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Uncinventional Machining Process Unit 4
Uncinventional Machining Process Unit 4
Fig.2 Line Diagram Indicating Working Principle and Process Details of EDM
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workpiece. It takes only a few micro seconds to complete the cycle and remove the material. The circuit
cam be adjusted for auto off after pre-decided time interval.
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Fig.5 shows the relationship between removal rate andsurface roughness in EDG. The corner
radius depends on the overcut and ranges from 0.013 to 0.130 mm. Greater voltages permit larger gaps,
which makes the process suitable for plunge grinding where ease of dielectric flushing is ensured.
Tolerances of 0.005 mm are normal with 0.001 mm possible. The surface finish improves with an
increase in pulse frequency and is typically 0.4 to 0.8 micro m Ra. These layers must be removed or
modified in case of highly stressed applications. Fig.6 shows the main elements of EDG.
Abrasive electrodischarge grinding (AEDG) employs the interactive effect of EDE and MA in
order to enhance the machining productivity. In the AEDG process the metallic or graphite electrode
used in electrodischarge grinding is replaced by a metallic bond grinding wheel. Therefore, electro
erosion in addition to the MA action occurs as shown in Figs. 7 and 8. An increase in performance
measures of the machining process becomes evident when machining super hard materials (plates with
synthetic polycrystalline diamond), engineering ceramics, sintered carbides, and metallic composites.
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rotation of the wheel electrode and, partly, by its radial oscillations. Further improvement in EDG
performance characteristics can be achieved with the use of vibrating electrodes.
4.2.1 Applications
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The workpiece is fed continuously and slowly past the wire in order to achieve the desired
cutting path. Numerical control is used to control the work-part motions during cutting. As it cuts, the
wire is continuously advanced between a supply spool and a take-up spool to present a fresh electrode of
constant diameter to the work. This helps to maintain a constant kerf width during cutting. As in EDM,
wire EDM must be carried out in the presence of a dielectric. This is applied by nozzles directed at the
tool-work interface as in the figure, or the workpart is submerged in a dielectric bath.
Wire diameters range from 0.08 to 0.30 mm, depending on required kerf width. Materials used
for the wire include brass, copper, tungsten, and molybdenum. Dielectric fluids include deionized water
or oil. As in EDM, an overcut in the range from 0.02 to 0.05 mm exists in wire EDM that makes the kerf
larger than the wire diameter. This process is well suited to production of dies for sheet metalworking,
cams, etc. Since the kerf is so narrow, it is often possible to fabricate punch and die in a single cut, as
illustrated in the figure:
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Metal removaltakes place as a result of the generation of extremely high temperatures generated by the
high-intensity discharges that melt and evaporate the two electrodes.
Fig.13 Typical EDM pulse current train for controlled pulse generator
A series of voltage pulses (Fig.13) of magnitude about 20 to 120 V and frequency on the order of
5 kHz is applied between the two electrodes, which are separated by a small gap, typically 0.01 to 0.5
mm. When using RC generators, the voltage pulses, shown in Fig.14, are responsible for material
removal.
High electrical conductivity electrons are cold emitted more easily and there is less bulk
electrical heating
High thermal conductivity for the same heat load, the local temperature rise would be less due
to faster heat conducted to the bulk of the tool and thus less tool wear
Higher density for the same heat load and same tool wear by weight there would be less
volume removal or tool wear and thus less dimensional loss or inaccuracy
High melting point high melting point leads to less tool wear due to less tool material melting
for the same heat load
Easy manufacturability
Cost cheap
The followings are the different electrode materials which are used commonly in the industry:
Graphite
Electrolytic oxygen free copper
Tellurium copper 99% Cu + 0.5% tellurium
Brass
4.7 Dielectric Fluid
In EDM, as has been discussed earlier, material removal mainly occurs due to thermal
evaporation and melting. As thermal processing is required to be carried out in absence of oxygen so
that the process can be controlled and oxidation avoided. Oxidation often leads to poor surface
conductivity (electrical) of the workpiece hindering further machining. Hence, dielectric fluid should
provide an oxygen free machining environment. Further it should have enough strong dielectric
resistance so that it does not breakdown electrically too easily but at the same time ionise when electrons
collide with its molecule. Moreover, during sparking it should be thermally resistant as well.
Generally kerosene and deionised water is used as dielectric fluid in EDM. Tap water cannot be
used as it ionises too early and thus breakdown due to presence of salts as impurities occur. Dielectric
medium is generally flushed around the spark zone. It is also applied through the tool to achieve
efficient removal of molten material.
4.8 Accuracy and Surface Integrity
The spark-machined surface consists of a multitude of overlapping crates that are formed by the
action of microsecond-duration spark discharges. These craters depend on the physical and the
mechanical properties of the material and the composition of the machining medium as well as on the
discharge energy and duration. The integral effect of many thousands of discharges per second leads to
the formation of the corresponding workpiece profile with a specified accuracy and surface finish. The
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depth of the resulting craters usually represents the peak to valley (maximum) surface roughness Rt. The
maximum depth of the damaged layer can be taken as 2.5 times the average surface roughness Ra.
According to Delpreti (1977) and Motoki and Lee (1968) the maximum peak to valley height, Rt, was
considered to be 10 times Ra. The average roughness can be expressed in terms of pulse current ip and
pulse duration tp (s) by
Jeswani added also that as the pulse energy is decreased, the surface finish improves and consequently,
the depth at which all formed craters disappear from the machined surface (free polishing depth) is
reduced. This depth was found to lie between 3 to 6 times Hrms and is important when polishing dies
and molds and when the residual stresses are to be removed from the machined surfaces. Masuzawa and
Saki (1978) adopted a quick electrochemical finishing technique, using a mate electrode.
Accordingly, a reduction of surface roughness from 22 m Rmax to 8 m has been reported
together with the removal of the heat-affected layer. In contrast, the matte appearance of the machined
surfaces has been found satisfactory in some applications of electro discharge texturing (EDT).
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4.10
Material - Metals with a high melting point and good electrical conductivity are usually chosen
as tool materials for EDM. Graphite is the most common electrode material since it has fair wear
characteristics and is easily machinable and small flush holes can be drilled into graphite electrodes.
Copper has good EDM wear and better conductivity. It is generally used for better finishes in the range
of 0.5m Ra. Copper tungsten and silver tungsten are used for making deep slots under poor flushing
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conditions especially in tungsten carbides. It offers high machining rates as well as low electrode wear.
Copper graphite is good for cross-sectional electrodes. It has better electrical conductivity than graphite
while the corner wear is higher. Brass ensures stable sparking conditions and is normally used for
specialized applications such as drilling of small holes where the high electrode wear is acceptable.
Movements - In addition to the servo-controlled feed, the tool electrode may have an additional
rotary or orbiting motion. Electrode rotation helps to solve the flushing difficulty encountered when
machining small holes with EDM. In addition to the increase in cutting speed, the quality of the hole
produced is superior to that obtained using a stationary electrode. Electrode orbiting produces cavities
having the shape of the electrode. The size of the electrode and the radius of the orbit (2.54-mm
maximum) determine the size of the cavities. Electrode orbiting improves flushing by creating a
pumping effect of the dielectric liquid through the gap.
Polarity - Electrode polarity depends on both the workpiece and electrode materials. Table 1
shows the possible electrode polarity for different workpiece and tool combinations.
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Tool Details
The tool used in WCEDM process is a small diameter wire as the electrode to cut narrow kerf in
the workpiece. During the process of cutting the wire is continuously advanced between a supply spoil
and wire collector. This continuous feeding of wire makes the machined geometry insensitive to
distortion of tool due to its erosion. Material of wire can be brass, copper, tungsten or any other suitable
material to make EDM tool. Normally, wire diameter ranges from 0.076 to 0.30 mm depending upon the
width of kerf.
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Machine portion
Fig.16 Line Diagram for Process Details of Working of Wire Cut Electric Discharge Machining
Advantages of WCEDM
Advantages are listed below:
(a) Accuracy and precision of dimensions are of very good quality.
(b) No force is experienced by the workpiece.
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(c) Hardness and toughness of workpiece do not create problems in machining operation.
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