CanEDMmachinethisshape..?

Example of the complex shapes that can be cut by wire

EDM and a taper cutting mechanism

Manufacturing Technology II (ME 312)

WIRE ELECTRIC DISCHARGE MACHINING

WIREELECTRICDISCHARGEMACHINING
(WIREEDM)

Dr. M. Ravi Sankar

MECHANICAL ENGINEERING DEPARTMENT
I.I.T Guwahati
e-mail : evmrs@IItg.ernet.in 2
 WIRE EDM/TW EDM

POWER SUPPLY - PULSATING DC.

COMPARED WITH BAND SAW MRR & QUALITY = (WIRE).
SPARKING BETWEEN WIRE & WORKPIECE
ERODES BOTH WIRE & WORKPIECE.

ULTIMA MODEL WIRE EDM OF ELECTRONICA, PUNE

 STRATIFIEDWIRE

CHARMILLES CORPORATION (SWTZERLAND)

CORE MADE OF COPPER DRAWN WIRE.

OUTSIDE LAYER OF Zn ALLOY (LOW

MELTING POINT)

MORE EXPENSIVE . DIA 0.025

0 025 TO 0.200
0 200 mm

WIRE NOT - RECYCLED WEAR S OUT

ALSO COMPARATIVETY CHEAP.

CHEAP

WHY TO USE STRATIFIED WIRE ?

FOR HIGH MRR HIGH ENERGY / SPARK WIRE BREAKAGE

TO AVOID WIRE BREAKAGE USE STRATIFIED WIRE

MELTING POINT OF Zn << M. P. OF COPPER / BRASS.

Zn LAYER WILL MELT FIRST

CORE TEMPERATURE < M. P. OF Zn

STRATIFIED WIRE CAN CARRY MORE CURRENT HIGHER

ENERGY / SPARK HIGHER MRR

A1AMP A2AMP A3AMP A4AMP

 BOWING OF WIRE

DISTANCE B ETWEEN WIRE AND WORKPIECE 25 m IN KERF.

GAS BUBBLES RUSH TO ESCAPE PRESSURE ON THE WIRE

WIRE BENDS LEADS TO INACCURACY (DIFFERENT IEG)

TO MINIMIZE BOWING OF WIRE INCREASE TENSION.

TO INCREASE MACHINING RATE MULTIPLE MACHINING

HEADS.

COMPONENTSMADEBYWIRE EDM

Statorcore stampingdiemachinedbywire EDM

 WIRE EDM+TAPERCUTTINGMECHANISM

Exampleofthecomplexshapesthatcanbecutbywire EDMandataper
cuttingmechanism

Manufacturing Technology II (ME 312)

(06-11-2013)

ELECTRIC DISCHARGE DIAMOND GRINDING

(EDDG )

Dr. M. Ravi Sankar

MECHANICAL ENGINEERING DEPARTMENT
I.I.T Guwahati
e-mail : evmrs@IItg.ernet.in 10
 INDUSTRIALPROBLEMS

#DIAMONDGRINDING:LIMITATIONS
HIGHCOST
HIGH COST
HIGHSPECIFICMATERIALREMOVALENERGY
STRENGHDEGRADATION
STRENGH DEGRADATION
WHEELWEAR/DRESSINGPROBLEMS

# EDM

LOWMATERIALREMOVALEFFICIENCY
RESOLIDIFIEDWHITELAYERINFESTEDWITHMICROCRACKS

Need of EDDG

GRINDING OF HARD MATERIAL:

HIGHNORMALFORCE
RAPIDFORMATIONOFWEARFLAT
RAPID FORMATION OF WEAR FLAT
WHEELCLOGGING
INFFICENTMECHANICALDRESSING
INFFICENT MECHANICAL DRESSING
 ELETRICALDISCHARGEDIAMONDGRINDING

# ELECTRICALDISCHARGEDIAMONDGRINDING
GRINDING + EDM

METAL BONDED WHEEL

CONDUCTING WORK MATERIAL

IN PROCESS,CONTINUOUSDRESSINGANDDECLOGGING

REDUCTIONINGRINDINGFORCE

ELECTRICAL DISCHARGE DIAMOND GRINDING

(EDDG)

NCEDDGsetup
 EDDGEXPERIMENTALSET UP

ELETRICALDISCHARGEDIAMONDGRINDING

Koshy,P.,Jain,V.K.,Lal,G.K.,(1993),ExperimentalInvestigationsintoEDMwithrotatingdiscelectrode,Precision
Engineering,Vol.15,No.1,pp.615
 3ZONEOFINTERELECTRODEGAP

17

# INCENTIVES
THERMALSOFTENINGOFWORK:
REDUCTIONINFORCES
BETTERACCURACY
BETTERSURFACEINTEGRITY
BETTER SURFACE INTEGRITY
IN PROCESSDRESSING:

MOREEFFICIENTTHANMECHANICALDRESSING
NOLOSSOFMACHINIGTIME
SELECTIVEDECLOGGING
NOSLIDINGCONTACTBETWEENBONDANDWORK
# COMPARISIONWITHECG
NOSLUDGEDISPOSALPROBLEM
MATERIALREMOVALMOSTLYDUETOABRASION
 # WORKPIECEMATERIALS
HSS
CEMENTEDCARBIDE

# PARAMETERS
WHEELSPEED
CURRENT
PULSE ON TIME

# RESPONSES
MRR
NORMALFORCE
NORMAL FORCE
TANGENTIALFORCE

METALBONDEDALUMINAWHEEL ECONOMIC

DELCLOGGINGOFGRINDINGWHEELDISCUSSION
MATERIAL REMOVAL BY BRITTLE FRACTURE AND DUCTILE DEFORMATION
WHEEL LOADING WHILE GRINDING CEMENTED CARBIDE
EFFECT OF DECLOGGING
DISLODGING OF ABASIVES AT HIGHER CURRENT
Reverse the polarity for dressing

ABRASIVE
DIAMOND GRINDING WHEEL

IEG

WORK PIECE