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Operation and Maintenance of CNC Wire EDM Machines

Presentation · December 2015

DOI: 10.13140/RG.2.2.16293.19681

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Srinivas Nandam
Indian Institute of Technology Bombay
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 Training on
Operation and Maintenance of
Wire Cut EDM Machines
Fundamentals and 
Principles of EDM 

Srinivasa Rao Nandam, Sc‐’E’ ,
Mechanical Engineering Group, DMRL.
g g p,
22nd December 2015, 14:30 Hrs
™ What is EDM   
Wh t i EDM
™ History of EDM Process   
™ Fundamentals and Principles of EDM  
™ Wire EDM Process 
™ EDM Section of MEG 
™ Applications of EDM
™ Advanced EDM Process 
™ Discussions (Q/A)
Discussions (Q/A)   
 EDM
EDM 
EDM Means : Electrical Discharge Machining 

EDM is also called as Un‐Conventional / Non Traditional Machining Process

EDM is a Electro Thermal Machining Process where electrical energy

gy is used
to generate electrical sparks of
Metal removal by Erosion / Melting and Evaporation   short duration and high
current density between tool
Why EDM Process ?  andd electrode.
l t d M t i l
Material
removal mainly occurs due to
thermal energy of these
9 Difficult to Cut Metals  sparks.
p
9 High Hardness Material 

9 Sharp Corners

9 Complicated Profiles 

9 Good Part Quality 
ƒ The
Th origin
i i off EDM dates
d back
b k to 1770 when
h English
E li h
scientist Joseph Priestly discovered the erosive
effect
e ect o
of e
electrical
ect ca d discharges.
sc a ges.
ƒ Erosion was caused by intermittent arc discharges
occurring in the air between the tool electrode and
the workpiece connected to a DC power supply.
ƒ The observation of this phenomenon was not very
precise because of the overheating of the
machining area, and may be defined as “arc
machining” rather than “spark machining” .
ƒ This
 Ionization Process 

Debris gathering at Bubble boundary 

High Frequency Sparks 
Debris and Bubble particles 
Wire EDM Process
Wire EDM Process 
 Work Material :
Application :
9 Steels
9 Die and Mould
9 Super Alloys

9 Tooling 9 Aluminum

9 Brass / Copper
9 Aerospace
9 Tungsten
9 Automobile
9 Co
Composites
pos tes

9 Medical 9 Ceramics

9 Thin Sections
9 Industrial
I d ti l
¾ Conductivity of work material 0.1 micro ohm/cm
Electrode
El t d :

9 Brass Wire (Soft wire)

Requirement of EDM Wire :
9 Zinc Coated (Hard Wire)
9 Conductivity
9 Diameter 0.25 mm
9 Strength
9 Diameter 0.2 mm
9 Dimensional Accuracy
9 Diameter 0.15 mm
9 Wear Resistance
9 Diameter 0.1 mm
9 Stiffness
9 Diameter 0.05mm

9 Diameter 0.3 mm
Dielectric
Di l t i Fluid
Fl id :

9 De-ionised Water

9 Distilled + Mineral Water

¾ 10-20 TDS

Ideal Properties of EDM oil

Requirement for Dielectric :
Densityy 0.78 ggm/lit
9 Breakdown Characteristics
Flash Point 105 0 C
9 High Latent Heat
Pour Point -9 0 C
9 Low Viscosity
Vi
Viscosity
i 2 16 cs
2.16
9 Cooling Media
Di electric Strength 45 KV/min
 Work Material (Conductive)

Electrode (Brass Wire of 0

0.25
25 mm)

Dielectric Fluid ( Deionized Water)

Ion Exchange Resins

Process Parameters (Ton,

(Ton PC,
PC SV,
SV WT,
WT WF,
WF FP etc.)
etc )

CNC Part Program

Cutting Operation ( Job Setting)

¾ Use Rubber Hand Gloves While loading and Unloading Component

¾ Never Touch the component

p during
g machining
g process
p

¾ Never touch the brass wire with bare hand while running

¾ Prevent leakage of deionized water from the machine

¾ Use Protective Shoes

¾ Never wear loose shirt etc.

etc

¾ Not recommended use conductive materials Watches / gold rings etc.

 2. UltraCut
1. SuperCut
3. EzeeCut
EDM Drilling EDM Sawing
EDM Sinking
3. SCCGR Specimen
Angular Sliding Insert for 
HPT V
HPT Vane Wax Pattern Die 
 W  P  Di  
Aerofoil Profiles for Brazing Experiments  Root Profiles of Gas 
Turbine Blade 
¾ High Capital Cost

¾ Low Cutting Time

¾ Conductive Materials only

¾ Post finishing Operations required

¾ Corrosion (Rusting) of Components

¾ Oxidation of components

¾ Internal Stresses due to thermal loads

¾ Regular Maintenance

¾ Trained Operators (Semiskilled)

Rotary EDM  Vibratory / Ultrasonic  EDM 
Magnetic Assisted EDM 
Nanotechnology‐ Lathe

Micro vessel
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