EDM
Content
1.0 TITLE:
Electrode Discharge Machine Wirecut (EDM Wirecut)
2.0 OBJECTIVE:
1. To produce the NC programming for machining the specimen using EDM wirecut.
2. To machine and produce the specimen using the developed NC programming.
3.0 INTRODUCTION:
Electrode Discharge Machining (EDM) is a machining method primarily used for
hard metalsor those that would be impossible to machine with traditional techniques. The
EDM process was invented by two Russian scientists, Dr. B.R. Lazarenko and Dr. N.I.
Lazarenko in 1943. The first numerically controlled EDM was invented by Makino in Japan.
EDM can cut small or odd-shaped angles, intricate contours or cavities in pre-hardened steel
without the need for heat treatment to soften and re-harden them as well as exotic metals such
as titanium, hastelloy, kovar, and inconel. There are two main types of EDM machines;
Sinker EDM (also called Conventional EDM and Ram EDM) and wirecut EDM.
EDM is a non-traditional method of removing material by a series of rapidly recurring
electric arcing discharges between an electrode (the cutting tool) and the work piece, in the
presence of an energetic electric field. The process is accomplished by establishing a large
potential (voltage) difference between the workpiece to be machined and an electrode. A
large burst (spark) of electrons travels from the electrode to the workpiece, workpiece
material is eroded away. Thus the machining is accomplished by electrical spark erosion. This
phenomenon has been known since the discovery of electricity, it was not until the 1940s that
a machining process based on this principal was developed. The EDM process has become
one of the most important and widely used production technologies in manufacturing.
Wire EDM, or electrical-discharge wire cutting is a variation of EDM. In this process,
which is similar to contour cutting with a band saw, a slowly moving wire travels along a
prescribed path, cutting the workpiece, with the discharge sparks acting like cutting teeth.
This process is used to cut plates as thick as 300 mm (12 in.), and for making punches, tools,
and dies from hard metals. It can also cut intricate components for the electronics industry.
In Electrical-Discharge Machining (EDM) Wire Cut a very thin wire serves as the
electrode. Special brass wires are typically used, the wire is slowly fed through the material
and the electrical discharges actually cut the workpiece. In Electrical-Discharge Machining
(EDM) Wire Cut is usually performed in a bath of water. If observe in Electrical-Discharge
Machining (EDM) Wire Cut process under a microscope, the wire itself does not actually
touch the metal to be cut; the electrical discharges actually remove small amounts of material
and allow the wire to be moved through the workpiece.
Spark Properties
1. Spark temperatures are between 8,000 and 12,000 ˚C (plasma zone)
2. The range of the sparks varies from a few microns to 1 mm
3. Controlled by the generator and are adjustable for different material types and desired
surface finishes.
The path of the wire is typically controlled by a computer, which allows extremely
complex shapes to be produced. In the case of the Electrical-Discharge Machining (EDM)
Wire Cut process, the required shape is generated by using a wire electrode. The wire is
passed through the part much like a cheese cutter through cheese. The wire is almost always
copper and since copper wears rapidly the wire is fed on reels. The wire also usually made of
brass, copper, or tungsten; zinc- or brass-coated and multi-coated wires are also used. This
gives the part being machined a fresh electrode at all times.
The movement of the wire is computer controlled in two axis (and sometimes more).
This is exactly like any other CNC controlled process but in CNC EDM the shape is
generated independently by guiding the wire. In the case of complicated shapes requiring cuts
or angled, conical, or other unusual surfaces, the upper and lower wire guide systems carry
out differing movements accordingly.
The Advantages of EDM Wire:
1. The Machining of Complex Geometric Forms Complex, contoured shapes can be produced
in one piece rather than several, in the exact configuration that is required.
2. The Rapid, Economic Production of Prototypes and Low Run Parts The ability to
accurately machine complex designs, can eliminate or reduce fixture and tooling costs for one
of a kind or low run production parts. Formed through the wire EDM process, parts can be
immediately used in assembly, with little or no additional finishing.
3. Precise Machining of Pre-hardened Materials because hardened materials can be EDM
eroded, the need for the heat treatment of machined parts is eliminated, avoiding potential
distortion.
4. Machining to Tight Tolerances, Avoiding Distortion and Stress Very low machining forces
allow tight tolerances of up to 2 microns to be achieved. With little or no stress imparted into
the work only light clamping is necessary. Thin materials can also be machined without
distortion.
5. The Accurate and Economic Machining of Exotic Materials Exotic materials including A286 Superalloys, medical grade stainless, titanium, Hastelloy, tungsten carbide, molybdenum,
aluminium alloys and copper can all be machined. Better utilisation of valuable materials is
provided through chipless machining.
6. Absolute Consistency between Machined Parts. Because with wire EDM there is no
contact between the cutting wire and the surface, there is no tooling wear and absolute
consistency can be achieved on every machined part.
The limitation of EDM wire cut is this machine only can operate on conductor
material only. This machines cannot cut soft material and insulator such as wood, nylon,
teflon and rubber.
4.0 APPARATUS:
4.1 INDUSTRIAL APPARATUS:
5.0 PROCEDURE:
1. The information of the machine was explained clearly by assistant lecturer.
2. The speculation of the G and M code was studied before the EDM wire cut process
started.
3. Each group was assigned to design a part
4. After we decided the part, we need to create the G-code and M-code of the part.
5. The workpiece which is aluminum with 15mm thickness and wire with diameter
0.2mm is prepared.
6. The G-code and M-code is key in NC program and the machine is run according to
the code.
7. The desired shape will appeared on the screen and the wire will cut the aluminum
according to the code that has been downloading.
8. The product is ready.
6.0 RESULT AND ANALYSIS:
Coding
00130
N100
G00
G21
G90
;
N102
N104
N106
N108
N110
N112
N114
N116
N118
N120
N122
N124
N126
N128
N130
N132
N134
N136
N138
N140
N142
N144
N146
G92
M60
M83
M81
S101
G41
G01
X10.
Y20.
G03
G02
G01
Y20.
X30.
Y25.
X35.
Y5.
X30.
G03
GO1
Y15.
M50
M30
X0.
;
;
;
D2
G01
X5.
;
;
X15.
X20.
X25.
;
;
;
;
;
;
X20.
X5.
;
;
;
Y15.
I15.
;
;
X5.
Y25.
Y15.
;
;
Y20.
Y25.
;
I5.
I5.
J0.
J0.
;
;
Y5.
Y5.
I-5.
;
J0.
;
7.0 DISCUSSION:
1. Brief process of EDM-Wire Cut.
Because EDM Wire-cut uses a constantly-moving wire as the cutting tool, it is also called
traveling-wire EDM. The wire is threaded around the machine and though the material.
In EDM wire-cut, the sides of the wire acts like a band saw to cut through the workpiece
material. Once the machine starts, the wire is in continuous motion so that the cutting is
actually being done by a new electrode all the time, thus solving the problem of electrode
wear. The used wire is then discarded.
Wire-cut EDM is used with computer numerical control (CNC), and machines frequently
operate unattended (non-operator). Today's computers with sophisticated software packages
have cut programming time and extended geometric capabilities. Hardware advances allow
automatic rethreading for machines that work unattended. A wire-cut EDM system is
composed of a power supply, an electrode, a dielectric coolant and ancillary equipment. Like
vertical EDM, technology is rapidly improving the systems' capabilities.
Wire-cut EDM equipment can cut at speeds in excess of 20 square inches per hour. The
workpiece typically is mounted on a table with two degrees of freedom. The movement of the
table and wire are controlled by a computer that can compensate for overcut, wire thickness,
and known errors in the workpiece.
Wire-cut EDM is efficient because the wire erodes a thin line around the perimeter of the
required cut rather than the full volume of the cavity as with vertical EDM.
2. Axes of EDM wirecut machine.
A two-axis wire EDM can only make cuts at right-angles to the work table, while a CNC
positioning system with a two-axis table can perform a wide variety of angled cuts.
Independent four-axis machines can cut tapered angles and make cuts that result in different
top and bottom profiles. This capability is needed in making extrusion dies and flow valves.
The wire never touches the work during cuts.
The wire-control servo system is able to maintain a wire-to-work distance of approximately .
001 inch. The wire cuts along a programmed path starting at either an edge or in a drilled
hole. Parts to be cut can be stacked for production quantities. Wire-Cut12 EDM requires the
movement of the workpiece on the electrode in the X and Y axes. In most instances the
workpiece moves and the electrode wire remains stationary. Electrode travel is perpendicular
to the workpiece. In some instances the workpiece may travel in the Y-direction and the
electrode wire will travel in the X-direction. It is even possible that the electrode would travel
in both the X and Y directions with the part being stationary. It makes no difference how the
X and Y movements are made so long as there is relative movement between the electrode
and the workpiece. Movement of the X-Y axes is under the command of the NC or CNC
control. The axis contour is programmed into the NC or CNC control unit.
5 Axis Precision Machining allows machining of all 5 sides in one Set up. While this can
certainly be a cost saving factor, 5 Axis machining is used more often for complex contour
work, which may need simultaneous movement of all 5 Axes. Current generation 5 Axis
machines offer excellent tolerances - as close as 3 microns.
5 axes EDM
5 Axis Wire EDM actually is on different axes as compared to the 5 Axis CNC
Machining processes. Often, people would consider the tilting of the wire head as being 5
Axis work. In actuality, true 5 Axis EDM would have a rotary indexer that could actually
rotate the part – even simultaneously during the Wire EDM process. The rotary indexer is
actually use to index on the preset increments. A 5 Axis Wire EDM with fine wire capability
would be able to use a .001"diameter wire and can even offer sub-micron tolerances.
3. Advantages of 5 axis Wire EDM technology.
5 axes Wire EDM can be extremely useful when close tolerances are involved. The
use of fine wires with very small diameters in the range of .001-.004" can guarantee a very
high precision work on wire EDM machines. Because EDM is a no-contact and no-force
process, it is well suited for making frail or fragile parts that cannot take the stress of standard
machining; it can cut parts 16 inches tall with a straightness of ±0.0005 inch per side! Parts
requiring small inside radii are now easily achieved using this technology. The use of a .001"
wire would be that the corner radii can be as sharp as .0015 (there is usually an over burn of .
001" during the EDM process). But the most important advantage came with the increased
sophistication of EDM controls in rams and the new EDM processes that use simple-shaped
electrodes to 3D mill complex shapes with extremes accuracy! Now users demand and need
maximum productivity and throughput, increased accuracy, higher angles of taper, thicker
work pieces, automatic wire threading, and long periods of unattended operation, make the
Wire EDM machining a breakthrough precision technology. 5 axis Wire EDM is used to
manufacture complex parts for the aerospace, medical and telecommunication Industries.
4. Safety issues when handling EDM-Wire Cut.
The safety issues of when handling EDM-Cut are pre-machining condition. Such
safety issues are like the setup of the machine must be right such the clamp of the workpiece
is tighten securely and firmly. Since the machine is supplied by high current therefore
carelessness will result to injury or worst fatality. If the machine suddenly hanged or running
awkwardly press the emergency button to stop it immediately and shut down the power
supply. Report to the technician.
5. Differences between EDM and EDM-Wire Cut.
In EDM the electrodes used are shaped electrodes which are mirror image of the workpiece.
This type of electrodes can be used many times. The machine can make fine blind holes. The
dielectric used can be paraffin oil or kerosene, light oil. However in wire EDM or EDM-Wire
Cut it uses only a very thin wire as its electrodes. In contrast to EDM, the wire can only be
used once at one time. The machine cannot make blind holes but only through holes. It uses
deionized water as it dielectric.
8.0 CONCLUSION:
It can be conclude that the wire EDM, or electrical-discharge wire cutting process is
based on the principal energy mode is thermal with the electrical discharge. It is also similar
to contour cutting with a band saw, a slowly moving wire travels along a prescribed path,
cutting the workpiece, with the discharge sparks acting like cutting teeth. This process is used
to cut plates as thick as 300 mm (12 in.), and for making punches, tools, and dies from hard
metals. It can also cut intricate components for the electronics industry. Special brass wires
are typically used and usually performed in a bath of water.
As technology advances in speed, workpiece size and geometry complexity, accuracy,
ease of use, unattended operation, industry education and affordability. In the case of
complicated shapes requiring cuts or angled, conical, or other unusual surfaces, the upper and
lower wire guide systems carry out differing movements accordingly.
9.0 RECOMMENDATIONS:
1. The operator needs to make every effort to be constantly aware of the machine and
its surroundings. When coming into contact with any part of the fluid or the electrode
can cause severe injury or even death.
2. A second concern is the dielectric fluid, which is an oil based liquid. As with any
oil, the proper handling of parts, measuring tools, etc. should be taken into
consideration
3. Applying High Energy Applied Technology (H.E.A.T) to reduce wire EDM burn
times.
4. Cover all skin surfaces and wear safety boots for protection from sparks.
5. Control and monitoring the software to get outstanding part straightness and
accurate dimensions.
10.0 REFERENCES:
i.
Serope Kalpakjian, Steven R. Schmid, Manufacturing Technology and Fundamental,
5th edition, Prentice Hall, 2004.
ii.
Serope Kalpakjian & Steven R. Schmid, Manufacturing Processes for Engineering
iii.
Materials, 4th Edition, Illinois Institute Of Technology, PrenticeHall, 2003.
Singh, A. & Ghosh, A. A Thermo-Electric Model of Material Removal DuringElectric
iv.
v.
Discharge Machining. (1999).
http://en.wikipedia.org-wiki-electrical_discharge_machining.
http://www.wisegeek.com/what-is-edm.ht m.
Electrode Discharge Machine Wirecut (EDM Wirecut)
2.0 OBJECTIVE:
1. To produce the NC programming for machining the specimen using EDM wirecut.
2. To machine and produce the specimen using the developed NC programming.
3.0 INTRODUCTION:
Electrode Discharge Machining (EDM) is a machining method primarily used for
hard metalsor those that would be impossible to machine with traditional techniques. The
EDM process was invented by two Russian scientists, Dr. B.R. Lazarenko and Dr. N.I.
Lazarenko in 1943. The first numerically controlled EDM was invented by Makino in Japan.
EDM can cut small or odd-shaped angles, intricate contours or cavities in pre-hardened steel
without the need for heat treatment to soften and re-harden them as well as exotic metals such
as titanium, hastelloy, kovar, and inconel. There are two main types of EDM machines;
Sinker EDM (also called Conventional EDM and Ram EDM) and wirecut EDM.
EDM is a non-traditional method of removing material by a series of rapidly recurring
electric arcing discharges between an electrode (the cutting tool) and the work piece, in the
presence of an energetic electric field. The process is accomplished by establishing a large
potential (voltage) difference between the workpiece to be machined and an electrode. A
large burst (spark) of electrons travels from the electrode to the workpiece, workpiece
material is eroded away. Thus the machining is accomplished by electrical spark erosion. This
phenomenon has been known since the discovery of electricity, it was not until the 1940s that
a machining process based on this principal was developed. The EDM process has become
one of the most important and widely used production technologies in manufacturing.
Wire EDM, or electrical-discharge wire cutting is a variation of EDM. In this process,
which is similar to contour cutting with a band saw, a slowly moving wire travels along a
prescribed path, cutting the workpiece, with the discharge sparks acting like cutting teeth.
This process is used to cut plates as thick as 300 mm (12 in.), and for making punches, tools,
and dies from hard metals. It can also cut intricate components for the electronics industry.
In Electrical-Discharge Machining (EDM) Wire Cut a very thin wire serves as the
electrode. Special brass wires are typically used, the wire is slowly fed through the material
and the electrical discharges actually cut the workpiece. In Electrical-Discharge Machining
(EDM) Wire Cut is usually performed in a bath of water. If observe in Electrical-Discharge
Machining (EDM) Wire Cut process under a microscope, the wire itself does not actually
touch the metal to be cut; the electrical discharges actually remove small amounts of material
and allow the wire to be moved through the workpiece.
Spark Properties
1. Spark temperatures are between 8,000 and 12,000 ˚C (plasma zone)
2. The range of the sparks varies from a few microns to 1 mm
3. Controlled by the generator and are adjustable for different material types and desired
surface finishes.
The path of the wire is typically controlled by a computer, which allows extremely
complex shapes to be produced. In the case of the Electrical-Discharge Machining (EDM)
Wire Cut process, the required shape is generated by using a wire electrode. The wire is
passed through the part much like a cheese cutter through cheese. The wire is almost always
copper and since copper wears rapidly the wire is fed on reels. The wire also usually made of
brass, copper, or tungsten; zinc- or brass-coated and multi-coated wires are also used. This
gives the part being machined a fresh electrode at all times.
The movement of the wire is computer controlled in two axis (and sometimes more).
This is exactly like any other CNC controlled process but in CNC EDM the shape is
generated independently by guiding the wire. In the case of complicated shapes requiring cuts
or angled, conical, or other unusual surfaces, the upper and lower wire guide systems carry
out differing movements accordingly.
The Advantages of EDM Wire:
1. The Machining of Complex Geometric Forms Complex, contoured shapes can be produced
in one piece rather than several, in the exact configuration that is required.
2. The Rapid, Economic Production of Prototypes and Low Run Parts The ability to
accurately machine complex designs, can eliminate or reduce fixture and tooling costs for one
of a kind or low run production parts. Formed through the wire EDM process, parts can be
immediately used in assembly, with little or no additional finishing.
3. Precise Machining of Pre-hardened Materials because hardened materials can be EDM
eroded, the need for the heat treatment of machined parts is eliminated, avoiding potential
distortion.
4. Machining to Tight Tolerances, Avoiding Distortion and Stress Very low machining forces
allow tight tolerances of up to 2 microns to be achieved. With little or no stress imparted into
the work only light clamping is necessary. Thin materials can also be machined without
distortion.
5. The Accurate and Economic Machining of Exotic Materials Exotic materials including A286 Superalloys, medical grade stainless, titanium, Hastelloy, tungsten carbide, molybdenum,
aluminium alloys and copper can all be machined. Better utilisation of valuable materials is
provided through chipless machining.
6. Absolute Consistency between Machined Parts. Because with wire EDM there is no
contact between the cutting wire and the surface, there is no tooling wear and absolute
consistency can be achieved on every machined part.
The limitation of EDM wire cut is this machine only can operate on conductor
material only. This machines cannot cut soft material and insulator such as wood, nylon,
teflon and rubber.
4.0 APPARATUS:
4.1 INDUSTRIAL APPARATUS:
5.0 PROCEDURE:
1. The information of the machine was explained clearly by assistant lecturer.
2. The speculation of the G and M code was studied before the EDM wire cut process
started.
3. Each group was assigned to design a part
4. After we decided the part, we need to create the G-code and M-code of the part.
5. The workpiece which is aluminum with 15mm thickness and wire with diameter
0.2mm is prepared.
6. The G-code and M-code is key in NC program and the machine is run according to
the code.
7. The desired shape will appeared on the screen and the wire will cut the aluminum
according to the code that has been downloading.
8. The product is ready.
6.0 RESULT AND ANALYSIS:
Coding
00130
N100
G00
G21
G90
;
N102
N104
N106
N108
N110
N112
N114
N116
N118
N120
N122
N124
N126
N128
N130
N132
N134
N136
N138
N140
N142
N144
N146
G92
M60
M83
M81
S101
G41
G01
X10.
Y20.
G03
G02
G01
Y20.
X30.
Y25.
X35.
Y5.
X30.
G03
GO1
Y15.
M50
M30
X0.
;
;
;
D2
G01
X5.
;
;
X15.
X20.
X25.
;
;
;
;
;
;
X20.
X5.
;
;
;
Y15.
I15.
;
;
X5.
Y25.
Y15.
;
;
Y20.
Y25.
;
I5.
I5.
J0.
J0.
;
;
Y5.
Y5.
I-5.
;
J0.
;
7.0 DISCUSSION:
1. Brief process of EDM-Wire Cut.
Because EDM Wire-cut uses a constantly-moving wire as the cutting tool, it is also called
traveling-wire EDM. The wire is threaded around the machine and though the material.
In EDM wire-cut, the sides of the wire acts like a band saw to cut through the workpiece
material. Once the machine starts, the wire is in continuous motion so that the cutting is
actually being done by a new electrode all the time, thus solving the problem of electrode
wear. The used wire is then discarded.
Wire-cut EDM is used with computer numerical control (CNC), and machines frequently
operate unattended (non-operator). Today's computers with sophisticated software packages
have cut programming time and extended geometric capabilities. Hardware advances allow
automatic rethreading for machines that work unattended. A wire-cut EDM system is
composed of a power supply, an electrode, a dielectric coolant and ancillary equipment. Like
vertical EDM, technology is rapidly improving the systems' capabilities.
Wire-cut EDM equipment can cut at speeds in excess of 20 square inches per hour. The
workpiece typically is mounted on a table with two degrees of freedom. The movement of the
table and wire are controlled by a computer that can compensate for overcut, wire thickness,
and known errors in the workpiece.
Wire-cut EDM is efficient because the wire erodes a thin line around the perimeter of the
required cut rather than the full volume of the cavity as with vertical EDM.
2. Axes of EDM wirecut machine.
A two-axis wire EDM can only make cuts at right-angles to the work table, while a CNC
positioning system with a two-axis table can perform a wide variety of angled cuts.
Independent four-axis machines can cut tapered angles and make cuts that result in different
top and bottom profiles. This capability is needed in making extrusion dies and flow valves.
The wire never touches the work during cuts.
The wire-control servo system is able to maintain a wire-to-work distance of approximately .
001 inch. The wire cuts along a programmed path starting at either an edge or in a drilled
hole. Parts to be cut can be stacked for production quantities. Wire-Cut12 EDM requires the
movement of the workpiece on the electrode in the X and Y axes. In most instances the
workpiece moves and the electrode wire remains stationary. Electrode travel is perpendicular
to the workpiece. In some instances the workpiece may travel in the Y-direction and the
electrode wire will travel in the X-direction. It is even possible that the electrode would travel
in both the X and Y directions with the part being stationary. It makes no difference how the
X and Y movements are made so long as there is relative movement between the electrode
and the workpiece. Movement of the X-Y axes is under the command of the NC or CNC
control. The axis contour is programmed into the NC or CNC control unit.
5 Axis Precision Machining allows machining of all 5 sides in one Set up. While this can
certainly be a cost saving factor, 5 Axis machining is used more often for complex contour
work, which may need simultaneous movement of all 5 Axes. Current generation 5 Axis
machines offer excellent tolerances - as close as 3 microns.
5 axes EDM
5 Axis Wire EDM actually is on different axes as compared to the 5 Axis CNC
Machining processes. Often, people would consider the tilting of the wire head as being 5
Axis work. In actuality, true 5 Axis EDM would have a rotary indexer that could actually
rotate the part – even simultaneously during the Wire EDM process. The rotary indexer is
actually use to index on the preset increments. A 5 Axis Wire EDM with fine wire capability
would be able to use a .001"diameter wire and can even offer sub-micron tolerances.
3. Advantages of 5 axis Wire EDM technology.
5 axes Wire EDM can be extremely useful when close tolerances are involved. The
use of fine wires with very small diameters in the range of .001-.004" can guarantee a very
high precision work on wire EDM machines. Because EDM is a no-contact and no-force
process, it is well suited for making frail or fragile parts that cannot take the stress of standard
machining; it can cut parts 16 inches tall with a straightness of ±0.0005 inch per side! Parts
requiring small inside radii are now easily achieved using this technology. The use of a .001"
wire would be that the corner radii can be as sharp as .0015 (there is usually an over burn of .
001" during the EDM process). But the most important advantage came with the increased
sophistication of EDM controls in rams and the new EDM processes that use simple-shaped
electrodes to 3D mill complex shapes with extremes accuracy! Now users demand and need
maximum productivity and throughput, increased accuracy, higher angles of taper, thicker
work pieces, automatic wire threading, and long periods of unattended operation, make the
Wire EDM machining a breakthrough precision technology. 5 axis Wire EDM is used to
manufacture complex parts for the aerospace, medical and telecommunication Industries.
4. Safety issues when handling EDM-Wire Cut.
The safety issues of when handling EDM-Cut are pre-machining condition. Such
safety issues are like the setup of the machine must be right such the clamp of the workpiece
is tighten securely and firmly. Since the machine is supplied by high current therefore
carelessness will result to injury or worst fatality. If the machine suddenly hanged or running
awkwardly press the emergency button to stop it immediately and shut down the power
supply. Report to the technician.
5. Differences between EDM and EDM-Wire Cut.
In EDM the electrodes used are shaped electrodes which are mirror image of the workpiece.
This type of electrodes can be used many times. The machine can make fine blind holes. The
dielectric used can be paraffin oil or kerosene, light oil. However in wire EDM or EDM-Wire
Cut it uses only a very thin wire as its electrodes. In contrast to EDM, the wire can only be
used once at one time. The machine cannot make blind holes but only through holes. It uses
deionized water as it dielectric.
8.0 CONCLUSION:
It can be conclude that the wire EDM, or electrical-discharge wire cutting process is
based on the principal energy mode is thermal with the electrical discharge. It is also similar
to contour cutting with a band saw, a slowly moving wire travels along a prescribed path,
cutting the workpiece, with the discharge sparks acting like cutting teeth. This process is used
to cut plates as thick as 300 mm (12 in.), and for making punches, tools, and dies from hard
metals. It can also cut intricate components for the electronics industry. Special brass wires
are typically used and usually performed in a bath of water.
As technology advances in speed, workpiece size and geometry complexity, accuracy,
ease of use, unattended operation, industry education and affordability. In the case of
complicated shapes requiring cuts or angled, conical, or other unusual surfaces, the upper and
lower wire guide systems carry out differing movements accordingly.
9.0 RECOMMENDATIONS:
1. The operator needs to make every effort to be constantly aware of the machine and
its surroundings. When coming into contact with any part of the fluid or the electrode
can cause severe injury or even death.
2. A second concern is the dielectric fluid, which is an oil based liquid. As with any
oil, the proper handling of parts, measuring tools, etc. should be taken into
consideration
3. Applying High Energy Applied Technology (H.E.A.T) to reduce wire EDM burn
times.
4. Cover all skin surfaces and wear safety boots for protection from sparks.
5. Control and monitoring the software to get outstanding part straightness and
accurate dimensions.
10.0 REFERENCES:
i.
Serope Kalpakjian, Steven R. Schmid, Manufacturing Technology and Fundamental,
5th edition, Prentice Hall, 2004.
ii.
Serope Kalpakjian & Steven R. Schmid, Manufacturing Processes for Engineering
iii.
Materials, 4th Edition, Illinois Institute Of Technology, PrenticeHall, 2003.
Singh, A. & Ghosh, A. A Thermo-Electric Model of Material Removal DuringElectric
iv.
v.
Discharge Machining. (1999).
http://en.wikipedia.org-wiki-electrical_discharge_machining.
http://www.wisegeek.com/what-is-edm.ht m.
