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ACKNOWLEDGEMENTI ABHISHEK SHARMA have taken efforts in

this project. However, it would not have been

possible without the kind support and help of

many individuals and organizations. I would like to

extend my sincere thanks to all of them.

I am highly indebted to LOVELYPROFESSIONAL UNIVERSITY for their guidance

and constant supervision as well as for providing

necessary information regarding the project &

also for their support in completing the project.

I would like to express my gratitude towards my

parents & member of MANUFACTURINGDEPARTMENT for their kind co-operation and

encouragement which help me in completion of

this project.

I would like to express my special gratitude and

thanks to industry persons for giving me such

attention and time.

My thanks and appreciations also go to my

colleague in developing the project and people

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who have willingly helped me out with their

abilities.

CONTENTS

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INTRODUCTION

A wire electric discharge machining method of machiningthe workpiece with different thickness into a required

shape with first cut and second cut. The method

includes the steps of

(a) detecting a position of the wire electrode relative

to the workpiece,

(b) detecting change in thickness of the workpiece

during first cut,

(c) storing the position of wire electrode as athickness change position (Q1) when change in thickness

of the workpiece from a first thickness (t1) to a

second thickness (t2) is detected,

(d) forming a zone () around the thickness change

position,

(e) comparing the position of wire electrode to the

zone during second cut, and

(f) changing at least one machining condition during

times when it is determined that the wire electrode is

positioned in the zone.

There are two primary EDM methods:

1.ram EDM and

2.wire EDM.

The primary difference between the two involves the

electrode that is used to perform the machining. In a

typical ram EDM application, a graphite electrode is

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machined with traditional tools. The now specially-

shaped electrode is connected to the power source,

attached to a ram, and slowly fed into the workpiece.

The entire machining operation is usually performed

while submerged in a fluid bath. The fluid serves thefollowing three purposes:

y flushes material awayy serves as a coolant to minimize the heat affected

zone, thereby preventing potential damageto theworkp acts as a conductor for the current to

pass between the electrode and the workpiece.

y acts as a conductor for the current to passbetween the electrode and the workpiece.

EDM is sometimes called "spark machining" because it

removes metal by producing a rapid series of repetitive

electrical discharges. These electrical discharges are

passed between an electrode and the piece of metal

being machined. The small amount of material that is

removed from the workpiece is flushed away with acontinuously flowing fluid. The repetitive discharges

create a set of successively deeper craters in the

work piece until the final shape is produced.

Electrical discharge machining is frequently used to

make dies and molds. It has recently become a standard

method of producing prototypes and some production

parts, particularly in low volume applications. For moredetails regarding a typical application, you can read

about a custom bronze branding-iron that was made

with EDM.

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The History of EDM Machining

ThehistoryofEDM Machiningtechniquesgoes asfarback asthe 1770s whenit was

discovered by an English Scientist. However, Electrical Discharge Machining wasnotfullytaken advantageofuntil 1943 when Russianscientistslearned how theerosiveeffectsofthe

technique could be controlled and used formachining purposes.

Whenit wasoriginallyobserved by Joseph Priestlyin 1770, EDM Machining wasvery

imprecise and riddled withfailures. Commercially developed inthe mid 1970s, wire EDM

beganto be a viabletechniquethathelped shapethe metalworkingindustry weseetoday.

Inthe mid 1980s,the EDM techniques weretransferred to a machinetool. This migrationmade EDM more widely available and appealingovertraditional machining processes.

Today,Wire EDM makesit possibleto work withhardermaterials and metals while keeping

theexactnessofprecision cutting.

The Sinker EDM Machining Process

IntheSinkerEDM Machining process,two metal partssubmerged in aninsulatingliquid are

connected to a sourceofcurrent whichisswitched on and offautomatically dependingonthe

parameterssetonthe controller. Whenthe currentisswitched on, anelectric tensioniscreated betweenthetwo metal parts. Ifthetwo parts are broughttogetherto within a fractionofaninch,theelectricaltensionis discharged and a spark jumps across. Whereitstrikes,the

metalisheated up so muchthatit melts.

Sinker EDM Machining Process

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ThesinkerEDM machining (Electrical Discharge Machining) processuses anelectricallycharged electrodethatis configured to a specific geometryto burnthegeometryofthe

electrodeinto a metal component. ThesinkerEDM processis commonlyused intheproductionofdies and molds.

How Sinker EDM worksTwo metal partssubmerged in aninsulatingliquid are connected to a sourceofcurrent whichisswitched on and offautomatically dependingonthe parameterssetonthe controller. When

the currentisswitched on, anelectric tensionis created betweenthetwo metal parts.

Ifthetwo parts are broughttogetherto within a fractionofaninch,theelectricaltensionis

discharged and a spark jumps across. Whereitstrikes,the metalisheated up so muchthatit

melts.

Innumerablesuchsparksspray,one aftertheother(neversimultaneously) and gradually

shapethe desired form inthe pieceofmetal, accordingtotheshapeoftheelectrode. Severalhundred thousand sparks mustfly persecond beforeerosiontakes place.

Die-sinking EDM Machining

Inthe caseofdie-sinking EDM,therequired shapeisformed negativelyinthe metal with athree-dimensionalelectrode. Bysuperimposed movementsinthe main axesx,y, c, z,the

mostvaried shapes,indentations and cavities are created,such as cannotin part be achieved

by anyothermachiningsystem.

Forexample, a helicoid cavityora rectangularholeinonesinglesteel blockorthe machining

ofanextremelythin,hardened steelsheetthat maynot besubjected to any mechanical

pressure.

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EDM Machining Process & Techniques

(Electrical Discharge Machining)

A machining method typicallyused forhard metals, Electrical Discharge Machining(commonly known as "EDM Machining") makesit possibleto work with metalsforwhich

traditional machiningtechniques areineffective. Animportant pointtorememberwith EDM

Machiningisthatit willonly work with materialsthat areelectrically conductive.

Withgood EDM Machiningequipmentitis possibleto cutsmallodd-shaped angles, detailed

contoursorcavitiesinhardened steel as well asexotic metalsliketitanium,hastelloy, kovar,

inconel, and carbide.

The EDM Processis commonlyused intheTool and Dieindustryformold-making,however

inrecentyears EDM has become a integral partformaking prototype and production parts.

Thisisseeninthe aerospace and electronicsindustries where productionquantitiesremain

low.

The Wire EDM / Spark EDM Process

Wire EDM Machining (also known as Spark EDM)is anelectrothermal production process

in which a thinsingle-strand metal wire (usually brass)in conjunction with de-ionized water

(used to conductelectricity) allowsthe wireto cutthrough metal bytheuseofheatfrom

electricalsparks. Duetotheinherent propertiesofthe process, wire EDM caneasily machine

complex parts and precision componentsoutofhard conductive materials.

Wire EDM Machining Process

Wire EDM machining (Electrical Discharge Machining)is anelectrothermal production

processin which a thinsingle-strand metal wirein conjunction with de-ionized water(used to

conductelectricity) allowsthe wireto cutthrough metal bytheuseofheatfrom electricalsparks.

Duetotheinherent propertiesofthe process, wire EDM caneasily machine complex parts

and precision componentsoutofhard conductive materials.

How Wire EDM Works

Wire EDM machining (also known as "spark EDM") works by creating anelectricaldischarge betweenthe wireorelectrode, & the workpiece. Asthespark jumps acrossthegap,

materialisremoved from boththe workpiece & theelectrode.

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Tostop thesparking processfrom shortingout, a non conductivefluid ordielectric is also

applied. The waste materialisremoved bythe dielectric, and the process continues.

Wire EDM Machining According to Wikipedia.org:

"...In [wire EDM machining], a thinsingle-strand metal wire,usually brass,isfed throughthe

workpiece. The wire, whichis constantlyfed from a spool,isheld betweenupperand lower

guides. Theguides moveinthe X-Y plane, and sometimestheupperguide can also move

independentlygivingrisetotransitioningshapes (circleonthe bottom square atthetop). This

givesthe Wire EDM the abilityto be programmed to cutveryintricate and delicateshapes.The wire-cutuses waterasits dielectric withthe water'sresistivity and otherelectrical

properties carefully controlled byfilters and de-ionizerunits." [View Wikipedia EntryThe Sinker EDM Machining Process

IntheSinkerEDM Machining process,two metal partssubmerged in aninsulatingliquid are

connected to a sourceofcurrent whichisswitched on and offautomatically dependingonthe

parameterssetonthe controller. Whenthe currentisswitched on, anelectric tensionis

created betweenthetwo metal parts. Ifthetwo parts are broughttogetherto within a fraction

ofaninch,theelectricaltensionis discharged and a spark jumps across. Whereitstrikes,the

metalisheated up so muchthatit melts.

Sinker EDM Machining Process

ThesinkerEDM machining (Electrical Discharge Machining) processuses anelectrically

charged electrodethatis configured to a specific geometryto burnthegeometryoftheelectrodeinto a metal component. ThesinkerEDM processis commonlyused inthe

productionofdies and molds.

How Sinker EDM works

Two metal partssubmerged in aninsulatingliquid are connected to a sourceofcurrent whichisswitched on and offautomatically dependingonthe parameterssetonthe controller. When

the currentisswitched on, anelectric tensionis created betweenthetwo metal parts.

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Ifthetwo parts are broughttogetherto within a fractionofaninch,theelectricaltensionisdischarged and a spark jumps across. Whereitstrikes,the metalisheated up so muchthatit

melts.

Innumerablesuchsparksspray,one aftertheother(neversimultaneously) and gradually

shapethe desired form inthe pieceofmetal, accordingtotheshapeoftheelectrode. Several

hundred thousand sparks mustfly persecond beforeerosiontakes place.

Die-sinking EDM Machining

Inthe caseofdie-sinking EDM,therequired shapeisformed negativelyinthe metal with a

three-dimensionalelectrode. Bysuperimposed movementsinthe main axesx,y, c, z,the

mostvaried shapes,indentations and cavities are created,such as cannotin part be achieved

by anyothermachiningsystem.

Forexample, a helicoid cavityora rectangularholeinonesinglesteel blockorthe machining

ofanextremelythin,hardened steelsheetthat maynot besubjected to any mechanical

pressure.

For More Information

Formoreinformationonthe SinkerEDM process, contactthe people at:

IDS Machining (www.IDSmachining.com).

Ifyouhavequestions about EDM Machiningcontactus.

Wire EDM Machining Process

Wire EDM machining (Electrical Discharge Machining)is anelectrothermal productionprocessin which a thinsingle-strand metal wirein conjunction with de-ionized water(used to

conductelectricity) allowsthe wireto cutthrough metal bytheuseofheatfrom electrical

sparks.

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Duetotheinherent propertiesofthe process, wire EDM caneasily machine complex partsand precision componentsoutofhard conductive materials.

How Wire EDM Works

Wire EDM machining (also known as "spark EDM") works by creating anelectricaldischarge betweenthe wireorelectrode, & the workpiece. Asthespark jumps acrossthegap,

materialisremoved from boththe workpiece & theelectrode.

Tostop thesparking processfrom shortingout, a non conductivefluid ordielectric is also

applied. The waste materialisremoved bythe dielectric, and the process continues.

Wire EDM Machining According to Wikipedia.org:

"...In [wire EDM machining], a thinsingle-strand metal wire,usually brass,isfed throughthe

workpiece. The wire, whichis constantlyfed from a spool,isheld betweenupperand lower

guides. Theguides moveinthe X-Y plane, and sometimestheupperguide can also move

independentlygivingrisetotransitioningshapes (circleonthe bottom square atthetop). This

givesthe Wire EDM the abilityto be programmed to cutveryintricate and delicateshapes.

The wire-cutuses waterasits dielectric withthe water'sresistivity and otherelectrical

properties carefully controlled byfilters and de-ionizerunits." [View Wikipedia Entry]

Ifyouhavequestions about EDM Machiningcontactus.

EDM Machining Equipment

Someofthe EDM machiningequipmentused by professional companiesincludes machines

by: GBI Cincinnati, Elox, Japax, and Mitsubishi. Alltop-quality EDM machiningequipment

providethesame basic functionality, withthe differences betweeneach model beingspecific

features.

User-interface,numberand gaugesofwires, and thetanksize where machiningis actually

done are justsomeofthefeaturesthat differentiateeach model .

Forexample,the professionals atIDS MachiningusethefollowingEDM machiningequipment and inspectiontools:

y EDM Machines:o SodickAQ35L Wire EDMo SodickAM3L SinkerEDM

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The SodickAQ-35L Wire EDM is a fast precision EDM machinethat providesthe dynamic

responseoflineartechnology-highspeed machininginlesstimehas become an

economicallyefficientreality.

Itfeatureslineardrivetechnology and simplified control mechanisms, which provide a direct

link betweenthe drive and the control.

The SodickAM3L SinkerEDM Machineis anultra fastlinearmachinethat drivestotheleftand rightofthe z axisreachfeed ratesof36 m/min and are completely balanced tofacilitate

precise,frictionless,rapid travelforthe machinehead.

Theintegrated coolingsystem furtherenhancesthermalstability and precision.

Agood machiningshop should alsohavethefollowingtypesofequipmenttofurther

machining capabilities. Again,thisequipmentlististakenfrom IDS Machining:

y Machining Centers: o Mazak 510C Vertical Machining Center(NEXUS)

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y Mills:o Bridgeport Manual Knee Mill

y Precision Measuring Tools:o Mitutoyoheightgauge zeroto 12 incheso Micrometerssizes 1 inchthrough 12 incheso Pingauges 0.011 through 0.500o Bore Gauges 0.7 to 4 incheso Gauge Blocks 0.100 through 5.00o Calipers zeroto 24 inches

y Other Tools:o Clark Fork Lift (2500 lb. capacity)o Grand Rapids Surface Grindero RamCo Horizontal Saw

Ifyouhavequestions about EDM Machiningcontactus.

EDM Machining Metalwork Examples

Following aresome EDM machining metalworkexamples. Clickeachsampletoview larger: