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Wire EDM Lab Report

The document summarizes an experiment on wire electro discharge machining (EDM). It describes the objectives of the experiment which are to identify wire EDM as a machining process, understand the material removal physics, and understand the major machine components and their functions. It then lists the machines used like the power supply, control panel, servo control, stabilizer, and deionization plant. It explains that wire EDM uses a continuously moving wire as an electrode to cut through electrically conductive materials with sparks generated between the wire and workpiece using a dielectric fluid. It concludes that wire EDM enables high-precision cuts and is commonly used in industries like automotive and aerospace.

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Edgar Thorpe
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593 views

Wire EDM Lab Report

The document summarizes an experiment on wire electro discharge machining (EDM). It describes the objectives of the experiment which are to identify wire EDM as a machining process, understand the material removal physics, and understand the major machine components and their functions. It then lists the machines used like the power supply, control panel, servo control, stabilizer, and deionization plant. It explains that wire EDM uses a continuously moving wire as an electrode to cut through electrically conductive materials with sparks generated between the wire and workpiece using a dielectric fluid. It concludes that wire EDM enables high-precision cuts and is commonly used in industries like automotive and aerospace.

Uploaded by

Edgar Thorpe
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Name – Shreya Maheshwari Entry No –2021EEB1212 Date:24/01/22

EXPERIMENT 5 – Wire EDM


❖Aim of the experiment
(a) Objectives
• To identify the Wire Electro Discharge Machining (Wire EDM) as a special type of
machining process
• To understand the physics of the material removal in the process of Wire EDM
• To understand the major components of the machine used in the process and their
functions

(b) Machines and Tools used in the experiment

❑ Machines used-
➢ MAIN POWER SUPPLY : For machine operations, LAN household power supply of
220-240 Volts and 50 Hz is used.

➢ EDM POWER SUPPLY: For EDM, DC power is used. We define electrodes for the
process and this can only be done by DC source.

➢ CONTROL PANEL : This is used for establishing an interface between user and
machine.

➢ SERVO CONTROL : These are machines used to move wire guide in different
directions like on x-y axis with respect to horizontal workpiece and z- axis in up and
down movement of wire guides.

➢ STABILIZER : Used to stabilize fluctuating voltage from the main power supply.

➢ DE-IONIZATION PLANT : Used to deionize the tap water or any mineral water.

➢ DIELECTRIC FLUSHING AND CIRCULATING SYSTEM : This is used to supply dielectric


to the cut zone through pipes and nozzle.

❑ Tools used
❖ WORKPIECE : It is a sheet of conductive material out of which we cut the required
shape and this acts as anode in sparking process.

❖ CUTTING WIRE : A tense and continuously moving wire which acts as machine
while sparking is done.
❖ DIELECTRIC FLUID : This fluid creates a path for electric discharge as it becomes
ionized in the gap. The build should be inflammable, non-toxic and should not cause
any ill effect on user.

❖EXPERIMENTAL PROCEDURE
Wire Electro Discharge Machining is an electro thermal production process where a thin
single strand metal wire, along with de-ionised water allows the wire to cut through metal
by the use of heat from electrical sparks, while preventing rust. The function of de-ionised
water is to conduct electricity. Wire diameters range from 0.076 to 0.30 mm (0.003–0.012
in), depending on required kerf width. Materials used for the wire include brass, copper,
tungsten, and molybdenum.

→ In the Wire EDM process, a metal part is placed into dielectric fluid, and a wire is fed
through the submerged metal component. It creates an electrical discharge between
the wire or the electrode and the workpiece.
→ As this spark jumps across the gap, the material is then removed from the workpiece
and the electrode.
→ When the distance separating the electrodes narrows, it increases the intensity of
the electric field, and thus increases the strength of the dielectric fluid. The current
more easily passes between the two electrodes under these conditions, leading to
the separation of the component from the metal sheet with each spark.
→ To stop the sparking process from shorting out, a non-conductive fluid or dielectric
is also used in the process.
→ The dielectric removes the waste material, and the process continues further.
❖OUTPUT OF THE EXPERIMENT
There are not many items in our day-to-day life which we can see but they are used to make
many objects. EDM is most commonly used to manufacture parts and components for the
automotive, aerospace, and electronics industries.
❖LIMITATIONS OF WIRE EDM
• Though speed has increased due to technological advancements still Wire EDM is
a slow process as compared to other machining methods.
• Maintenance of wire EDM machines is more demanding than that conventional
machine tools and hence the cost effectiveness decreases.
• Since wire EDM is a thermal process, some stresses can be imparted to the
workpiece.
• Brass deposits can also be found on the part post-machining which makes the final
piece rough.
• The tighter the tolerance the more cuts required to hold and thus, each pass results
in additional processing time.
• The wire must pass through the entire part which makes this process unsuitable for
‘blind-hole’ applications.
• The method is limited to electrically conductive materials. Therefore, any material
that is a composite or coated with a dielectric is not feasible for EDM.

❖ OBJECTS IN MY NEIGHBOURHOOD MADE FROM


WIRE EDM
In general WEDM is not found in our surroundings but we get the workpiece
which has been cut by an EDM machine. EDM helps in making cuts with high
levels of precision which are quite sharp. Holes with very small diameters can
also be made with EDM machines. So here it may require components made
from wire EDM.

❖USE OF WIRE EDM IN MY FIELD OF


SPECIALISATION
Wire EDM is most commonly used in mold and die manufacturing processes, particularly
for extrusion dies and blanking punches. Since I am studying electrical engineering so
there is not much use of wire EDMs in my field. But still EDM is used for making
instruments of high precision which are the most essential parts of many electrical
machines like transformers, ac generators etc.
❖CONCLUSION
After this experiment, I can say that Wire EDM is one on of the greatest innovation in
the tooling and machining industry. This process has bought dramatic improvements
to industry in accuracy, quality, productivity, and earnings. A significant advantage of
wire EDM over conventional EDM is that the continuous supply of wire minimizes the
wear that occurs with a fixed electrode. Many of the wire EDM machines are self-
threading so that in case of a
wire breaks, the process can be continued without any disruption. One of the best
parts about Wire EDM is that parts may be cut after heat treatment, eliminating the
possibility of distortion arising from post-machining treatments. Because the wire
EDM method exerts no tooling pressure upon the workpiece, small, delicate parts are
finely machined. Hence, very fine surfaces are possible by Wire EDM.

THANK YOU

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