Wire-Electro-Discharge Machining

(WEDM)
Objectives
i.
ii.

To identify the process parameters of the WEDM process.

To study the features and operation of a WEDM Machine.

Features of the WEDM machine in the NTM

laboratory
Electric discharge machining (EDM), sometimes colloquially also referred
to as spark machining, spark eroding, burning, die sinking, wire burning or
wire erosion, is a manufacturing process whereby a desired shape is
obtained using electrical discharges (sparks). Material is removed from the
work piece by a series of rapidly recurring current discharges between two
electrodes, separated by a dielectric liquid and subject to an electric
voltage. One of the electrodes is called the tool-electrode, or simply the
"tool" or "electrode", while the other is called the work piece-electrode, or
"work piece".
Wire EDM is a type of electric discharge machine which uses a wire as the
tool.

There are four basic elements of this machine tool:

(i)

(ii)

(iii)

Power Supply System :

Wire EDM power supply system differs from conventional EDM.
Power supply system basically in pulse frequency which is about 1
MHz . It results in reduced crater size or better surface finish.
Dielectric System :
Water is a likely substitute for kerosene as dielectric in EDM. It is an
attractive proposition because of its availability, desirable thermal
properties, low viscosity and pollution-free working. It gives higher
MRR and better surface finish under the identical machining
conditions.
Positioning System
Usually positioning system is a computerized numerical control
(CNC) two-axis table. However, it operates in an adaptive control
mode so that in case wire approaches very near to the work piece,

(iv)

or the gap is bridged by debris and causes a short circuit, the

positioning system should be capable to sense it. Instantaneously, it
should move back to re-establish proper cut-ting conditions in the
gap.
Wire Drive System
This system serves two purposes, viz continuously delivers fresh
wire, and always keeps the wire under appropriate tension so that it
moves in the machining zone as a straight wire. The latter
requirement is important from the point of view of quality of the
machined surface. For example, it helps to minimize taper, streaks
as well as vibration marks. It also minimizes the "wire breaks"
during machining.

FIG: Schematic Diagram of a wire EDM

Wire Electric Discharge Machine

Machine Name: ELECTRONICA, ELEKTRA ELPLUS 40
SUPE.RCUT 734, SERIES 2000.

SPECIFICATIONS:
Max Cutting Speed: 160 mm2/min
Table size: 440X650 mm
Complex profile cutting
Auto job setting parameters

Experimental Observations
Tool: .18 mm diameter molybdenum

Conclusion
Importance of Wire EDM:

Complex Geometry can be machined.

Wide range of materials can be machined.

Wire EDM allows precision machining of most electrically-conductive
materials such as aluminium, steel, copper, brass, as well as hightechnology aerospace materials such as Titanium and Inconel.

Stress-Free and Burr-Free Cutting

Extremely thin section can be machined because the wire electrode
never contacts the material being cut. Wire EDM is a non-contact,
force-free, metal-removing process which eliminated cutting stress
and resultant mechanical distortion.

Close Tolerances and Excellent Finishes.

They are used to machine parts that require high accuracy and
surface finish. They can produce narrow slots, keyways etc.

Reliable Repeatability
The constant reliability of wire EDM is one of the greater advantages
of this process. Because the programs are computer generated and
the electrode is constantly being fed from a spool (the wire
electrode is used only once), all parts are identical.

Error due to cutter wear is eliminated.

Since the wire is not reused, errors due to cutter wear does not
exist.