me10b017 edm
TRANSCRIPT
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Electro Discharge
Machine
Lab-5
METEREOLOGY & MACHINING LAB
SUMIT JADHAV
ME10B017 | Lab-5
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OBJECTIVE:
To get acquainted with one of the non-Conventional machining methods, ELECTRO DISCHARGE
MACHINING by machining an ASTM standard fatigue and tensile specimen
APPARATUS REQUIRED:
1. Electronicas EDM machine.2. High conducting brass wire.3. Computer software for solid modelling of desired part.4. Fanuc's software to generate the CNC program based upon the input 2D geometry (.dxf File
Format)
THEORY:
Electric discharge machining (EDM), sometimes also referred to as spark machining/ spark eroding, is a
manufacturing process whereby a desired shape is obtained using electrical discharges (sparks).Materialis 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.
The wire used as electrode is made up of copper-zinc alloy. It has good conductance process which is a
must for this process. The wire is negative terminal and the work-piece is the positive terminal. Upon
passing the current, fast moving electrons are emitted from the wire which moves at a high velocity due
to the presence of a strong electric field created by the presence of a dielectric material.
Upon reaching the work-piece, the fast moving electrons collide with the work-piece thereby convertingthe total kinetic energy in the form of thermal energy which helps in cutting/abrading the work-piece.
The machine used in the workshop is a 4-axes machine. It uses de-ionized water as the dielectric
material and brass wires as the negative electrode. The u and v axes are generally used to create
tapered cuts.
The wire-cut process uses water as its dielectric fluid, controlling its resistivity and other electrical
properties with filters and de-ionizer units. The water flushes the cut debris away from the cutting zone.
Flushing is an important factor in determining the maximum feed rate for a given material thickness.
The wire-cut process uses water as its dielectric fluid, controlling its resistivity and other electrical
properties with filters and de-ionizer units. The water flushes the cut debris away from the cutting zone.
Flushing is an important factor in determining the maximum feed rate for a given material thickness.
Current passing through the wire is generally in the form of discrete pulses.
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Why not use copper wire even if it is more conductive:
1. Low tensile strength of Cu (if high tension is applied it breaks).2. Poor flush ability (A good portion of the heat from the EDM spark was transferred to the wire
and carried away from the work-zone instead of using that heat to melt and vaporize the work-
piece).3. By optimization they chose Brass as standard one.
PROCEDURE:
1. Create the 3d models of desired components to be manufactured.2. Prepare a .dxf file which contains the top view of the modelled component.3. Import the .dxf file into the automatic CNC program generator software and follow the
stipulated procedure to obtain the CNC code for thedesired geometry.
4. Using a USB flash drive, transfer the program to the EDM machine controller computer.5. Load the generated program into the Controller's RAM and start the cutting operation.6. The CNC machine guides the electrode (wire) into the desired places where the cut is to be
formed.
Created 2D models:
FATIGUE FLAT MODEL
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TENSILE FLAT MODEL
CNC CODE GENRATED BY THE COMPUTER:
5.3.2013,11:00:10
G71
G9
G27
G40
G47
G50
G90
G75
; Wire Compensation Definitions
D0=0
D1=0.175
;#1.0 Cavity=1 RoughCut
G0 X-194.0481493 Y-100.606529 U0 V0
M21
G41 D0 ;D0=0
G1 X-194.0481493 Y-98.606529
G41 D1 ;D1=0.175
G1 X-170.708872 Y-98.606529
G1 X-170.708872 Y-98.606529
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G1 X-270.708872 Y-98.606529
G1 X-270.708872 Y-98.606529
G1 X-194.081493 Y-98.606529
M0
G41 D0; D0=0
G1 X-194.0481493 Y-100.606529
G40
M0
OBSERVATIONS & CONCLUSIONS:
1. EDM process has been effectively put into use to generate the required model.2. Heat affected zone is limited to 2-4 mm of spark crater. The accuracy of the process is very high
compared to that of conventional machining techniques.3. The residual stresses developed in the machined component are less because of the reduced
forces of cutting.
4. The time consumed in the process is pretty high and hence there is a trade-off betweenmachining accuracy and time to machine.
5. Intricate parts which require a lot of detailing can be machined using this technique.6. Hence, although more accurate, there is less acceptance in mainstream industry due to low
productivity but this technique becomes ubiquitous where high accuracy is desired and
complexity of the component is high.
LEARNING: 1. How to operate the EDM machine and the set-up required before the commencement of the
actual machining operation.
2. The need for non-conventional machining techniques.3. The process of EDM, it's pros and cons and applicability.4. Using computer software to generate 3d solid models and to obtain the CNC code directly from
the solid model using real time simulation software.