1. Title: EDM wire cut.

2. Objective

To examine engineering product of an EDM, wire cut process

To understand wire cutting process

To understand the process of programming CNC

3. Theory
Electrical Discharge Machining is a process in which the workpiece is connected in a circuit with an
electrode. The electrode is placed a certain
space apart from the workpiece, this creates
voltage buildup and eventually will produce
sparks. The spark produces intense heat with
temperature ranging from 8000 to 12000 degrees celcius, melting almost anything. The spark is in a
controlled manner meaning it is focused onto the surface of the material only. The workpiece is
submerged in an insulating liquid more typically oil or, less frequently, other dielectric fluids
The electrode shape is in the form of a die or a wire. The die shape is to
erode the material in accordance to the shape of the die. EDM that uses
wire is called Wire cutting. EDM wire cutting uses a metallic wire to cut
a programmed contour in a workpiece. On common wire cut machines the
cutting process can only be performed on a x-y axis frame. The wire is fed
by a spool and cuts along a kerf, all of this is preprogrammed by using CAM technology specifically
G-Code programming. The work is done under submerged dielectric liquid directing all the spark
along the guided kerf. The wire can cut with kerfs as wide as 3 inches and precise positioning. This
allow for parts that require precision such as extrusion dies and blanking punches. The cuting process
is always through the entire workpiece. To start machining it is first necessary to drill a hole in the
workpiece or start from the edge. The wire is usually made of brass or stratified copper, and is
between 0.1 and 0.3 mm diameter.
Depending on the accuracy and surface finish needed, a part will either be one cut or it will be
roughed and skimmed. On a one cut the wire ideally passes through a solid part and drops a slug or
scrap piece when it is done. This will give adequate accuracy for some jobs, but most of the time,

skimming is necessary. A skim cut is where the wire is passed back over the roughed surface again
with a lower power setting and low pressure flush. There can be from one to nine skim passes
depending on the accuracy and surface finish required. Usually there are just two skim passes. A skim
pass can remove as much as 0.002" of material or a as little as 0.0001". During roughing ( i.e. the first
cut) the water is forced into the cut at high pressure in order to provide plenty of cooling and eliminate
eroded particles as fast as possible. During skimming (accuracy / finish cuts) the water is gently
flowed over the burn so as not to deflect the wire.

EDM Circuit

Wire Cut Process

G-Code

According to wikipidea; G-code the common name for the most widely used numerical
control (NC) programming language. The main purpose for G-code is too instruct automated machine
tools to carry out commands, usually in computer-aided manufacturing process. G-code is sometimes
called G programming language.
In fundamental terms, G-code is a language in which people tell computerized machine tools how to
make something. The how is defined by instructions on where to move, how fast to move, and
through what path to move. The most common situation is that, within a machine tool, a cutting tool is
moved according to these instructions through a toolpath, cutting away excess material to leave only
the finished workpiece.
In wire cut the commands used were as follow:

G01 = cut to mentioned coordinate

G02 = clockwise cut

G03 = counter-clockwise cut

G41 = offset tool from workpiece, right side

G42 = offset tool from workpiece, left side

G91 = the origin moves with the new point. For non-linear jobs.

4. Apparatus

CAD software

Graphing paper

EDM machine

4.1.

Industrial Apparatus
Exceteks Wire-cutting EDM V650G

A somewhat similar machine compared to the labs EDM wirecut, the V650G uses damping
equipment to maintain accurate cuts. It uses a Mono bloc Meehanite cast elements designed using
Finite Element Methods (FEM) provide exceptional damping properties and exceptional machining
rigidity. To ensure thermal stability, rib location has been designed using Finite Element Analysis,
assuring optimised structural rigidity.
Specifications
Maximum workpiece (mm)
Max. Work piece Weight

650G
1000 x 700 x 345 mm(39.4" x 27.6" x 13.6")
800kg(1764 lb)

Travel of X/Y axes

650 x 400 mm(25.6"x 15.7")

Travel of U/V axes

160 x 160 mm(6.3"x 6.3")

Travel of Z axis
Wire diameter
Number of axes controlled
Max taper angle
Machine size
Machine Weight
Water tank capacity

350mm(13.8") Option 410mm(16.1")

0.15~0.3mm(0.004"~0.012")
5 Axis AC Servo Motor
30/ 100mm(30/ 3.9") with wide diamond guide and nozzle
2520 x 2720 x 2290 mm(99.2" x 107.1" x 90.2") (89")
4000kg(8818 lb)
850L

CHMER Submeged EDM wirecut, G53S

Another EDM wirecut with more varying feature. It provides high level of flexibility with low
running cost. Also includes the laser alignment and mechanical structure to promote higher accuracy
Specification

5. Procedure
1. A design was made in solidwork to gauge the coordinates; the design included both curved
and straight features.
2. Design was transferred to a graphing paper
3. The coding was done according to the design on the graph paper
4. Code was inputed into the EDM machine.
5. Code was save in library of the EDM cut CAM software.
6. The program was graphed on the wire cut interface to ensure no error occurs
7. The CNC program is carried out on the EDM wire cut

6. Results

CNC Program
00181

Reference number

N100 G00 G21 G;

N102 G92 X0 Y10;

Initial Position

N104 M60;

Wire Connection

N106 M83;

Water Flow

N110 S1D1 0;

Offset from Spark gap

N112 G41 G1 X10. Y10.;

N114 G01 X26. Y66.;
N116 G01 X26. Y63.;
N120 G01 X36. Y61.;
N122 G01 X28. Y61.;
N124 G01 X28. Y57.;
N126 G01 X34. Y57.;
N128 G01 X34. Y55.;
N130 G01 X28. Y55.;
N132 G01 X28. Y48.;
N134 G01 X26. Y48.;
N136 G01 X26. Y45.;
N138 G01 X28. Y45.;
N140 G01 X28. Y40;
N142 G01 X35.5. Y46.;
N144 G01 X37.5 Y46.;

N146 G01 X31. Y40.4;

N148 G01 X38. Y31.;
N150 G01 X35.5 Y31.;
N152 G01 X29. Y39.;
N154 G01 X28. Y38.;
N156 G01 X28. Y31.;
N158 G01 X26. Y31.;
N160 G01 X26. Y28.;
N162 G01 X29. Y28.;
N164 G01 X33. Y18.;
N166 G01 X37. Y28.;
N168 G01 X40. Y28.;
N170 G01 X40. Y13.;
N172 G01 X38. Y13.;
N174 G01 X38. Y25.;
N176 G01 X34. Y15.;
N178 G01 X32. Y15.;
N180 G01 X32. Y15.;
N182 G01 X28. Y13.;
N184 G01 X26.Y13.;
N186 G01 X26. Y9.;
N188 G01 X21. Y9.;
N190 G03 X15.Y10.I-3.;
N192 G01 X10. Y10.;

N194 G40 X0.;

N196 M50;
N198 M30;

Closing Commands

7. Discussion
Precaution

Precautions when doing the programming are to make sure the correct coordinate is inputted
as shown on the graph.

The programming should be graphed first before running on the CNC to check for errors

The initial position of the tool bit should ideally be from the left or right side of the object
being made and not from the top or bottom as this would cause confusion for the CNC
machine.

The operation should end on the boundary of the work piece or the initial starting position.

Dots should be placed after each x and y coordinate to indicate a correct point.

A large object can be scaled to fit the work piece dimensions.

The object should ideally be done on a graphed paper or solid work to ensure proper
dimensioning.

In this experiment we encountered several problems with the object. The endpoint of the object wont
match the initial point even though the graphing and size of the object seems right. This resulted in an
open looped object. Closed loop object is needed in wire cut process to ensure proper work piece
removal. The problem may lie in the programming of the CNC machine.
The solution was to move the y coordinate up by one point in the base region of the object. The result
is a slight edge in the initial frame of the object but it can be CNC.
Also the graphing of the program should always be done on a 1 scale.

We have concluded several advantages and disadvantages for EDM wire cut
Advantages

Disadvantages

1. Suitable for delicate and small parts

1. Closed loop profile only.

2. Accurate and precise dimension.

2. Not suitable for large and huge parts.

Dimension can be measured in

millimeters

3. Computer automated. Less human errors

3. Skilled labor may be needed in order to

operate the machine

4. Cost
5. Slow material removal rate
6. Geometry constrain; sharp corners are
difficult due to electrode properties
7. Can only be used in presence of
electricity

8. Conclusion
The G-Code programming is an example of Computer-Aided Manufacturing and it is highly suitable
in EDM wire cut where the process involves highly fine workpiece and small parts not possibly done
by humans. The wirecut machine manage to cut up to 1mm resolution. The product was precise
according to the graphed model. The only drawback is the time taken to cut is far too long (one day)
and the EDM encountered many problems during the cutting phase.

9. Recommendation
The improvement that can be made on this is the integration of CAD software during the designing
process and live feed onto the CAM software of the EDM wirecut machine. This can also skip the
graphing procedure and parse the design directly onto the CAM by converting the CAD data into
CNC G-Code programming.

10.

Reference

Website
http://www.chmer.com/index.php
http://www.excetek.com/
http://www.xactedm.com/edm-capabilities/how-edm-works/
http://en.wikipedia.org/wiki/Electrical_discharge_machining
Books
Manufturing Engineering and Technology, 7th Edition SI units, Pearson, Serope Kalpakjian, Steven R.
Schmid. 2014