ME3300 Die-Sinking EDM

Aakash R -ME14B149

February 21, 2017

1 Aim
To study the effects of various parameters such as the gap voltage, current on time ,etc on the surface
finish obtained.

2 Theory
2.1 Working of EDM
This is an unconventional machining operation which consists of 2 oppositely charged electrode . Here
the tool is the cathode , the work piece is the anode.The above is chosen in accordance with the MRR
in mind. Since the electrons have high energy they produce high temperatures as high as 10,000 C ,
which vaporises the workpiece. Here the shape of the cavity produced by the material removal depends
on the insulation of the tool,hence a badly insulated tool can produce taper cut,while an insulated
tool produces an over cut. In order to maintain the gap voltage, control precise Z-Direction motion
servo control is used.

2.2 Types of EDM

1. Die-Sinking EDM :This is an uncoventional machining machining operation which is used to
produce negative impression in the shape of the impression is based on the shape of the tool,the
two types of tools commonly used is graphite,copper. The tool is completely immersed in the
dielectric fluid,which helps in the break down (therefore arc generation) , as well as removal of
the debris produced. The surface produced during machining consists of black spots which is
just carbon deposits. The dielectric material used in our case is the kerosene,water mixture.
2. Wire EDM : In Wire EDM, a thin wire will be used as the tool, deionised water as dielectric
fluid, the conductive material will be cut using thin wire which follows the programmed path.

2.3 Process parameters

1. The open circuit voltage - Vo
2. The working voltage - Vg
3. The maximum current - Io
4. The pulse on time - ton
5. The pulse off time - tof f
6. The gap between the workpiece and the tool spark gap -
7. The polarity straight polarity tool (+ve)
8. The dielectric medium
9. External flushing through the spark gap.

1
3 Results
3.1 Data
S.no Current (Io ) Gap Voltage (Vg ) Pulse on time-Ton (s) Ra (m) Rz (m) Rmax (m)
1 10 70 50 5.6256 31.3898 54.6620
2 10 70 75 6.8573 32.6941 50.2237
3 10 70 100 4.2612 21.6500 29.9736
4 14 70 50 4.0483 19.5274 30.9427
5 14 70 75 4.2548 21.3817 27.5339
6 14 70 100 7.0671 35.3087 44.8363

3.2 Model Fitting

(Ra ) = 1.7582Io 0.2464Ton + 0.0219Io Ton + 25.2099 (1)

(Rz ) = 10.3634Io 1.4709Ton + 0.1276Io Ton + 146.8219 (2)
(Rmax ) = 17.0971Io 2.4229Ton + 0.1929Io Ton + 252.9569 (3)

4 Graphs
4.1 Case 1
Current (Io ) = 10 A.

2
4.2 Case 2
Current (Io ) = 14 A.

5 Observation
1. As can be seen for the Current value of Io = 10A an optimum in surface roughness is reached
at Ton = 75s.

2. Also for the Current value of Io = 14A there exists a monotonic increase in surface roughness.

6 Inference
1. From various research papers it should be duly noted that increasing current for a particular
pule width should increase MRR thereby increasing surface roughness.(due to many crater
formation). This unfortunately in our dataset can be noted only for Ton = 100s.

2. Also the MRR peaks for a particular Ton for constant I.This trend can be seen in our first
graph. In our second graph the peak To n may be is at the right.

3. Also it should be noted that all these trend are highly dependent on the material being machined.