Chemical Machining (CHM) Photochemical Machining (PCM) etc INTRODUCTION TO WIRE-CUT EDM In all the machining processes EDM

M is one of the importantnon-traditional machining processes. Here we are mainlyconcerned about wire cut EDM. Wire cut EDM or ElectricalDischarge Machining is a technique used to slice through metal.The technique uses thin brass wire for the purpose and can createintricate profiles with the process. The EDM machine uses sparkdischarges that are fast, repetitive, and controlled for cutting. Thisprocess works with electrically conductive metals. The process isspecially suited for contours and cavities that are not possiblewith other cutting tools. EDM is also known as spark machining as it uses repetitiveelectrical discharges to remove metal. The electrical dischargesare passed between the metal part and the electrode. A stream ofcontinuously flowing liquid is used to remove the metal remnantsproduced during the process. A set of successively deeper cratersis formed till the final shape is created by the discharges. Different types of EDM: 1.Ram EDM In ram EDM, a graphite electrode is used along with traditionaltools. This electrode is connected to the ram with the help of apower source and is fed into the workpiece. The whole process iscarried out in a fluid bath. The fluid helps to flush away thematerial, serves as a coolant to reduce the heat, and acts as aconductor for passing current between the workpiece and theelectrode. 2.Wire EDM In this method, a thin wire is used as an electrode. The wire isfed 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 cuttingwork is done by the electrical discharge. Computer software controlsthe whole operation including the path of the wire. The process can 6

produce all sorts of complex shapes that are very difficult with other processes. Principle of edm It is the most versatile electrical machining process whereerosion is caused due to electric spark. The rate of metal removaland the resulting surface finish can be controlled by proper variationin energy and duration of spark discharge. It is the process ofrepetitive sparking cycles. Graphical Representation: Fig 1: Series of Electric pulses at the inter electrode gap Fig 2: Inter electrode gap voltage waveform during sparking 7

Fig 3: Inter electrode gap current waveform during sparking Where, Ton :- Pulse on period Toff :- Pulse of period Td :- Spark ignition period Vp :- Open gap voltage Vg :- Average gap voltage Ip :- Machining peak current A series of electrical pulse generated by the pulse generatorunit is applied between the workpiece and travelling wire electrode.In the event of spark discharge, there is a flow of current across wireelectrode workpiece gap. The energy contained in the tiny sparkremoves a fraction of workpiece material. Large number of suchtime spaced tiny discharges between the workpiece and wireelectrode cause the electro erosion of the workpiece material.

Water dielectric 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. 2.Dielectric strength Since the insulation characterization of dielectric fluid decidesthe overcut so it is important to keep the conductivity of dielectricwater constant.Conductivity of water changes due to generation ofmetallic ions and dissolution of ambient gases. The conductivity canbe decreased by passing the water through de-ionize resin. This isdone automatically by the machine. 3.Flushing Flushing is important to achieve stable condition. It plays veryimportant role as far as cutting speed concerned. Both the nozzlesupper and lower should be just about 0.22 mm away from theworkpiece, otherwise cutting performance drops considerably. Alsoboth 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 filters.