ACKNOWLEDGEMENT

I ABHISHEK SHARMA have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. to LOVELY PROFESSIONAL UNIVERSITY for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I am highly indebted I would like to express my gratitude towards my parents & member of MANUFACTURING DEPARTMENT for their kind co-operation and encouragement which help me in completion of this project. I would like to express my special gratitude and thanks to industry persons for giving me such attention and time. My thanks and appreciations also go to my colleague in developing the project and people

who have willingly helped me out with abilities.

their

CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

INTRODUCTION
A wire electric discharge machining method of machining the workpiece with different thickness into a required shape with first cut and second cut. The method includes the steps of (a) detecting a position of the wire electrode relative to the workpiece, (b) detecting change in thickness of the workpiece during first cut, (c) storing the position of wire electrode as a thickness change position (Q1) when change in thickness of the workpiece from a first thickness (t1) to a second thickness (t2) is detected, (d) forming a zone ( ) around the thickness change position, (e) comparing the position of wire electrode to the zone during second cut, and (f) changing at least one machining condition during times when it is determined that the wire electrode is positioned in the zone.

There are two primary EDM methods: 1.ram EDM and 2.wire EDM. The primary difference between the two involves the electrode that is used to perform the machining. In a typical ram EDM application, a graphite electrode is

machined with traditional tools. The now speciallyshaped electrode is connected to the power source, attached to a ram, and slowly fed into the workpiece. The entire machining operation is usually performed while submerged in a fluid bath. The fluid serves the following three purposes:
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flushes material away serves as a coolant to minimize the heat affected zone, thereby preventing potential damage to the workp acts as a conductor for the current to pass between the electrode and the workpiece. acts as a conductor for the current to pass between the electrode and the workpiece.

EDM is sometimes called "spark machining" because it removes metal by producing a rapid series of repetitive electrical discharges. These electrical discharges are passed between an electrode and the piece of metal being machined. The small amount of material that is removed from the workpiece is flushed away with a continuously flowing fluid. The repetitive discharges create a set of successively deeper craters in the work piece until the final shape is produced. Electrical discharge machining is frequently used to make dies and molds. It has recently become a standard method of producing prototypes and some production parts, particularly in low volume applications. For more details regarding a typical application, you can read about a custom bronze branding-iron that was made with EDM.

The History of EDM Machining

The history of EDM Machining techniques goes as far back as the 1770s when it was discovered by an English Scientist. However, Electrical Discharge Machining was not fully taken advantage of until 1943 when Russian scientists learned how the erosive effects of the technique could be controlled and used for machining purposes.

When it was originally observed by Joseph Priestly in 1770, EDM Machining was very imprecise and riddled with failures. Commercially developed in the mid 1970s, wire EDM began to be a viable technique that helped shape the metalworking industry we see today.

In the mid 1980s, the EDM techniques were transferred to a machine tool. This migration made EDM more widely available and appealing over traditional machining processes. Today, Wire EDM makes it possible to work with harder materials and metals while keeping the exactness of precision cutting.

The Sinker EDM Machining Process

In the Sinker EDM Machining process, two metal parts submerged in an insulating liquid are connected to a source of current which is switched on and off automatically depending on the parameters set on the controller. When the current is switched on, an electric tension is created between the two metal parts. If the two parts are brought together to within a fraction of an inch, the electrical tension is discharged and a spark jumps across. Where it strikes, the metal is heated up so much that it melts.

Sinker EDM Machining Process

The sinker EDM machining (Electrical Discharge Machining) process uses an electrically charged electrode that is configured to a specific geometry to burn the geometry of the electrode into a metal component. The sinker EDM process is commonly used in the production of dies and molds.

How Sinker EDM works

Two metal parts submerged in an insulating liquid are connected to a source of current which is switched on and off automatically depending on the parameters set on the controller. When the current is switched on, an electric tension is created between the two metal parts.

If the two parts are brought together to within a fraction of an inch, the electrical tension is discharged and a spark jumps across. Where it strikes, the metal is heated up so much that it melts. Innumerable such sparks spray, one after the other (never simultaneously) and gradually shape the desired form in the piece of metal, according to the shape of the electrode. Several hundred thousand sparks must fly per second before erosion takes place.

Die-sinking EDM Machining

In the case of die-sinking EDM, the required shape is formed negatively in the metal with a three-dimensional electrode. By superimposed movements in the main axes x, y, c, z, the most varied shapes, indentations and cavities are created, such as cannot in part be achieved

by any other machining system. For example, a helicoid cavity or a rectangular hole in one single steel block or the machining of an extremely thin, hardened steel sheet that may not be subjected to any mechanical pressure.

EDM Machining Process & Techniques

(Electrical Discharge Machining)
A machining method typically used for hard metals, Electrical Discharge Machining (commonly known as "EDM Machining") makes it possible to work with metals for which traditional machining techniques are ineffective. An important point to remember with EDM Machining is that it will only work with materials that are electrically conductive. With good EDM Machining equipment it is possible to cut small odd-shaped angles, detailed contours or cavities in hardened steel as well as exotic metals like titanium, hastelloy, kovar, inconel, and carbide. The EDM Process is commonly used in the Tool and Die industry for mold-making, however in recent years EDM has become a integral part for making prototype and production parts. This is seen in the aerospace and electronics industries where production quantities remain low.

The Wire EDM / Spark EDM Process

Wire EDM Machining (also known as Spark EDM) is an electro thermal production process in which a thin single-strand metal wire (usually brass) in conjunction with de-ionized water (used to conduct electricity) allows the wire to cut through metal by the use of heat from electrical sparks. Due to the inherent properties of the process, wire EDM can easily machine complex parts and precision components out of hard conductive materials.

Wire EDM Machining Process

Wire EDM machining (Electrical Discharge Machining) is an electro thermal production process in which a thin single-strand metal wire in conjunction with de-ionized water (used to conduct electricity) allows the wire to cut through metal by the use of heat from electrical sparks. Due to the inherent properties of the process, wire EDM can easily machine complex parts and precision components out of hard conductive materials.

How Wire EDM Works

Wire EDM machining (also known as "spark EDM") works by creating an electrical discharge between the wire or electrode, & the workpiece. As the spark jumps across the gap, material is removed from both the workpiece & the electrode.

To stop the sparking process from shorting out, a non conductive fluid or dielectric is also applied. The waste material is removed by the dielectric, and the process continues.

Wire EDM Machining According to Wikipedia.org:

"...In [wire EDM machining], a thin single-strand metal wire, usually brass, is fed through the workpiece. The wire, which is constantly fed from a spool, is held between upper and lower guides. The guides move in the X-Y plane, and sometimes the upper guide can also move independently giving rise to transitioning shapes (circle on the bottom square at the top). This gives the Wire EDM the ability to be programmed to cut very intricate and delicate shapes. The wire-cut uses water as its dielectric with the water's resistivity and other electrical properties carefully controlled by filters and de-ionizer units." [View Wikipedia Entry

The Sinker EDM Machining Process

In the Sinker EDM Machining process, two metal parts submerged in an insulating liquid are connected to a source of current which is switched on and off automatically depending on the parameters set on the controller. When the current is switched on, an electric tension is created between the two metal parts. If the two parts are brought together to within a fraction of an inch, the electrical tension is discharged and a spark jumps across. Where it strikes, the metal is heated up so much that it melts.

Sinker EDM Machining Process

The sinker EDM machining (Electrical Discharge Machining) process uses an electrically charged electrode that is configured to a specific geometry to burn the geometry of the electrode into a metal component. The sinker EDM process is commonly used in the production of dies and molds.

How Sinker EDM works

Two metal parts submerged in an insulating liquid are connected to a source of current which is switched on and off automatically depending on the parameters set on the controller. When the current is switched on, an electric tension is created between the two metal parts.

If the two parts are brought together to within a fraction of an inch, the electrical tension is discharged and a spark jumps across. Where it strikes, the metal is heated up so much that it melts. Innumerable such sparks spray, one after the other (never simultaneously) and gradually shape the desired form in the piece of metal, according to the shape of the electrode. Several hundred thousand sparks must fly per second before erosion takes place.

Die-sinking EDM Machining

In the case of die-sinking EDM, the required shape is formed negatively in the metal with a three-dimensional electrode. By superimposed movements in the main axes x, y, c, z, the most varied shapes, indentations and cavities are created, such as cannot in part be achieved

by any other machining system. For example, a helicoid cavity or a rectangular hole in one single steel block or the machining of an extremely thin, hardened steel sheet that may not be subjected to any mechanical pressure.

For More Information

For more information on the Sinker EDM process, contact the people at: IDS Machining (www.IDSmachining.com). If you have questions about EDM Machining contact us.

Wire EDM Machining Process

Wire EDM machining (Electrical Discharge Machining) is an electro thermal production process in which a thin single-strand metal wire in conjunction with de-ionized water (used to conduct electricity) allows the wire to cut through metal by the use of heat from electrical sparks.

Due to the inherent properties of the process, wire EDM can easily machine complex parts and precision components out of hard conductive materials.

How Wire EDM Works

Wire EDM machining (also known as "spark EDM") works by creating an electrical discharge between the wire or electrode, & the workpiece. As the spark jumps across the gap, material is removed from both the workpiece & the electrode.

To stop the sparking process from shorting out, a non conductive fluid or dielectric is also applied. The waste material is removed by the dielectric, and the process continues.

Wire EDM Machining According to Wikipedia.org:

"...In [wire EDM machining], a thin single-strand metal wire, usually brass, is fed through the workpiece. The wire, which is constantly fed from a spool, is held between upper and lower guides. The guides move in the X-Y plane, and sometimes the upper guide can also move independently giving rise to transitioning shapes (circle on the bottom square at the top). This gives the Wire EDM the ability to be programmed to cut very intricate and delicate shapes. The wire-cut uses water as its dielectric with the water's resistivity and other electrical properties carefully controlled by filters and de-ionizer units." [View Wikipedia Entry] If you have questions about EDM Machining contact us.

EDM Machining Equipment

Some of the EDM machining equipment used by professional companies includes machines by: GBI Cincinnati, Elox, Japax, and Mitsubishi. All top-quality EDM machining equipment provide the same basic functionality, with the differences between each model being specific features. User-interface, number and gauges of wires, and the tank size where machining is actually done are just some of the features that differentiate each model . For example, the professionals at IDS Machining use the following EDM machining equipment and inspection tools:
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EDM Machines: o Sodick AQ35L Wire EDM o Sodick AM3L Sinker EDM

The Sodick AQ-35L Wire EDM is a fast precision EDM machine that provides the dynamic response of linear technology - high speed machining in less time has become an economically efficient reality. It features linear drive technology and simplified control mechanisms, which provide a direct link between the drive and the control.

The Sodick AM3L Sinker EDM Machine is an ultra fast linear machine that drives to the left and right of the z axis reach feed rates of 36 m/min and are completely balanced to facilitate precise, frictionless, rapid travel for the machine head. The integrated cooling system further enhances thermal stability and precision. A good machining shop should also have the following types of equipment to further machining capabilities. Again, this equipment list is taken from IDS Machining:
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Machining Centers: o Mazak 510C Vertical Machining Center (NEXUS)

Mills:
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Bridgeport Manual Knee Mill

Precision Measuring Tools: o Mitutoyo height gauge zero to 12 inches o Micrometers sizes 1 inch through 12 inches o Pin gauges 0.011 through 0.500 o Bore Gauges 0.7 to 4 inches o Gauge Blocks 0.100 through 5.00 o Calipers zero to 24 inches Other Tools: o Clark Fork Lift (2500 lb. capacity) o Grand Rapids Surface Grinder o RamCo Horizontal Saw

If you have questions about EDM Machining contact us.

EDM Machining Metalwork Examples

Following are some EDM machining metalwork examples. Click each sample to view larger: