MAJOR PROJECT REPORT

ON
ELECTRIC DISCHARGE MACHINE (EDM)
Submitted to the Department of Mechanical Engineering

Of
CGC Technical Campus Jhanjeri, Mohali

As Part of Course Work of

B.Tech (Mechanical Engineering)

I.K GUJRAL PUNJAB TECHNICAL UNIVERSITY,

KARPURTHAL, JALANDHAR
Submitted to: Submitted By:
Dr. RAJEEV KUMAR PRIYANSHU RAJ
HOD (MECHANICAL) NAVAM SINGLA
Mechanical department AKASH GUPTA
Faculty incharge: HIMANSHU BHALLA
Er. SUNNY PURI RISHABH TIWARI
 Department of Mechanical Engineering
CHANDIGARH GROUP OF COLLEGES TECHNICAL
CAMPUS JHANJERI ,MOHALI (PUNJAB)

CERTIFICATE OF ORIGINALITY OF WORK

I Priyanshu Raj Univ. Roll No. 1535693 Student of Mechanical Branch fourth Year, have

undergone the Project Work at the college. I have done the following projects during my

training period: -

1. DESIGN

2. FABRICATION

……. . . . . . . . . . . . . . . . . . . . . . . .

I hereby declare that the work is an original one and has not been submitted earlier to

this university or any other institution for fulfillment of the requirement of a course of study.

Er.SUNNY PURI NAME OF STUDENT

(Project Guide) PRIYANSHU RAJ

Univ. Roll No.: 1535693

Branch: MECHANICAL
Semester: 7th
CGCTC, Jhanjeri, Mohali

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DEVELOPMENT OF TABLE TOP MODEL OF
ELECTRIC DISCHARGE MACHINE

submitted in the partial fulfillment of the award of degree in mechanical engineering

BY

NAME OF STUDENT ROLL NO.

Akash Gupta 1535649

Himanshu Bhalla 1535672
Navam Singla 1535685
Priyanshu Raj 1535693
Rishabh Tiwari 1535698

Under the supervision of

Er. Sunny Puri

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 Development Of Table Top Model Of
Electric Discharge Machine

TABLE OFCONTENTS
S. NO. TOPIC PAGE NO.

I. DECLARATION 5
II. ACKNOWLEDGEMENT 6
III. ABSTRACT 7
1 INTRODUCTION 8

2 HISTORY 10

3 11
METHODOLOGY

3.1 METAL REMOVAL PROCESS 12

3.2 CHARACTERISTICS OF SPARK ERODED SURFACE 14
3.3 DIELECTRIC FLUID 16
3.4 ELECTRODE 17
3.5 TYPE OF EDM 19
3.6 APPLICATION OF EDM 21
3.7 ADVANTAGES &DISADVANTAGES 23
4 FABRICATION 24

4.1 PART WITH SPECIFICATION 25

4.2 MATERIAL REMOVAL RATE(MRR) 39
4.3 ASSEMBLY 40
5 PROCESS CHART 43

5.1 PROCESS SHEET OF TABLE 44

6 COST ESTIMATION 45

6.1 COST OF STAND 46

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 Development Of Table Top Model Of
Electric Discharge Machine

6.9 MISCELLANEOUS COST 47

7 FUTURE TREND OF EDM 48

8 RESULT AND DISCUSSIONS 49

9 REFERENCES 50

4
 Development Of Table Top Model Of
Electric Discharge Machine

DECLARATION

DEVELOPMENT OF TABLE TOP MODEL OF

ELECTRIC DISHCHARGE MACHINE
(EDM)

The project dissertation is submitted/fulfillment of acedemic requirement of

8th semester of b.tech in mechanical department(engineering college of
mmu). This dissertation is a result of our own investigation. All section of
this text and result which have been obtained from the other sources are
fully.

TEAM MEMBERS:

NAME ROLL NO. SEMESTER

Akash Gupta 1535649 7th
Navam Singla 1535685 7th
Himanshu Bhalla 1535672 7th
Priyanshu Raj 1535693 7th
Rishabh Tiwari 1535698 7th

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 Development of Table Top Model of
Electric Discharge Machine

ACKNOWLEDGEMENT
I would like to place on record my deep sense of gratitude to Er. Sunny puri,
for his generous guidance, help, useful suggestions and continuous
encouragement.

I also wish to extend my thanks to Dr Rajeev Kumar (H.O.D Mechanical)

for valuable suggestions and motivation and other Staff Members for guiding
and providing the knowledge related to machinery and processes.

I am extremely thanks to Prof. Rajneesh Talwar, Principal Chandigarh Group

of Colleges Technical Campus Jhanjeri, Mohali (Punjab) and management for
support and encouragement.

NAME ROLL NO. SEMESTER

Akash Gupta 1535649 7th
Navam Singla 1535685 7th
Himanshu Bhalla 1535672 7th
Priyanshu Raj 1535693 7th
Rishabh Tiwari 1535698 7th

6
 Development Of Table Top Model Of
Electric Discharge Machine

ABSTRACT

Development Of Table Top Model Of Electric Discharge Machine(EDM) have

been taken for the reason that this process is fast developing machining process.
This process started with the itration on specification and availibility of
equipment in local market and drawing of the specification was the main task.

The edm process can be compared with the

conventional cutting process, except that in this case, a suitable shaped tool
electrode, with a precision controlled feed movement is employed in the place of
cutting tool, and the cutting energy is provided by means of short duration
electrical impulses. EDM has found ready application in machining of hard
metals or alloys which can not be machine easily by conventionnal methods. this
phenomenon is same as the breakdawn of a capacitor or breakdawn voltage. As a
result material is removed from both the electrode.

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 HISTORY
In 1920, the english scientist, priestley, first detected the erosive effect of electrical
discharge on metals. more recently, during research, to eleminate erosive effect on
electrical contacts, the soviet scientist, lazarenko decided to exploit the distractive
effect of electrical discharge and developed a controlled method of metal machining.
in 1943, they announced the constraction of first spark erosion machine. The spark
generator used in 1943, known as the lizarenko circuit, has been employed over
many year in power supplies for EDM machine and an improve form is being used
in many current application. Agie launches in 1969 the world’s first numerically
controlled wire cut eedm machine. Seibu developed the world first cnc wire edm
machine 1972 and the first system is manufactured in Japan.

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 WORKING PRINCIPLE
In Electrical discharge machining; a potential difference is applied across the tool and
w/p in pulse form. The tool and workpiece must be electrically conductive and a small
gap is maintained in between them. The tool and workpiece is immersed in a dielectric
medium (kerosene or deionized water). As the potential difference is applied, electrons
from the tool start to move towards the workpiece. Here the tool is negative and w/p is
positive. The electrons moving from the tool to the w/p collide with the molecules of
dielectric medium. Due to the collision of electrons with the molecule, it gets converted
into ions. This increases the concentration of electrons and ions in the gap between the
tool and w/p. The electron moves towards the w/p and ions towards the tool. An electric
current is set up in between the tool and w/p and called as plasma. As the electrons and
ions strikes the w/p and tool, its kinetic energy changes to heat energy. The temperature
of the heat produced is about 10000 degree Celsius. This heat vaporizes and melts the
material from the workpiece. As voltage is break down, the current stops to flow
between the tool and w/p. And the molten material in the w/p is flushed by circulating
dielectric medium leaving behind a crater.

The spark generation is not continuous because constant voltage is not applied across the
electrodes. The voltage is applied in pulse form.

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 DEVELOPMENT OF TABLE TOP MODEL OF
Fabrication
Parts with specification
1.1 Basin
1.2 Storage Tank
1.3 Table
1.4 Circuit
1.5 Electromagnet
1.6 Electrode and Work Piece
1.7 Guide way
1.8 X-Y Slide
1.9 Z-Slide
1.10 Guide way and work piece assembly
1.11 Dielectric material
1.12 Other Material

Assembly
Sub assemblies
1. Guide way assembly
2. Basin assembly
Full assembly

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Electrode:

Fig.1
Transformer

Fig.2

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X-Y Slide:

Fig.3
Z Slide:

Fig.4
12
BASIN:-

Material used : G.I Sheet

Dimensions : 300*200*200

Fig.5

13
DESIGN OF BASIN:

Fig.6

14
TABLE:-

Material Used :

Dimension : 800*400*400

Fig.7

15
DESIGN OF TABLE:

Fig.8
16
ELECTROMAGNET:-

Fig.9

17
ELECTRODE AND WORKPIECE:-

a) Electrode
Copper electrode is brazed to the electromagnet for
proper functioning

Material Used : Copper

Dimension : 3 Mmdia.,25mm Length

b) Work piece
Work piece on which the copper electrode will work.

Material used: shaving blade on stainless steel

Fig.10
18
GUIDE WAY:

Guide Way is use for the proper sliding of work piece on into the
basin

Fig.11

19
DESIGN OF GUIDEWAY

Fig.12

WORK PIECE HOLDER

Work piece holder is used for holding the work piece against the tool. In this, work piece
holder is fixed in between the guide way for sliding the work piece forth & back.

Fig.13
20
 Fig.14

21
ASSEMBLY:
SUBASSEMBLIES:-
1. Guide way assembly

Fig.15

22
BASIN ASSEMBLY

Fig.16

23
FULL ASSEMBLY

Fig.17
24
Circuit:

Fig.18

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 Applications:

Prototype production
The EDM process is most widely used by the mold-making, tool, and die
industries, but is becoming a common method of making prototype and
production parts, especially in the aerospace, automobile and electronics
industries in which production quantities are relatively low. In sinker EDM, a
graphite, copper tungsten, or pure copper electrode is machined into the desired
(negative) shape and fed into the workpiece on the end of a vertical ram.

Coinage die making

For the creation of dies for producing jewelry and badges, or blanking and
piercing (through use of a pancake die) by the coinage (stamping) process, the
positive master may be made from sterling silver, since (with appropriate
machine settings) the master is significantly eroded and is used only once. The
resultant negative die is then hardened and used in a drop hammer to produce
stamped flats from cutout sheet blanks of bronze, silver, or low proof gold
alloy. For badges these flats may be further shaped to a curved surface by
another die. This type of EDM is usually performed submerged in an oil-based
dielectric. The finished object may be further refined by hard (glass) or soft
(paint) enameling and/or electroplated with pure gold or nickel. Softer
materials such as silver may be hand engraved as a refinement.

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Small hole drilling
Small hole drilling EDM is used in a variety of applications.
On wire-cut EDM machines, small hole drilling EDM is used to make a
through hole in a workpiece in through which to thread the wire for the wire-
cut EDM operation. A separate EDM head specifically for small hole drilling
is mounted on a wire-cut machine and allows large hardened plates to have
finished parts eroded from them as needed and without pre- drilling.

Metal disintegration machining

Several manufacturers produce MDM machines for the specific purpose of
removing broken tools (drill bits, taps, bolts and studs) from work pieces. In
this application, the process is termed "metal disintegration machining" or
MDM. The metal disintegration process removes only the center of the tap, bolt
or stud leaving the hole intact and allowing a part to be reclaimed.
The EDM process is most widely used by the mould-making tool and die
industries, but is becoming a common method of making prototype and
production parts, especially in the aerospace, automobile and electronics
industries in which production quantities are relatively low.

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Advantages

Some of the advantages of EDM include machining of:

(a) Complex shapes that would otherwise be difficult to produce with

conventional cutting tools.

(b) Extremely hard material to very close tolerances.

(c) Very small work pieces where conventional cutting tools may damage the
part from excess cutting tool pressure.

(d) There is no direct contact between tool and work piece. Therefore delicate
sections and weak materials can be machined without any distortion.

(e) A good surface finish can be obtained.

(f) Very fine holes can be easily drilled.

(g) Electrically non-conductive materials can be machined only with specific

set-up of the process.

Disadvantages
Some of the disadvantages of EDM include:

(a) The slow rate of material removal.

(b) The additional time and cost used for creating electrodes for ram/sinker EDM.

(c) Reproducing sharp corners on the work piece is difficult due to electrode wear.

(d) Specific power consumption is very high.

(e) Power consumption is high.

(f) "Over cut" is formed.

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