Limited bandwidth of current sensors and influence of insulation sleeves and

bypass bridge regarding bearing currents were investigated in this paper. The analysis
of current sensor showed that used sensor has appropriate bandwidth. Insulation
sleeves and bypass bridge have some influence to initial system and therefore they
have to be designed in a way that stray capacitances and inductances are as low as
possible. Stray inductance in bearing during discharge is low and could be neglected.
Proposed model of EDM-current circuit provide relatively good results and therefore can
be used for further analyses of bearing currents.

A current sensor is a device that detects and converts current to an easily measured
output voltage, which is proportional to the current through the measured path.
When a current flows through a wire or in a circuit, voltage drop occurs. Also, a
magnetic field is generated surrounding the current carrying conductor. Both of these
phenomena are made use of in the design of current sensors. Thus, there are two types
of current sensing: direct and indirect. Direct sensing is based on Ohms law, while
indirect sensing is based on Faradays and Amperes law.
Direct Sensing involves measuring the voltage drop associated with the current passing
through passive electrical components.

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3- 3D SENSOR

3D-Sensors are very precise and wide-ranging measurement devices for milling and
EDM machines. They are clamped into a tool holder and inserted into a milling spindle
or EDM machines and make it possible to position the spindle axis exactly on the edges
of the workpiece. This allows for zeros to be set and the length to be measured quickly
and easily. You may approach in any direction (X-, Y-, Z-Axis). When the dial gage
shows zero, the spindle axis is exactly on the workpiece edge.

The sensor follows the principles of the echolocation of a bat, which can see tiny objects
by emitting ultrasound signals and receiving their reflections. We adapted this method
and developed a small sensor system based on ultrasound. The 3D sensor therefore
enables machines and robots to better perceive their surroundings without the
disadvantages inherent to optical systems. Due to its innovative approach, the 3D
sensor opens up new fields of application. Its characteristics enable the operation of the
sensor also under difficult environmental circumstances. The innovative sensor can
perceive 3D positions of objects and people.

Detection, counting and tracking of people in real-time e.g. for retail stores,
smart homes, offices or public buildings. Completely anonymous and secure sensor
solution to generate real-time data for customer analyses, automating processes or
installing safety functions. Further applications include gesture control, collision
avoidance for robots, autonomous driving and virtual reality. The sensor enables the
realization of completely new use-cases. Sophisticated algorithms and optimized
hardware design are combined to provide you with the ideal 3D sensor experience

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4- SENSOR MONITORING

The sensor signal acquisition was carried out only during the surfacing phase, the last
phase of the workpiece machining process which in total involves three phases:
roughing, trimming and surfacing.

Sensor monitoring system. The sensor monitoring system employed for signal
acquisition during WEDM surfacing comprised three sensors. Two current sensors to
acquire the upper and lower head current signals and one voltage probe to acquire the
voltage signal. The current sensors were chosen due to their high frequency up to 200
MHz since the considered WEDM surfacing process is characterised by high frequency
(715 kHz). In addition to the voltage and current signals, the instantaneous position of
the wire during WEDM was acquired.

how the sensor work?

The sensor continuously records and monitors exhaust system temperature and
backpressure. Its sends alerts to the vehicle operator via the In-Cab Display when
abnormal or undesirable conditions are detected or when routine filter maintenance is
required. The recorded information aids in troubleshooting and analysing vehicle
operating trends.

Figure 3

The drawing illustrates an arrangement for monitoring the machining conditions in a

travelling wire EDM apparatus shown only as far as the elements illustrated are

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necessary for a clear understanding of the invention. The illustrated EDM apparatus
comprises a pulse generator 1 supplying electrical pulses to a machining zone between
a travelling wire electrode 2 and a workpiece 3. Machining fluid nozzles 4 are disposed
such as to supply fluid to the machining zone between the electrode wire 2 and the
workpiece 3. Means, not shown but well known in the art, are provided for feeding the
electrode wire 2 longitudinally to the machining zone and for laterally displacing the
electrode wire 2 and the workpiece 3 relative to each other such as to effectuate in the
workpiece a cut 5 of appropriate path. [5]

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PRINCIPLE OF ELECTRICAL DISCHARGE MACHINING

The basic principle involved in this process is the described below. Electrical Discharge
Machining comprises of a dielectric medium, a tool, a source power supply of around
50-450 Volts, a speed reduction gear box, a rack and pinion and an electric circuit. The
job is connected to the positive terminal of source, it acts as anode and the tool which is
connected to negative terminal acts as a cathode. Both the job and the tool are
separated by a small distance known as spark gap. When the appropriate amount of
current is passed between the tool and the job, a dielectric solution, which occupies the
gap causes to break down. As a result, the electrons initiate to flow from cathode to fill
and ionize the gap.

An electrical breakdown takes place when there is a consistent drop in resistance and
discharge of electrical energy. An electric spark with appropriate force and velocity hits
the surface of the job. Thus a very high temperature of about 10,000
degrees centigrade is generated on the spot of the hit by electric spark discharge and
this completes the cycle in few microseconds. This high temperature melts the metal as
well as vapourises it. The melted or vapourised particles of the metal are thrown into the
gap by electromagnetic and electrostatic forces and are finally driven away by dielectric
flowing fluid.

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TROUBLESHOOT PROBLEM

1. The measuring of high current is particularly problematic. Resistors used in many

circuits often cannot handle the high voltage. As a result, measuring at this level
requires a special-purpose current transformer or transducer to reduce the
magnitude of the current in the circuit to a manageable level.
The major challenge of using current sensors is that the outputs of multiple
sensors employed throughout a system are often very different. Consequently, if
the wrong sensor is connected, or if it is connected improperly, equipment
damage or a safety hazard to personnel can result.
The measuring of high current is particularly problematic. Resistors used in many
circuits often cannot handle the high voltage. As a result, measuring at this level
requires a special-purpose current transformer or transducer to reduce the
magnitude of the current in the circuit to a manageable level.

2. There is no output signal when input signal is applied and power is on

-Cut off power supply and check if all connections are correct, the
terminals and wires are connected properly, the screws of terminal are
tightened securely and reliably.

-Check if the power supply and input meets the requirements shown on
the label, and the polarity of DC input is connected correctly.

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CONCLUSION

The popularity of Electrical Discharge Machining (EDM) is on the rise when it comes to
machining precision parts. It is a proven complementary method to traditional
manufacturing processes like Swiss turning and milling, and is well suited to producing
geometrically complex high precision gears, mechanical components and quick turn
prototypes.

EDM (Electrical Discharge Machining) is a non-traditional precision machining

process whereby a typically conductive material work piece has features created by the
controlled erosion of material using electrical discharges (sparks). At its core, Electrical
Discharge Machining involves two electrodes (one being the work piece) separated by a
dielectric liquid, typically deionized water or oil. When the field strength between the two
electrodes is high enough, the dielectric breaks down, current flows across, and
material is removed from both electrodes. The current flow between electrodes is NOT
constant; rather it is instantaneous, producing debris which is flushed out by the fluid.
This can be done repeatedly to erode a finely controlled feature that would be
impossible to create utilizing traditional machining methods.

A sensor is a device that detects and responds to some type of input from the
physical environment. The specific input could be light, heat, motion, moisture,
pressure, or any one of a great number of other environmental phenomena. The output
is generally a signal that is converted to human-readable display at the sensor location
or transmitted electronically over a network for reading or further processing. Sensors
gather data quickly and record it accurately, whether in the classroom, science
laboratory or on field trips. Sensor technology can store the data in memory, from where
it can be retrieved later for processing, analysis and presentation. Alternatively, sensor
technology can display graphs of data in "real time", the graph is constructed as the
data is being collected, and the graph is then modified on the screen as the data is
processed.

This paper presents the design and fabrication of three miniaturized mechanical
sensors to demonstrate the three-dimensional machining capabilities of micro-electro-

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discharge machining (EDM). The first sensor is an inertial bi-axial inclination sensor.
The displacement of an inertial mass is measured optically by means of a two-
dimensional position sensitive device (PSD). The machining freedom of micro-EDM
makes it possible to produce both sensor and housing in one monolithic structure. The
second sensor is an inertial uni-axial inclination sensor, which demonstrates the
compatibility of the micro-EDM technology with the conventional photolithographic
micromachining technologies. The mechanical structure of the sensor is machined by
micro-EDM and the capacitive sensing part is produced by lithography. The aim of the
integration is to set up a hybrid technology, which inherits the benefits of both micro-
EDM and photolithography. The third miniaturized sensor is a three-component force
sensor. The mechanical structure of the force sensor converts forces into
displacements, which are measured optically. The mechanical structure of the force
sensor is produced by wire-EDM and micro-EDM

Graphite materials are widely utilized as electrical discharge machining (EDM)

electrodes for fabricating molds for die-casting, plastics and more. Graphite has the
versatility to machine very large to small precision sizes used in the medical field.
Compared to copper electrodes, graphite electrodes offer excellent cutting performance
and produce fewer burrs and similar issues, thereby enabling speed improvements in
both cutting and EDM processes.
The TTK grades where developed has an ultrafine particle structure in the order of
microns. In addition to cutting and EDM, it also has superior characteristics to wire
EDM, which has been something that has conventionally been difficult for graphite
materials.
It also exhibits great improvements in the production of fine surface finishes, the
reduction of electrode wear and the processing of microscopic profiles, things that could
be not achieved with existing graphite electrode materials.

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REFERENCE

1-Muto, K., Futamura, S., & Tsutsumi, M. (1992). Monitoring Electric Discharge
Machining Phenomena by Acoustic Emission Sensor. 1st Report. Relationship between
Electric Discharge Conditions and Output Voltage of AE Sensor. Transactions of the
Japan Society of Mechanical Engineers Series C, 58(549), 1521-1525.
doi:10.1299/kikaic.58.1521

2-Edge, L. E. (n.d.). Electrical Discharge Machining ( EDM ) Design Consideration

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http://www.engineersedge.com/edm.shtml.

3-3D Sensor. (n.d.). Retrieved April 20, 2017, from https://www.toposens.com/

4- Muetze A., Binder A., Techniques for Measurement of the Parameters Related to Inverter-
Induced Bearing Currents,
IEEE Transactions on Industry Applications, 43 (2007), No. 5, 1274-1283
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1056, 2009
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capabilities/how-edm-works/

9- Caggiano, A., Teti, R., Perez, R., & Xirouchakis, P. (2015). Wire EDM Monitoring for
Zero-defect Manufacturing based on Advanced Sensor Signal Processing. Procedia
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