CHAPTER -1

COMPANY PROFILE
1.1 INTRODUCTION
STEP TOOL is a reputed firm in the field of dies and sheet metal industry , founded in 2009 by Mr.
Virender Sharma . It is currently located in Kadipur industrial area, Gurgaon, Haryana. The firm is
stored with multiple wire cut machines of latest versions.
STEP TOOLS is a trusted and certified manufacturing partner of firms like MINDA Group, JET TECH
, BEST AUTO LIMITED.
Quality is the essence and Step Tools always stress on customer satisfaction.

1.2 FACILITIES AND TECHNOLOGIES

1. Product and tool design
2. Tool Room

1.3 STEP TOOLS PRODUCTS

STEP TOOL deals in the manufacturing of dies and punches mainly in tools and dies. Some of
which are punches , dies etc.

Fig 1.1-PUNCH Fig 1.2-PUNCH

1
Fig 1.3-DIE

Fig 1.4 –DIE

2
 CHAPTER-2

NON-CONVENTIONAL MACHINING

2.1 INTRODUCTION
From some time past engineering industries have witnessed a rapid growth in the development of
harder and difficult to machine materials such as hastalloy, nitralloy, waspalloy, nimonics, carbides,
stainless steel, heat resisting steels and many other high strength temperature resistant(HSTR) alloys.
These materials find wide application in aerospace, nuclear engineering and other industries owing to
their high strength to weight ratio, hardness and heat resisting qualities. For such materials the
conventional edged tool machining is highly uneconomical and the degree of accuracy and surface
finish are poor. Besides, machining of these materials in to complex shapes is difficult, time
consuming and sometimes impossible.
Considering the seriousness of the problem, Merchants in 1960’s emphasized the need for the
development of newer concepts in metal machining. Consequently, non- traditional machining
processes have emerged to overcome these difficulties. These processes are non-conventional or non-
traditional (NTM) in the sense that they do not employ a conventional or traditional tool for metal
removal, instead they directly utilize some from of energy for machining.

2.2 Characteristics of non-traditional machining

Non Conventional Machining Processes are characterized as follows:
• Material removal may occur with chip formation or even no chip formation may take place. For
example in AJM, chips are of microscopic size and in case of Electrochemical machining
material removal occurs due to electrochemical dissolution at atomic level.
• In NTM, there may not be a physical tool present. For example in laser jet machining,
machining is carried out by laser beam. However in Electrochemical Machining there is a
physical tool that is very much required for machining.
• In NTM, the tool need not be harder than the workpiece material. For example, in EDM, copper
is used as the tool material to machine hardened steels.

3
Mostly NTM processes do not necessarily use mechanical energy to provide material removal. They
use different energy domains to provide machining. For example, in USM, AJM, WJM, mechanical
energy is used to machine material, whereas in ECM electrochemical dissolution constitutes material
removal.
2.3 Classification of non-traditional machining processes
Classification of NTM processes is carried out depending on the nature of energy used for material
removal. The broad classification is given as follows:
❖ Mechanical Processes
⎯ Abrasive Jet Machining (AJM)
⎯ Ultrasonic Machining (USM)
⎯ Water Jet Machining (WJM)
⎯ Abrasive Water Jet Machining (AWJM)
❖ Electrochemical Processes
⎯ Electrochemical Machining (ECM)
⎯ Electro Chemical Grinding (ECG)
⎯ Electro Jet Drilling (EJD)
❖ Electro-Thermal Processes
⎯ Electro-discharge machining (EDM)
⎯ Laser Jet Machining (LJM)
⎯ Electron Beam Machining (EBM)
⎯ Ion Beam Machining (IBM)
⎯ Plasma Arc Machining (PAM)

4
 CHAPTER -3
WIRE CUT EDM

3.1 INTRODUCTION TO WIRE-CUT EDM

In all the machining processes EDM is one of the important non-traditional machining
processes. Here we are mainly concerned about wire cut EDM. Wire cut EDM or Electrical
Discharge Machining is a technique used to slice through metal. The technique uses thin brass
wire for the purpose and can create intricate profiles with the process. The EDM machine uses
spark discharges that are fast, repetitive, and controlled for cutting. This process works with
electrically conductive metals. The process is specially suited for contours and cavities that are
not possible with other cutting tools.
EDM is also known as “spark machining” as it uses repetitive electrical discharges to remove
metal. The electrical discharges are passed between the metal part and the electrode. A stream
of continuously flowing liquid is used to remove the metal remnants produced during the
process. A set of successively deeper craters is formed till the final shape is created by the
discharges.

Principle of edm
It is the most versatile electrical machining process where erosion is caused due to electric spark.
The rate of metal removal and the resulting surface finish can be controlled by proper variation in
energy and duration of spark discharge. It is the process of repetitive sparking cycles.

Different types of EDM:

1. Ram EDM
In ram EDM, a graphite electrode is used along with traditional tools. This electrode is
connected to the ram with the help of a power source and is fed into the workpiece. The whole
process is carried out in a fluid bath. The fluid helps to flush away the material, serves as a
coolant to reduce the heat, and acts as a conductor for passing current between the workpiece
and the electrode.

5
 2. Wire EDM
In this method, a thin wire is used as an electrode. The wire is fed in the metal and the discharges are
used to cut the material. The process is carried out in a bath of water. When closely observed, you can
see that the wire does not touch the metal. All the cutting work is done by the electrical discharge.
Computer software controls the whole operation including the path of the wire. The process can
produce all sorts of complex shapes that are very difficult with other processes.

Fig 3.1: Different types of Wire EDM

6
3.2 CONCEPTS OF 4- AXES WIRE CUT EDM

The wire-cut electric discharge machine is comprised of a machine tool, a power supply unit
(ELPLUS), dielectric supply and chiller unit.

❖ Machine tool
The ELECTRA machine tool unit comprises of a main work table (called X-Y table) on which the
workpiece is clamped, an auxiliary table (called U-V table) and wire drive mechanism. The
workpiece is mounted and clamped on the min work table. The main table moves along X-Y axis in
the steps of 1 micrometer, by means of servo motors. U & V are parallel to X & Y axes respectively.
A travelling wire which is continuously fed from wire feed spool is caused travel through the work
piece and goes finally to the waste wire box. Along its travelling path the wire is supported under
tension between a pair of wire guide, which is supported by the U-V table. The upper wire guide can
be displaced transversely along the U-V axes with respect to lower wire guide. It can also be
positioned vertically along Z axis by moving the vertical arm.
As the material removal or machining proceeds, the work table carry the work piece is displaced
transversely along a predetermined path which is stored in the controller. The path specification (path
program) can be supplied to the controller by the program or directly through the controller key
board.
When X-Y table moves along the predetermined path, the U-V table is kept stationary as stationary
cut with the predetermined pattern is formed.
In order to produce taper machining the wire electrode has to be tilted. This is achieved by displacing
the upper wire guide (along the U-V axes) with respect to lower wire guide. The desired taper angle is
achieved by simultaneous control of the movement of X-Y table and U-V table along their
respective predetermined path stored in the controller.

The path information if the X-Y table and U-V table is given to the controller in terms of linear &
circular elements via NC programme.

7
 ❖ Power supply
The power supply unit comprises of electric pulse generator, motor drive unit for X- Y, U-V axes
and controller.

❖ Dielectric Supply
While the machining is continued, the machining zone is continuously flushed with chilled
distilled water through the nozzle on both side of workpiece. The spark discharge across the
workpiece and the wire electrode causes ionization of the water which is used as a dielectric medium.
It is important to note that ionization of water leads to the increase in conductivity of water.
An ion exchange resin is used in dielectric distribution system in order to prevent the increase in
conductivity of water.

❖ Part programming
The geometry of the profile and the motion of wire electrode tool along the profile are fed to the
part programming system using keyboard. The profile geometry is defined in terms of various
geometrical definition of points, lines and circles as the wire tool path elements on graphical screen
by using a totally menu driven software. The wire compensation (for wire diameter and machining
overcuts) and taper angle can be specified for total path or for each path element separately. After the
profile is fed to the computer all the numerical information about the path is calculated automatically
and its print out is generated. The entered profile canbe verified on the graphic displayed screen and
modified if necessary. After successful profile definition, the profile is recorded by the computer on a
floppy disk which can be used in the controller for the execution.

8
3.3 WORK PREPRATION

1. Work piece material

Any slight dislocation in the work piece material may result distorted job. It is important to use the
material free from residual stresses, arising from various processes. This may affect the machining
accuracy to a very large extent. Work piece material should be
• Electrically conductive (at least 0.1 micro-ohm/cm)
• Suitable for clamping
• Non-combustible
• Non-violent chemical reactions with water, oxygen and hydrogen

2. Wire electrode
The wire electrode is required to have a sufficient tensile strength and should be of uniform diameter
and free from kinks and twist. The electrode wire material should be
• Brass/super alloy (coated)
• Diameter variation within + 0.02 mm
• Tensile strength more than 50 kgf/mm2
• Even winding free from kinks/breaks

Fig 3.2- Wire Roll

9
Wire diameter and minimum corner radius:

The diameter of wire imposes a restriction on the minimum achievable corner radius.
Minimum corner radius = (0.5*diameter) + overcut Current carrying capacity of the wire:

As a thumb rule a brass wire of 0.2 mm in diameter can easily pass current of about 0.3-
0.7 amperes in air but the same wire can pass current of about 6-9 amperes in water. While
machining water should always be surrounded by the water column to avoid wire strength.

Wire tension (WT):

Wire tension determines how much the wire has to be stretched between upper and lower guides.
More thickness of the job more is the tension required. Improper setting of tension may result
inaccuracy in the job as well as wire breakage. Following chart gives nominal value of the wire
tension for different settings. Minimum tension (for zero setting of WT) is approximately 200 gms
which can be adjusted by clutch adjustment provided on feed spool mounting rod. This should be
adjusted for different weight of spool.

Table 3.1-Nominal tension value corresponding to WT

W TENSION (GMS) NOMINAL VALUES

T
1 300
2 420
3 540
4 660
5 780
6 900
7 1020
8 1140
9 1260
1 1380
0

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Wire feed (WF):
Due to spark erosion the travelling wire electrode becomes thin and brittle. Wire feed is the rate at
which the wire electrode travels along wire guide path. It is always desirable to set the wire feed to
the maximum. This will result in less wire breakage, better machining, stability and little more cutting
speed. With more feed set as 8 m/min on an average of a 0.25 mm diameter brass wire spool of 5 kg
will last for 24 sparking hours. Setting WF at 15 will correspond to 15 m/min (approx.).
Overcut:
It is lateral distance between the wire and workpiece during the sparking. Overcut is larger if
❖ Machining gap voltage is higher
❖ Discharge energy is higher
❖ Wire tension is lower
❖ Guide span is higher
❖ Job thickness is higher
❖ Dielectric conductivity is higher
❖ Machining is unstable

Wire compensation (offset):

Wire compensation = (0.5*wire diameter) + overcut
Wire compensation can be to the left (G41) or right (G42) of profile depending upon the direction of
motion and wire being inside or outside of the profile as shown:

Fig 3.3: wire compensation

11
WATER DI-ELECTRIC

1. Characterization & suitability of wire cut medium

❖ The use of water as dielectric permits widening of spark gap to minimize short circuit,
resulting in high cutting speed.
❖ Water has good wire electrode cooing effect (than kerosene as example).
❖ It is non flammable and its vapours are non-toxic.

Fig 3.4- Dielectric tank

2. Dielectric strength
Since the insulation characterization of dielectric fluid decides the overcut so it is important to
keep the conductivity of dielectric water constant. Conductivity of water changes due to generation of
metallic ions and dissolution of ambient gases. The conductivity can be decreased by passing the
water through de-ionize resin. This is done automatically by the machine.

3. Flushing
Flushing is important to achieve stable condition. It plays very important role as far as cutting speed
concerned. Both the nozzles upper and lower should be just about 0.22 mm away from the workpiece,
otherwise cutting performance drops considerably. Also both the nozzles should also be checked
periodically for damages, scratches or slight damage on the contact edge affect cutting speed. Purity
of the water should be machined by firm displacements of filter

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 .

3.5 SETTING UP AND OPERATIONS

1. Job mounting:
Mount the job and damp by maximum possible clamp, dial the top surface of the job by dial gauge.
The dial gauge can be marked on the upper flushing assembly. Provision for the same is provided.
Make the wire vertical with the help of vertical block provided with the machine.

2. Dialing:
Now the job is dialed by using dial indicator .Dialing of the job is done to align the job in Correct
way. It is necessary that is properly aligned to prevent rough cut during machining process.

Fig 3.5- Dialing of block

3. Job reference point

It is always desirable to have a reference point on the work piece for setting the work co-ordinate
system (WCS). The reference point can be defined by the ground edge of the work piece or the centre
of the bored hole on the work piece.

13
 a) Edge finding (EF):

This function should be used to find the edge for the setting work co-ordinate system. Find the
edge of the work piece from a distance of 2-5 mm. After edge finding the wire system is always
from the work piece edge by a distance equal to wire radius.

Fig3.6: Edge Distance Fig 3.7-Edge finding

a) Center finding (CF):

This function should be used to find the centre of the reference hole. Centre finding
should be repeated at least few times to verify consistency.
❖ Care should be taken to perform CF and EF functions.
❖ Workpiece surface should be taken to perform CF and EF functions.
❖ Upper assembly section should not be wet.
❖ WF should be at 3 and WT at 6.

Fig 3.8-Centre finding

Flow chart for job progress 14
 Job obtained as a cast or forged or
machine product

Drawing using elapt software as

per job drawing

Defining of wire path in connect mode

Generation of CNC program as per

drawing in CNC programming mode

Clamping of workpiece on table and

defining job reference point

Dry cutting at high speed (dummy)

Rough cut

Trim cut

Defect inspection

15
 CHAPTER -4

TECHNOLOGY AND GUIDELINES

The technology chart gives guideline to the operator to set up the parameter and get optimum
performance from the machine. Actual process results may differ to same extent.
Generally by increasing the spark energy one can achieve the desired cutting rate. To achieve
optimum results of cutting rate and the job accuracies, the machining parameter should be properly
set.
The parameters which control its pulse energy and ultimately its machining speed are described
below:

4.1 MACHINING AND PARAMETERS

Different parameters controlling its pulse energy and machining conditions are given below along
their setting:

Fig 4.1 Machine parameters

• Ton : Pulse on time

During this period the voltage (Vp) is applied across the electrodes. Range:-
000-031 (in step of 1)
Higher is the Ton setting larger the pulse on period. The single pulse discharge energy increases
with increasing Ton period, resulting in higher cutting rate. With higher values of Ton surface
roughness tends to be higher. The higher values of discharge energy may also cause wire breakage.

16
 • Toff : Pulse off time
Voltage for the gap is absent during the period.
Range : - 00-63 (in step of 1) .
Higher the Toff setting larger is the pulse off period. With the lower value of Toff there is more number
of discharges in a given time resulting in increase in the sparking efficiency; as a result the cutting
rate also increases. Using very low value of Toff period may cause wire breakage which reduces the
cutting efficiency. When the discharge and its ions become unstable one can increase the Toff period.
This will allow lower pulse duty factor and will reduce the average gap current.
• Ip : Peak current (A)
This is for selection of pulse peak current. Range : 010-230
(in step of 10)
Higher is the Ip setting larger the peak current value. Increase in Ip value will increase the pulse
discharge energy which can improve the cutting rate further. For higher value of Ip gap conditions
may become unstable with improper combination of Ton , Toff , SV and SF value settings. When the
discharge conditions become unstable one must reduce the Ip value (and/or increase the Toff period).

• Vp : Pulse peak voltage

This is for selection of open gap voltage. Range : 1
or 2
Increase in Vp value will increase the pulse discharge energy which can improve the cutting rate.
Normally it is always ‘2’.
• WP : Flushing pressure of water dielectric This is
selection of flushing input pressure. Range : 0 or 1 (0-
low pressure, 1-high pressure).
High input pressure of water dielectric is necessary for cutting with higher values of pulse
power and also cutting the jobs of higher thickness. Lower input pressure used for thin jobs
and in trim cuts.

17
 • WF : Wire feed rate setting
This is the feed rate at which the fresh wire is fed continuously for sparking. Range :- 01
– 15 (in step of 1)
Higher values of wire feed rate (above 6) are required for working with higher pulse power
(where job cutting rate are higher)

• WT : Wire tension setting

This is a gram equivalent load with the continuously fed wire is kept under tension so that it remains
straight between the wire guides.
Range :- 01-15 (in step of 1)
While the wire is being fed continuously appropriate wire tension avoids the unintentional wire
deflection from its straight path (between the wire guides). The wire deflection is caused due to spark
induced reaction forces and water pressure.

• SV : Spark gap set voltage

This is the reference voltage for the actual (gap voltage). Range :- 00-99
(in step of 1) volt

• SF : Servo feed setting

This parameters decides the servo speed, the servo speed at the set value of SF, can vary in proportion
with the gap voltage (normal feed mode) or can be kept constant while machining (with constant feed
mode).
Range : 0000-0990 (for normal feed) 1000-1999
(for constant feed)
In constant feed mode, the 3 least significant digit of SF define the feed rate in 10th of
mm/min. 1050 will give 5mm/min constant feed. Here SF can be vary from 000-990 in normal feed
mode and 000-999 in constant feed mode by pressing up or down arrow keys or by page up or down,
where as selection of first digit 0 or 1 can be done by pressing numeric key 0 or 1.

• T : Threshold setting
Threshold setting (in percent of SV) is for correcting action in abnormal discharge condition.
Range : 0-99 (%)

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Guidelines parameters
Apart from these parameters, the technology guideline charts also includes following two parameters for
process monitoring purpose:
• Ig : Average gap current (A)
This is the actual value of gap current read on ammeter. The value of average machining current
given in the guideline chart is indicative.
• Vg : Average gap voltage (volt)
This is the actual value of gap voltage read on yellow voltage bar on the screen. It depends on set
values of SV & SF. For stable machining, SF should be set such a way that Vg is higher is higher
than SV by 3 – 9 volt

4.2 Guideline charts

The technology charts are prepared to support the wire EDM user and provide some guidelines.
Every technology chart comprises of a set of guide pertaining to a specific wire job thickness
combination.
Technology guidelines are available for the following wire and workpiece material:

WIRE : Material: ELECTRA DURACUT

Diameter: 0.25 mm

JOB : Material: Steel

Hardness: 48 – 50 RC
Prior to machining, job materials were properly stress relieved.

CONDUCTIVITY : The guide refers to the de-ionized water as a dielectric with conductivity
value of 20 units.

PRESSURE The maximum water inlet pressure is 15 kg/cm2.

FLOW TOP : This is the flow rate of water dielectric in liters/min (LPM) through the top wire
guide nozzle.

19
FLOW BOT : This is the flow rate of water dielectric in liters/min (LPM) through bottom wire
guide nozzle.
C- FEED : This is job cutting rate displayed on the screen as the job is being cut in units of
mm/min. Guideline chart provides the cutting feed values found under the test conditions (with all
required machining parameters probably set as given in the guideline chart for a selected job and
wire thickness).
OFFSET : This is guideline value for wire offset (in mm). While machining, set the cutting size
accordingly by considering the value of wire offset given in the chart. Guideline chart provides the
wire offset values found under the test conditions.

4.3 IMPORTANT CONDITIONS

I. PROPER TEMPERATURE CONTROL

a) Room temperature control :

To achieve better machining accuracies, it is recommended that the machine be installed in
controlled atmosphere with room temperature of 200 C (+ 1).

b) Water dielectric temperature:

The dielectric water temperature must be maintained within the 10 C below the machine tool
temperature (approx. same as room temperature). Set the temperature difference -10 C on
temperature controller of dielectric cooling system. Before starting any job alignment or
machining operation, the room temperature, machine tool temperature and the job temperature
must be stabilized by keeping the room air conditioner, machine power and the dielectric
cooling system power on for at least half an hour. The dielectric water should also be kept
splashing on the job and in the work area.

20
 II. Proper heat treatment
Proper heat treatment of the job material is necessary machining. This is to reduce the residual
stresses to a minimum (quite often the cause of instability and inaccuracies).
III. Conductivity of water
Conductivity of water (S) should be maintained during machining and be checked periodically.
Replace paper filters and resins periodically.

IV. Proper flushing - Rate of dielectric flow adjustment.

Case 1. For rough finishing

❖ To achieve maximum cutting rate in case when both guide nozzle can be closely connected
with both the sides of work surface (0.1-0.2 mm away from workpiece) keep under and lower
flushing valves fully open. Adjust the position of upper flushing nozzle so as to achieve the
required flow rate as per the technology guidelines.
❖ In case when upper guide nozzle can’t be closely connected with the work surface. Keep the
lower flushing valve fully open. Adjust the flow through the upper flushing valve in such
away that the flushing flow from upper guide suppresses the flushing flow of the lower guide.
❖ In case when neither of the guide nozzle (upper or lower) be closely connected with the work
surface, select low pressure (WP =0) for dielectric flushing.

Case 2. For finishing machining

a) With die machining (without taper cut)

For job thickness less than 30 mm keep lower flushing valve fully close and upper flushing flow
at about 1.2 liters/min.

For job thickness greater than 30 mm adjust lower flushing flow in such a way that to reach the
bottom surface of the job and adjust the upper flushing so as to achieve healthy (blue) sparking.
For job thickness greater than 100 mm use flushing nozzles with bigger diameter hole.

21
b) With taper cut machining

For cutting job taper profiles proceed as…

❖ Keep the clearance of 0.5-1 mm between upper flushing nozzle and top surface of the job.
❖ Specify the Z height (quill position) in the program (new height = job thickness + 1 mm).
❖ Apply flushing condition as for die machining.
❖ The cutting speed for taper cut should be lower (by 20-40 %) than straight cut machining.
c) With punch machining- Adjust the lower flushing flow in such a way so as to reach the bottom
surface of the job and adjust the upper flushing to 2-3 liters/min.

4.4 PRECAUTIONS
Maximum cutting speed should not be used in single pass cutting of highly accurate jobs. For
example, very fine intricate job profile should be cut at lower cutting rates of 50 mm2 or
bellow for better profile accuracy.
the selected cutting rate as in following situation. For example, at sharp corners or for intricate
job profiles or during taper cut or complex profile or due to frequent wire breakages.
Under such circumstances increase the value of pulse off time (Toff) and reduces SF to
maintain same Vg, since it has minimum effect on overcut values.

22
Trim cut
The trim cut (skim cut) mode is used for machining of job profiles in multi pass cuts. Multi pass
cutting of jobs is usually had in 2 or 3 cuts.
Trim cutting is used for :
* Higher job accuracies
*Improved surface finish
*Reducing inaccuracies produced by miner job deformation after 1st cut due to residual stream in
the job material.
*Reducing bow effect on cut job surface produced in the 1st cut due to adverse flushing conditions.
*Improving die life by reducing thermally affected layer formed in the 1st cut on the
machined surface.

Fig 4.2- Machine parameters during trim cut

23
 CHAPTER -5

DESCRIPTION OF WIRE CUT MACHINE

Top tank (T1): - It always contains filtered water.

Bottom tank (T2): - It is sub divided into 3 tanks:

a) Setting tank-1 (inner most cylinder)

b) Setting tank-2 (space between inner and middle cylinder)
c) Setting tank-3 (space between inner and bottom cylinder)

Drain: - This carries dirty water from water tank of the machine tool to control tank. Drain (D2)
is to drain water from top tank. Drain (D3) is to drain water from bottom tank.
Sponge: - It acts as primary filter. It catches coarse particle of eroded material.
Filter mesh: - Filter mesh of brass of 0.1 mm is provided below the sponge. It catches the
particles of eroded material which escape from sponge. Clean the sponge and filter mesh with
flowing water everyday.
Filter pump: - This sucks water for subsequent filtration. It delivers water to the filter.
Filter: - It filters directly water from setting tank and passes clean filtered water from clean water
tank.
Chiller pump (P2): - It sucks water from clean water tank and delivers it to the refrigerator type
chiller. There will not be chiller pump for HOBER chiller unit.
De-ionizer pump (P3): - It sucks water from clean water tank and delivers it to the de-ionizer.
De-ionizer: - This maintains conductivity of water. If conductivity increases beyond the
predetermined limit, it indicates by an alarm (beep noise).
Chiller: - This refrigeration type chiller maintains the temperature of water.
Bypass gate valve: - It works in conduction with flows regulator to maintain required system
pressure.
Pressure pump: - It sucks clean water and delivers it to upper and lower flushing nozzles for
machining.
Pressure gauge: - It indicates system water pressure.
Flow regulator: - It controls the water flow.
Check valve: - It is main returns valve and it prevents reveres water flow.
Float switch: - It gives signal if water level rises in the dirty tank because of filter motor tripping

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5.1 SPECIFICATIONS

Model: SUPERCUT 734 (ELECTRONICA M/C TOOLS LIMITED)

Fig 5.1- super cut machine

Travel Range:
Longitudinal Y-axis - 400 mm
V-axis - + 40 mm

Lateral X-axis - 300 mm

U-axis - + 40 mm

Vertical Z-axis – 225 mm

Table Size: 110 X 450 X 650 mm

Maximum workpiece size: 400 X 300 X 200 mm
Maximum workpiece weight: 400 kg
Wire diameter (Standard): 0.25 mm

Maximum taper angle: + 150 /100mm

Feed:

Main table feed rate: 170 mm/min

Resolution: 0.001 mm

Wire feed rate: 0-10 m/min

25
Wire tension: 1.5 kgf
Dielectric: distilled water

5.2Advantages:
❖ Enable high accuracy on tools and dies.
❖ Useful process for metal saving.
❖ It is quicker process for intricate shapes.
❖ Fine holes can easily be drilled.
❖ Any shape can be imparted to the tool can be produced on work.
❖ Weaker section can be machined.

5.3 Disadvantages:
❖ Capacity to machine small pieces only.
❖ Unsuitable for machining of non conductors.
❖ Thermal distortion may take place during machining.
❖ Inability to produce sharp corners.

5.4 APPLICATION:
1. In tool manufacturing industries (hard to machine metal).
2. Resharpening of cutting tools and broaches.
3. Trepanning of holes with straight and curved curves.
4. Machining of cavities for dies and remachining of die cavities without annealing.

Fig 5.2: Machined profiles by SUPER CUT EDM

26
 CHAPTER-6
Machining accuracy
6.1 How to achieve optimal machining accuracy:

1. Wire should be perpendicular to the top surface of the job.

2. The start point should be preferably a hole and should be at proper place. Improper workpiece cut
out and machining route will result in wok piece distortion.

a) Workpiece cut out and machining route:

❖ Inappropriate start point i.e. machining from outside the workpiece cause distortion. Be
sure to position start point inside the workpiece.
❖ Set the machine so that workpiece clamp side may be machined finely.
❖ Inadequate circumference thickness. Provide adequate circumference thickness that will
resist residual stress deformation.
b) Workpiece distortion

❖ Minimize workpiece internal stress by pre machining.

c) Heat treatment

❖ Vacuum heat treatment

❖ Sub zero annealing treatment

d) making of starting holes

❖ Steel unhardened: drill

❖ Steel hardened: make holes by sink erosion with tubular electrode.
e) clamping allowance for reliable mounting:

❖ Clamping allowance should be greater than 10 mm for light work piece.

❖ Greater than 35 mm for medium weight work piece
❖ Greater than 50 mm for heavy work piece to permit working without risk of collision.
3. The test cut should be performed on a trial piece to get the exact value of overcut.
The same technology parameters viz. Ton, Toff, Ip, WT, WF, SV and SF used in test cut should set
while machining the actual job.

27
4. The test cut should be performed on a trial piece to get the exact value of overcut.
The same technology parameters viz. Ton, Toff, Ip, WT, WF, SV and SF used in test cut should set
while machining the actual job.
5. Machining should be stable.

6. Corner shape accuracy is required especially for punch and die which are used to make thin plate
product. Deviation at corner can be reduced by machining at lower spark energy.
One can vary spark energy as follows:

❖ Ton position from 0 to 31 will increase spark energy insteps.

❖ Toff position from 0 to 63 will increase spark energy insteps.
❖ Ip position from 10 to 200 will increase spark energy insteps.

6.2 TROUBLES DURING MACHINING

Wire breakage:

There are lots of causes for wire breakage. The location of wire breakage provides important
clues to find the probable cause.

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 Table 6.1 – Wire break table

WIRE BREAKAGE CHECK CAUSES AND REMEDIES

POSITION
1. Wire inlet side Wire tension ❖ Reduce the wire tension slightly.
❖ The movement of the tension roller
should smooth.
❖ Check for any groove for the tension
roller.
❖ Change if the wire gets trapped
completely into the groove.
2. Wire outlet side Wire feed ❖ The wire after sparking has become weak
due to wear. Increase the feed.
Wire feed
mechanism
❖ Distributed wire feed causes wire
breakage or produces vertical streaks over
the machined surface. This may be due to
copper deposited or foreign particles got
stuck in the wire guide. Clean the guide.
❖ Unsmooth movement of lower roller.
Change the bearing of the roller.
Machining ❖ Feed spool break which prevents over
condition
travel of spool is not properly set. Set it
right.

❖ Setting of Ip, no load voltage etc. are too

high, increased electrode wear. Set as per
the technology chart.
❖ WF is too low, WT is too high. Set as per
the technology chart and trim if required.

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3. Inside of Flushing ❖ Clean the lower flushing nozzle.
machining gap
Dielectric water
❖ Excessive injection pressure causes water
dielectric to escape or mix with air thus
developing aerial discharge. Air will not
be trapped if upper and lower flushing
Conductivity
gets balanced in the spark gap. Adjust
flushing.
Wire
❖ Low conductivity will cause wire
breakage. Set at 20 and control it within 2
units.
Workpiece:
1. Stocked
workpiece
❖ Twisted or bent wire will develop
discharge concentration that causes wire
breakage. Wire position towards the end
2. Material of winding is liable to snap.
quality

❖ Machining of the stocked workpiece is to

3. Workpiece
be out at lower speed.
thickness
❖ Clearance between stocked pieces will
cause air to be trapped in between and
result aerial discharge.

❖ Crack holes or any flow in the internal

structure of the workpiece can cause wire
breakage.

❖ Machining thicker jobs 50 mm and

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 above, parameters like wire feed, tension,
flushing conductivity become critical.
Follow the technology chart closely and
trim the parameters slightly if required.

Fig 6.2 – Wire break

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 CONCLUSION
In the manufacturing industries it is necessary to manufacture product which have excellent quality
with optimum cost and optimum production time to survive in the global market. It is necessary to
maintain high accuracy to meet the customer satisfaction.
This project gave me to knowledge about the manufacturing process of tools of hard material like
titanium, high alloyed carbon steel etc. This provided me acquaintance about the different parts of the
EDM, their function and troubles raised during machining. It is useful process for metal saving which
reduce the production cost. Intricate shape, fine holes can be easily drilled through it. Observing the
manufacturing process of the templates, drills etc. certainly appreciable and bloom my knowledge.
Although, it includes some limitations but considering it as one of the important machining process
will not a big bid.

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 REFRENCES
• Mr. Rakesh (senior programmer ,Step Tools)
• http://home.iitk.ac.in/~nsinha/Non-traditional-machining
• https://en.wikipedia.org/wiki/Electrical_discharge_machining
https://www.americanwireedm.com/edm-services/edm-machining

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