Electric Discharge Machining

Aim
To understand the process of Electric Discharge Machining and to study the dependency of EDM on various process parameters.

Theory of Operation
EDM is a non-mechanical method of machining. It can be used to machine materials that are too hard for conventional machining, and can do things that are difficult for conventional machining such as make square inside corners. One limitation is that only electrically conductive materials can be machined. In its basic form and EDM consists of an electrically isolated head called a ram. The ram moves up and down and holds a cutting device called an Electrode. Ram electrodes are typically made out of Copper or Graphite and are manufactured to the shape of the material to be cut away. EDM cuts by spark erosion. The spark has a typical temperature of about 10,000 degrees centigrade. This basically vaporizes the work piece, and then the EDM oil solidifies the vapor and carries it away by means of flushing. Flushing can be accomplished by several means. Forcing EDM oil through the electrode or on the sides of the work piece is one method. Another method is to agitate the EDM ram or the work piece. The spark also causes the debris to moved away. Typically the Electrode and work piece are immersed in an oil that has characteristics suitable for EDM operation. These fluids are called EDM oils. Starting fires is a constant problem with EDM that use flammable oils, and oils that have high flashpoints are desirable. The electrode has to be precisely placed over the work piece, not only in the X and Y axis, but in the Z axis as well. In some cases agitation of the X and Y axes, aid in the improving the surface finish and in flushing operations. The controller supplies electricity to the EDM. It works on 415V , 3-phase power supply. It has a gap sence technology which is requred to maintain the constant gap between tool and workpiece. The output through the controller is 75V Square wave with desired Ton and Toff. Some of the common EDM oils are: Kerosene, Deionized water, paraffin etc. Some of the common tools are: Graphite, Copper, Akonite, Brass etc.

Process Parameters
open circuit voltage Vo working voltage Vw maximum current Io pulse on time Ton pulse off time Toff spark gap d

Process
Workpiece is weighed on which the EDM is to be performed. Workpiece material is mild steel. Workpiece is mounted on the table and flush adjusted such that it sweeps the entire surface which is to be machined. Now the EDM workspace is flooded with the paraffin by switching on the pump. The tool and workpiece is connected to a power supply. The needed value of current , Ton and Toff is set and z axis is set on auto-adjust mode. Make sure that paraffin level does not drop or rise. Start the machining for 20 minutes. Off the pump in order to drain out the paraffin. Now measure the weight of workpiece. Follow the same procedure for different parameters and note down the reading.

Observation
Workpiece: Mild Steel Tool: Graphite Density of Steel: 7850 kg/m3 Ton and Toff : 6 sec Total Time: 20 min Current (Ampere) Workpiece 1 Workpiece 2 Workpiece 3 4 6 8 Voltage (Volts) 75 75 75 Initial weight (g) 149.58 137.47 146.16 Final weight (g) 149.35 136.79 144.82 Weight difference (g) 0.23 0.68 1.34 Actual MMR (10-9m3/min) 1.47 4.31 8.54

Graph

Error Analysis
1. The Ton and Toff time were not precise. 2. The corners of the tool were worn out and were not perfectly 90 degrees as desired. 3. Flushing was not proper, which resulted in burned metal deposit at the crater.

Suggestion
More samples were required and also total time per sample need to be reduced.

Conclusion
1. The dependance of MRR with current I was found to be linear. 2. With increase in current surface finish was reduced.

-Vrushiket Patil(09003044) Mechanical B'tech 2009 Date: 12 / 8 / 2011