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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
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.
Erosion was caused by intermittent arc discharges
occurring in the air between the tool electrode and
the workpiece connected to a DC power supply.
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” .
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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