EDM (ELECTRIC DISCHARGE

MACHINE) WIRE CUT

ME – 323 Manufacturing Process Lab

NOVEMBER 2, 2018

HAMMAD FAROOQ
ME – 08 A
Registration # 175292
ME – 323 Manufacturing Process Lab 1

Contents
Objectives: .................................................................................................................................................... 2
Introduction:................................................................................................................................................. 2
TYPES: ....................................................................................................................................................... 2
Operation of EDM Wire-cut: .................................................................................................................... 3
Pros: .......................................................................................................................................................... 3
Cons: ......................................................................................................................................................... 3
Equipment: ................................................................................................................................................... 4
Procedure: .................................................................................................................................................... 4
Safety Precautions........................................................................................................................................ 4
ME – 323 Manufacturing Process Lab 2

Objectives:
This lab is meant to achieve following objectives:
 Introduction to minute cutting process and its uses in industries.
 Get familiar with the operation and control of Wire-cut Electric Discharge Machine.
 To design a basic NC program for Electrical Discharge Machining (EDM) wire cut
 To cut a product using the Electrical Discharge Machining (EDM) wire cut.

Introduction:
Electrical discharge machining (EDM), is a manufacturing process whereby a desired shape is obtained by
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.

Electrical discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark
eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing process whereby a desired
shape is obtained using electrical discharges (sparks). Material is removed from the 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".

TYPES:
Following are the types of EDM:

 Die Sinker or “Ram” EDM

 Wire or “Cheese Cutter” EDM
 Hole Drilling or “Hole Popper” EDM
ME – 323 Manufacturing Process Lab 3

Operation of EDM Wire-cut:

Wire EDM machining works by creating an electrical discharge between the wire or the electrode and
the work piece. As the spark jumps across the gap, material is then removed from the work piece and
the electrode. Due to the inherent properties of the process, Wire EDM can easily machine complex
parts and precision components out of hard conductive materials.

To stop the sparking process from shorting out, a non-conductive fluid or dielectric is also used in the
process. The waste material is removed by the dielectric, and the process continues.

Pros:
 Complex shapes that would otherwise be difficult to produce with conventional cutting tools.
 Extremely hard material to very close tolerances.
 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 perceivable distortion.
 A good surface finish can be obtained; a very good surface may be obtained by redundant
finishing paths.
 Very fine holes can be attained.
 Tapered holes may be produced.
 Pipe or container internal contours and internal corners down to R .001".

Cons:
 The slow rate of material removal.
 Potential fire hazard associated with use of combustible oil based dielectrics.
 The additional time and cost used for creating electrodes for ram/sinker EDM.
 Reproducing sharp corners on the work piece is difficult due to electrode wear.
 Specific power consumption is very high.
ME – 323 Manufacturing Process Lab 4

 Power consumption is high.

 "Overcut" is formed.
 Excessive tool wear occurs during machining.
 Electrically non-conductive materials can be machined only with specific set-up of the process.
 Difficulty finding expert machinists

Equipment:
 EDM wire cut Machine
 Aluminium work piece
 NC Programming
 copper wire electrode.

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

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