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Experiment Title:
6.1) Introduction:
Electrical discharge machining (EDM), also known as spark machining, spark eroding, burning, die
sinking, wire burning or wire erosion, is a manufacturing process whereby a desired shape is obtained by
using electrical discharges (sparks). Material is 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 workpiece-electrode, or "work piece." The process depends upon the tool and
work piece not making actual contact.
The Sinker EDM is also called a volume EDM or cavity EDM. This has got a work piece and an
electrode present in an insulating fluid. The work piece and the electrode are connected with specific
supply of power. Due to the power electrical potential is created between the two components. When
the electrode reaches the work piece then the dielectric discharged is released and forms a plasma
channel with slight sparks.
6.3) Surface roughness:
Whatever may be the manufacturing process used, it is not possible to produce perfectly smooth surface.
The imperfections and irregularities are bound to occur. The manufactured surface always departs from
the absolute perfection to some extent. The irregularities on the surface are in the form of succession of
hills and valleys varying in height and spacing. These irregularities are usually termed as surface
roughness, surface finish, surface texture or surface quality. These irregularities are responsible to a great
extent for the appearance of a surface of a component and its suitability for an intended applications.
1) Vibrations
3) Type of machining.
4) Rigidity of the system consisting of machine tool, fixture cutting tool and work
It shows the measured roughness depth (Rz) as well as the average roughness value (Ra) in µm.
Roughness testers allow a user to determine the material surface roughness quickly. The measurement
of surface roughness is very easy. Roughness testers get in contact with surfaces within a few seconds
and show the roughness value in Ra or in Rz. Our Roughness testers will be delivered with control cards,
probe protection, accumulators and chargers inside a carrying case.
Current = 21A
Rt =46.00
Rz =27.00
Current = 21A
Time = 4mints
Rt =24.50
Rz =16.00
Current = 21A
Rt =21.00
Rz =15.00
6.8) Comments:
Electrode wear
Slow removal rates
Thin brittle heat effected zone
Expensive set up
Expert machinist required
Non conductive materials can’t be machined
Can be used for special purposes
6.9) References:
Experiment Title
1) Dielectric pressure
2) Pulse on time
4) Wire tension
6) Gap voltage
7.2.2)Dielectric pressure:
Flushing is important in the process to achieve a stable machining condition. The pressure with which the
coolant strikes the inter-electrode gap is determined in two levels- high and low. The flushing pressure is
determined according to the material. For machining titanium, high flushing pressure is recommended.
7.2.3)Pulse on time:
Pulse on time is the period for which the voltage is applied across the gap. It is denoted by TON. The
range of pulse on time is 1 to 10, in steps of 1. Higher the TON setting larger is the pulse on period. The
single pulse discharge energy increases with increasing TON period, resulting in higher cutting rate and
poor surface finish.
7.4.0)Wire tension:
Wire tension is a gram-equivalent load with which the continuously fed wire is kept under tension so that
it remains straight between the wire guides. Wire tension can be adjusted by the wheel provided on
machine column. While the wire is being fed continuously, appropriate wire tension prevents the
undesirable wire deflection from its straight path. The wire deflection is caused due to spark induced
reaction forces and water pressure. A brass wire of 0.25mm diameter can be applied with a maximum
tension of 1600gm. Optimum wire tension results in high MRR and low surface roughness.
7.4.2)Gap voltage:
Gap voltage is the potential difference across the workpiece and wire electrode. It is read directly on the
voltmeter. Gap voltage depends on the set values of gap potentiometer and sensitivity potentiometer.
Ranges between 40-60V results in better MRR and fine finish. High gap voltage gives poor finish.
MRR= (5.5)2×12/645
MRR= 0.56mm/sec
2) Al workpiece of thickness= 3.5mm
MRR= (5.5)2×3.5/285
MRR= 0.37mm/sec
7.7) Comments:
7.8) References:
1) Semon, G. (1975). A Practical Guide to Electro-Discharge Machining, 2nd ed. Ateliers des
Charmilles, Geneva.
2) Dulebohn, "Tracer controlled machining by electrically induced erosion", U.S. Patent 3,614,372,
filed 4 December 1969, issued 19 October 1971.
Experiment No. 6 23
To measure surface roughness of Al plate by using tools, Brass ,Cu and Al by using EDM die
Sinker.
Experiment No. 7 28
To find the material removal rate of work pieces of various thickness by using EDM Wire Cut.