Machining Process 2

Report
Electro discharge machining
(EDM) (Wire cut- grinding)

PRESENTED BY:
‫حسن محمود حسن الدسوقي‬
Report supervisor:
‫عبدالخالق العدل‬.‫د‬

PRESENTED ON: 7-11-2023.

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Electrical discharge machining theory (EDM)
Electrical Discharge Machining (EDM) is a non-traditional machining
process used to shape and form hard materials, primarily metals, by
using electrical discharges. The theory behind EDM involves the
controlled removal of material through a series of electric sparks or
discharges between an electrode (tool) and the workpiece.

Electrical Discharge Machine Components

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Power Supply:
The power supply is responsible for providing the electrical energy
required for the electrical discharges to occur. It generates the high
voltage pulses necessary for creating the sparks between the electrode
and the workpiece.

Control Unit:
The control unit is the brain of the EDM machine. It contains the
programming interface and controls various parameters such as pulse
duration, frequency, current, and voltage. The operator uses the
control unit to input the desired machining specifications and monitor
the process.

Electrode:
The electrode, also known as the tool electrode or the active electrode,
is typically made of a conductive material such as copper or graphite. It
is shaped according to the desired final shape or contour and is
connected to the power supply. The electrode is responsible for
delivering electrical energy to the workpiece and creating electrical
discharges.

Workpiece:
The workpiece is the material being machined. It is typically made of a
harder material, such as steel or titanium. The workpiece is connected
to the power supply and serves as the passive electrode, completing
the electrical circuit. The EDM process removes material from the
workpiece according to the shape and contour of the electrode.
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Dielectric System(dielectric fluid):
The dielectric system includes a reservoir or tank that holds the
dielectric fluid, which is usually deionized water. The dielectric fluid acts
as a coolant, prevents arcing between the electrode and the workpiece,
flushes away the eroded particles, and provides a medium for electrical
discharge. The system also includes pumps and filters to circulate and
maintain the dielectric fluid.

Servo Mechanism:
The servo mechanism is responsible for precise movement and control
of the electrode and the workpiece. It enables the EDM machine to
accurately position the electrode relative to the workpiece, ensuring
the desired shape and contour are achieved.

Cooling System:
EDM machines often incorporate a cooling system to dissipate the heat
generated during the machining process. This helps maintain stable
machining conditions and prevents excessive thermal damage to the
workpiece and the electrode.

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Electrical Discharge Machining Applications
Mold and Die Making:
EDM is widely used in mold and die making industries. It allows for the
precise machining of intricate cavities, cores, and details in molds and
dies used for plastic injection molding, die casting, and stamping. EDM
is particularly beneficial when dealing with hardened tool steels or
complex mold geometries.

Aerospace Industry:
The aerospace industry utilizes EDM for manufacturing critical
components, such as turbine blades, vanes, and engine parts. EDM's
ability to machine heat-resistant alloys, like titanium and nickel-based
superalloys, with high precision makes it valuable in aerospace
manufacturing.

Medical Device Manufacturing:

EDM is employed in the production of medical devices and implants. It
enables the fabrication of intricate features and fine details in materials
like stainless steel, titanium, and cobalt-chromium alloys. Examples
include orthopedic implants, surgical instruments, and dental
prosthetics.

Electronics and Semiconductor Industry:

EDM plays a role in the fabrication of precision parts for the electronics
and semiconductor industries. It is used to produce intricate patterns,
micro-sized holes, and complex shapes in conductive materials .
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Automotive Industry:
EDM is utilized in the automotive industry for various applications. It is
employed in the production of engine components, such as fuel
injectors, spark plug electrodes, and piston rings. EDM is also used for
manufacturing intricate gears, turbocharger components, and electrical
connectors in automotive systems.

Tool and Die Maintenance:

EDM is valuable for the repair and maintenance of damaged or worn-
out tools and dies. It allows for the restoration of intricate shapes, re-
cutting of damaged features, and removal of broken taps or drills from
workpieces.

Advantages of Electrical Discharge Machining

Ability to Machine Hard Materials:
EDM is particularly well-suited for machining hard and electrically
conductive materials that are difficult to machine using conventional
methods. It can effectively cut through materials such as hardened
steel, titanium, carbide, and exotic alloys without causing excessive tool
wear.

Precision and Accuracy:

EDM is capable of achieving high levels of precision and accuracy. It
can create intricate and complex shapes with tight tolerances. The
process allows for fine control over the material removal rate, resulting
in precise and consistent machining results.
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No Mechanical Contact:
Unlike conventional machining processes that involve physical cutting
or abrasion, EDM operates without direct contact between the tool and
the workpiece. This eliminates the risk of tool wear, deformation, or
damage to delicate or brittle materials.

Minimal Heat Affected Zone:

EDM is a non-thermal process, meaning it generates very little heat
during machining. This minimal heat input results in a small heat-
affected zone (HAZ) in the workpiece.

Versatility in Shape and Contour:

EDM allows for the machining of intricate and complex shapes,
including deep cavities, narrow slots, and fine details. The process is not
limited by the geometry of the tool, allowing for the production of
unique and customized parts.

Burr-Free Machining:
EDM produces clean and burr-free surfaces, reducing the need for
secondary operations such as deburring. This results in time and cost
savings in the overall manufacturing process.

Disadvantages of Electrical Discharge Machining

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Slow Material Removal Rate:
Compared to conventional machining processes like milling or turning,
EDM typically has a slower material removal rate. As a result, EDM may
not be the most efficient option for high-volume production or when
rapid material removal is required.
Surface Finish and Recast Layer:
EDM can produce a rougher surface finish compared to some
conventional machining methods. The electrical discharges and the
erosion process can create a textured or pitted surface on the
workpiece. Additionally, a thin layer of recast material may form on the
machined surface, which can have different properties than the base
material.
Limited Accessibility:
EDM is not well-suited for machining deep or narrow cavities that are
difficult to access with the electrode. The electrode size and geometry
often limit the depth and aspect ratio that can be achieved. In such
cases, alternative machining methods may be more suitable.
Cost of Consumables:
EDM requires the use of consumables such as electrodes and dielectric
fluid. Electrodes can be worn over time or require replacement,
increasing the overall cost of the process. The dielectric fluid needs to
be properly maintained, filtered, and replenished, adding to the
operational costs.

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EDWC THEORY & PROCESS

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Components Of Wire EDM Machine

CNC Tools:
The CNC tools control the entire operation of the Wire EDM machining
process. Controlling the entire operations includes being in control of
the sequencing of the wire path and being able to manage the cutting
process automatically.
Power Supply:
The power supply unit is the component that delivers pulses (from
100V to 300V) to the wire electrode and the workpiece. Furthermore, it
controls the frequency and strength of the electrical charges that pass
through the wire electrode to interact with the workpiece.

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Wire:
The wire serves as the electrode to create the electrical discharge. The
shape and thickness of the workpiece directly influence the wire’s
diameter. Typically, one can use wires with diameters ranging from
0.05 to 0.25mm.
Dielectric Medium:
The wire cut EDM process must be carried out in a tank filled with
dielectric fluid. This liquid prevents the tiny particles from the
workpiece from getting attached to the wire electrode. The most
common medium is deionized water which cools the process and gives
the workpiece a good surface finish.
Electrodes:
The electrodes in the machine are the wire (cathode) and the
workpiece (anode). The servo motor controls the wire electrode,
ensuring it does not come in contact with the workpiece at any point
during the wire EDM cutting process.

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EDWC Application
Materials A Wire EDM Machine Can Cut :
Metals:
➢ Steel (tool steel, stainless steel, carbon steel)
➢ Aluminum-Brass-Copper-Titanium-Nickel Alloys-Tungsten
Conductive Alloys:
➢ Conductive carbides
➢ Conductive composites
Exotic Materials:
➢ Graphite
➢ Ceramic materials
➢ Composite materials (tungsten carbide)

EDWC Application:
• Precision Tool and Die Making
• Aerospace and Automotive Components
• Medical Device Manufacturing
• Electronics and Microtechnology
• Extrusion and Cutting Tools

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Advantages of Wire EDM
• Cost-Effective: in an EDM-wire cutting machine is just a simple wire,
the tool's cost is relatively modest. With wire EDM, there is no need
for expensive equipment or molds because workpieces are cut
directly.
• Very Little Distortion: Hard and delicate materials can be cut with
wire EDM without causing damage to the cutting tools or deforming
the material's surface or edges.
• Complexity in Part: Producing tiny, delicate, and detailed
components are best accomplished with wire EDM. This ability makes
it a very well-liked production choice for sectors like healthcare and
aerospace that need incredibly complicated and precise parts.
• It is Cutting Without Impact: Wire EDM cutting, in contrast to other
processing techniques, may cut tough, thin, and delicate materials
without impacts that could cause stress or bending.
• Extreme Tolerance: Wire EDM can achieve exceptionally tight
tolerances for accurate dimensions and fit because it doesn't apply
any force to the parts. This trait does away with the need for items
post-machining and polishing.
• Wire-cut machines can be used for cutting sharp corners with
negligible radius.
• EDM-wire cut method leaves no burrs or tool marks.
• The wire EDM machine works equally well to cut brittle materials like
graphite, strong materials like carbide and Inconel, and soft metals like
brass and copper.
• Workpiece material hardness does not affect cutting speed.
• Wire EDM results in improved surface finishes; thus, no further
finishing or polishing is needed.
• Tools and metal components are machined after heat treatment -
dimensional correctness is maintained.
• No special tooling is necessary.
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Disadvantages of Wire EDM
• Slow Material Removal Rate.
• A Charged Environment's Effects: The workpiece, deionized water,
and the entire EDM environment are charged. The wire's repetitive
electrical discharges can heat the workpiece's target area thousands of
degrees. This heat could put nearby areas under temperature stress
and generate some trash. In addition, damage to the wire causes the
EDM machine to feed in the new wire constantly.
• Another drawback of wire EDM cutting is that an oxide layer may
develop on the cut surface, depending on the metal being cut. This
coating can call for additional cleaning, which raises the price.
• Wire breaking is a problem in EDM wire cutting, resulting in time loss
and a small amount of wire material.
• Since the wire (electrode) used in EDM wire cutting must be thrown
away after usage, the cost is increased.

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EDG THEORY
The theory:
(EDG) removes conductive materials by rapid spark discharges between
a rotating tool and workpiece that are separated by a flowing dielectric
fluid. The spark gap is normally held at 0.013 to 0.075 mm by the
servomechanism that controls the motion of the workpiece. The dc
power source has capabilities ranging from 30 to 100 A, 2 to 500 kHz,
and 30 to 400 V. The conductive wheel, usually made of graphite,
rotates at 30 to 180 m/min in a dielectric bath of filtered hydrocarbon
oil.

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EDG COMPONENTS

Grinding Wheel:
The grinding wheel, typically made of conductive materials like copper
or graphite, serves as the tool in EDG.
Workpiece: The workpiece, made of electrically conductive material, is
the component being machined in the EDG process.
Dielectric Fluid: A dielectric fluid is used to facilitate the electrical
discharge and cool the machining area.
Power Supply: The power supply provides the necessary electrical
energy for generating discharges between the grinding wheel and the
workpiece.
CNC Controller: The computer numerical control (CNC) system controls
the movement of the grinding wheel and workpiece to achieve precise
machining according to the desired specifications.

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Advantages of Electrical Discharge Grinding (EDG):
Machining Hard and Brittle Materials:
EDG is particularly effective for machining hard and brittle materials that
are challenging to grind using conventional methods. It can be used to
process materials such as ceramics, carbides, hardened steels, and
superalloys.

Precise and Complex Shapes:

EDG allows for the machining of intricate and complex shapes with high
precision. It can produce precise profiles, sharp corners, and fine details,
making it suitable for applications that require tight tolerances.

Minimal Heat Affected Zone:

Similar to EDM, EDG is a non-thermal process, which means it generates
very little heat during machining. This results in a small heat-affected zone
(HAZ) in the workpiece.

Burr-Free Machining:
EDG produces clean and burr-free surfaces, eliminating the need for
secondary deburring operations. This saves time and reduces the overall
manufacturing costs.

Improved Surface Finish:

EDG can achieve excellent surface finishes, particularly in comparison to
traditional grinding processes. By combining the benefits of EDM and
grinding, EDG can provide smoother and more consistent surface finishes.

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Disadvantages of Electrical Discharge Grinding (EDG):

Slower Material Removal Rate: EDG typically has a slower material removal
rate compared to conventional grinding methods. The electrical discharge
erosion process is slower than the abrasive cutting action of grinding
wheels, which can limit its efficiency for high-volume production.

Increased Process Complexity: EDG is a more complex process compared to

conventional grinding, as it involves both electrical discharge erosion and
grinding stages. This complexity can lead to longer setup times and
increased process control requirements.

Electrode Wear and Maintenance: As with EDM, EDG requires the use of
electrodes that can be worn during the process. Regular electrode
maintenance, replacement, and precise control of electrode wear are
necessary to maintain machining accuracy and consistency.

Equipment Costs: The equipment required for EDG, including specialized

machines capable of combining EDM and grinding functions, can be
expensive. The initial investment and maintenance costs should be
considered when evaluating the feasibility of EDG for specific applications.

Limited Accessibility: EDG, similar to conventional grinding, may have

limitations in machining deep or narrow features that are challenging to
access with the grinding wheel or electrode. The aspect ratio and
accessibility of the features should be carefully considered in the design and
manufacturing process.

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