INTRODUCTION OF ELECTRIC DISCHARGE MACHINE (EDM)

Electric discharge machine (EDM) is a modern machine that , and other traditional machining operation. EDM now become the most important accepted technologies in manufacturing industries since many complex 3D shapes can be machined using a simple shaped tool electrode. Electric Discharge Machine (EDM) is commonly used for producing mould and die component. This machine is use because the ability of the machining process that is very accurate in creating complex or simple shape within parts and assemblies. The cost of machining is quite high payable to its initial investment and maintenance for the machine but very desirable machining process when high accuracy is required. Since electric discharge machine (EDM) was developed, much theoretical and experimental work has been done to identify the basic processes involved. It is now one of the main methods used in die production and has good accuracy and precision with no direct physical contact between the electrodes so that no mechanical stress is exerted on the work piece. The important output parameters of the process are the material removal rate (MRR) and tool electrode wear ratio (EWR).

EDM Wire Cut Machine

EDM Wire Cut Work

Two electrical conductors of the work piece and electrode meet each other where the work piece is a positive charge and electrode is a negative charge. So, the electric current flow is from positive to negative. The current flow is between 250 Hz to 500000 Hz per second. From the current flow, it will produce the pressure spark until 3000 degree celsius. The cable gap from work piece is between 0.01 to 0.02 mm to avoid the cable broken because touched the work piece. The cable diameter is 0.1 to 0.3 mm but usually used is 0.25 mm. EDM wire cut machine can read the straight line and circle direction only.

Main component in EDM wire cut 1. 2. 3. 4. 5. Electrode and dielectric liquid. Compressor. Storage tank and filter system. Machine table. Electric supply.

Types of electrodes. 1. 2. 3. Copper tungsten. Mixtures of carbon and copper. Silver tungsten.

Advantages and disadvantages of EDM wire cut.

Advantages Some of the advantages of EDM include machining of: 1. Complex shapes that would otherwise be difficult to produce with conventional cutting tools. 2. Extremely hard material to very close tolerances. 3. Very small work pieces where conventional cutting tools may damage the part from excess cutting tool pressure. 4. There is no direct contact between tool and work piece. Therefore delicate sections and weak materials can be machined without any distortion. 5. A good surface finish can be obtained. 6. Very fine holes can be easily drilled.

Disadvantages Some of the disadvantages of EDM include: 1. The slow rate of material removal. 2. Reproducing sharp corners on the work piece is difficult due to electrode wear. 3. Specific power consumption is very high. 4. Power consumption is high. 5. Overcut is formed. 6. Excessive tool wear occurs during machining.

G code programmer for EDM wire cut.

The G codes normally used in EDM wire cut programmer is: 1. G 00

I. II. III.

Called as Rapid traverse. This code will move straight to all direction but not cut the work piece.

2. G 02

I. II.

Called as clockwise circle interpolation. This code will cut the work piece in clockwise direction.

3. G 03 I. II. Call as anti clockwise circle interpolation. This code will cut the work piece in anticlockwise direction.

4. G 40, G 41, G 42 I. II. III. G 40 This code will start at centre before cut the work piece. G 41 This code will start outside or on left before cut the work piece. G 42 This code will start inside or on right before cut the work piece.

G 40

G 41

G 42

5. G 62 I. II. Call as setting of composition This code will start outside from drawing.

6. M 02 I. This code is end of programme

Question

1. What is EDM wire cut? - EDM is electric discharge machine that can drilling, milling, and grinding for producing mould and die component.

2. What the main component in EDM wire cut? - The component is 1. 2. 3. 4. 5. Electrode and dielectric liquid. Compressor. Storage tank and filter system. Machine table. Electric supply.

3. What the F8 ETC?