1.

0TI
TLE

Pr
oduct
ionTechnol
ogyofNon-
Tradi
ti
onal
Machi
ning

2.
0OBJECTI
VES

Todesi
gnabasi
cNCpr
ogr
am f
orEl
ect
ri
calDi
schar
geMachi
ning(
EDM)wi
re
cut
.

Tomachi
neapr
oductusi
ngt
heEl
ect
ri
calDi
schar
geMachi
ning(
EDM)wi
re
cut
.

3.
0INTRODUCTI
ON

El
ect
ri
caldi
schar
gemachi
ning(
EDM)i
samachi
ningmet
hodpr
imar
il
yusedf
or
har
d met
als ort
hose t
hatwoul
d be i
mpossi
blet
o machi
ne wi
tht
radi
ti
onal
t
echni
ques.TheEl
ect
ri
calDi
schar
geMachi
ning(
EDM)pr
ocesswasi
nvent
edbyt
wo
Russi
ansci
ent
ist
s,Dr
.B.
R.Lazar
enkoandDr
.N.
I.Lazar
enkoi
n1943.Thef
ir
st
numer
ical
l
y cont
rol
l
ed El
ect
ri
calDi
schar
ge Machi
ning (
EDM)was i
nvent
ed by
Maki
noi
nJapan.El
ect
ri
calDi
schar
geMachi
ning(
EDM)cancutsmal
lorodd-
shaped
angl
es,i
ntr
icat
econt
our
sorcav
iti
esi
npr
e-har
denedst
eelwi
thoutt
heneedf
orheat
t
reat
mentt
osof
tenorr
e-har
dent
hem aswel
lasexot
icmet
alssuchast
it
ani
um,
hast
ell
oy,kov
arandI
nconel
.Ther
ear
etwomai
nty
pesofEDM machi
nes,Si
nker
EDM (
alsocal
l
edConv
ent
ional
EDM andRam EDM)andWi
recutEDM.

Wi
reEl
ect
ri
calDi
schar
geMachi
ning(
WEDM)
,al
soknownaswi
recutEDM i
sa
pr
ocessofusi
ngat
hinsi
ngl
est
randedofmet
alwi
ref
edt
hroughawor
kpi
ece.The
wi
rei
sconst
ant
lyf
edf
rom aspooli
shel
dbet
weent
heupperandt
hel
owergui
des.
Thegui
desmov
eint
hex-
ypl
aneandcont
rolt
hemov
ementoft
hewi
ret
hrought
he
wor
kpi
ece dur
ing t
he cut
ti
ng pr
ocess.Mostmachi
nes i
n use t
oday ar
e CNC
cont
rol
l
ed.Wi
reEDM machi
nesar
ever
ypr
eci
seandcanbepr
ogr
ammedt
ocutv
ery
pr
eci
seandcanbepr
ogr
ammedt
ocutv
eryi
ntr
icat
eanddel
i
cat
eshapes.Thewi
re
cutpr
ocessusewat
erasi
tsdi
elect
ri
cwi
tht
hewat
er
sresi
sti
vi
tyandot
herel
ect
ri
cal
pr
oper
ti
escar
eful
l
ycont
rol
l
edbyf
il
ter
sanddei
oni
zeruni
ts.Thewat
eral
soser
ves

2
t
hev
erycr
it
icalpur
poseoff
lushi
ngt
hecutdebr
isawayf
rom t
hecut
ti
ngzone.
Fl
ushi
ngi
sani
mpor
tantdet
ermi
ningf
act
ori
nthemaxi
mum f
eedr
ateofmat
eri
al
av
ail
abl
einagi
vent
hickness,
andpoorf
lushi
ngsi
tuat
ionsnecessi
tat
ether
educt
ion
oft
hef
eedr
ate.

3
4.
0APPARATUS

1)El
ect
ri
cal
Dischar
geMachi
ning(
EDM)wi
recutwat
erj
et

2)Wi
recent
er(wi
redi
amet
er:
0.25mm)

4
5
4.
1INDUSTRI
ALAPPARATUS

Mi
tsubi
shi
EDM

SODI
CKEDM

6
Ki
ngr
edEDM

7
5.
0EXPERI
MENTALPROCEDURES

Pr
epar
eadesi
gn

i
) Dr
awadesi
gni
nagr
aphpaper
.

i
i
)Det
ermi
net
hest
art
ingpoi
nti
nthedesi
gnanddot
hecoor
dinat
e(x,
y)f
ort
he
desi
gn.Chooseei
theruseG90orG91f
ormat
.

I
nser
tthepr
ogr
am

i
) Fi
rst
,opent
hef
il
e.Thensel
ectt
henewf
il
ebet
weent
her
ange00019999.

i
i
)Got
oedi
tmodesect
ion.I
nser
tthenumberoft
hef
il
eandpr
essbut
toni
nput
.

i
i
i)Af
tert
hat
,sel
ectbut
toncr
eat
e.

i
v)Then,
inser
tthenameoft
hepr
ogr
am wi
thbr
acketandputt
hesy
mbol(
;)orof
t
hebl
ockaf
terf
ini
shi
nser
tthef
ir
stl
i
neoft
hebl
ockt
osepar
atest
hebl
ock.

v
)Thepr
ogr
am canent
erusi
ngt
heG codeandM codeaccor
dingt
othei
r
condi
ti
onandt
ask.

v
i)I
ffi
nishi
nser
tst
hepr
ogr
am pl
acet
hecur
soratt
hef
ir
stl
i
neoft
hebl
ockorwe
cancl
i
ckr
esetbut
tonorpageup.

8
5.
0RESULTANDDATAANALYSI
S

Fi
nal
desi
gn:

H1=0.
156;

E937F20.
0H1;

M 80;

M82;

M84;

G90;

G40;

G01X0.
0Y0.
0;

G01X10.
0Y0.
0;

G02X18.
0Y0.
0R4.
0;

G01X32.
0Y0.
0;

G02X40.
0Y0.
0R4.
0;

G01X50.
0Y0.
0;

G01X50.
0Y10.
0;

G01X40.
0Y10.
0;

G01X34.
0Y20.
0;

G01X16.
0Y20.
0;

GO1X10.
0Y10.
0;

G01X0.
0Y10.
0;

G01X0.
0Y0.
0;

M02;

M00;

9
 Fi
nal
Desi
gn

NCPr
ogr
am I
nput

10
Desi
gnOut
come:

11
7.
0DI
SCUSSI
ONOFRESULTS

I
nEl
ect
ri
cal
Dischar
geMachi
ning(
EDM)
,Numer
ical
Cont
rol
(NC)
Pr
ogr
ammi
ngi
susedt
ogi
vecommandt
otheEDM wi
recutmachi
ne.Ther
ear
etwo
t
ypesofNumer
ical
Cont
rol
Progr
ams;
whi
char
ewat
erj
etandsubmer
ge.I
nthi
s
par
ti
cul
arex
per
iment
,thet
ypeofNumer
ical
Cont
rol
Progr
ammi
ngusedi
sthewat
er
j
et.

Thepr
ocessi
sst
art
edbydesi
gni
ngt
hepr
oduct
.Thegr
oupmember
s
di
scussedaboutt
hedesi
redpr
oductandcameoutwi
thadesi
gn.Asi
mpl
esket
chi
s
obt
ainedasshowni
nFi
gur
e1.Basedont
hedesi
gn,
anNCpr
ogr
am codi
ngi
s
cr
eat
ed.Ther
ear
etwomai
ncodesi
nNumer
ical
Cont
rol
Progr
ammi
ngwhi
char
ethe
M codesandt
heGcodes.TheM codesr
epr
esentoper
ati
onmachi
neormachi
ne
mov
ement
,whi
l
etheGcodesr
epr
esentoper
ati
oncut
ti
ng.

TheNumer
ical
Cont
rol
Progr
am i
sst
art
edbychoosi
ngt
het
ypeofpr
ogr
am.
Ther
ear
etwot
ypesofpr
ogr
am;
G90whi
chi
stheabsol
utepr
ogr
am,
orG91whi
chi
s
t
hei
ncr
ement
alpr
ogr
am.I
nthi
sexper
iment
,G90i
sused.Thegr
oupmember
spr
efer
usi
ngt
hiscodebecausei
tiseasi
ert
obecr
eat
edcompar
edt
otheG91pr
ogr
am.
Af
tercompl
eti
ngt
heNumer
ical
Progr
am codi
ng,
thedat
aist
ransf
err
edt
otheEDM
machi
nebyusi
ngt
hecont
rol
l
er.Themachi
newi
l
lthenst
artt
oreadt
hedat
aandt
he
desi
gnwi
l
lbedi
spl
ayed.Then,
simul
ati
onpr
ogr
am wi
l
lini
ti
ateandt
hemachi
newi
l
l
pr
oducet
hedesi
redout
come.

Ther
ear
esev
eral
possi
bleer
ror
sthatcoul
dhav
eoccur
redt
hroughoutt
he
exper
iment
.Themostcommononei
sdur
ingt
het
ransf
erofdat
aont
hecont
rol
l
er.
Wr
ongi
nputwi
l
lresul
tinwr
ongpr
oductout
come.Howev
er,
thi
ser
rorcan
compl
etel
ybeav
oidedast
hemachi
newi
l
ldi
spl
ayt
hedesi
gnbef
oresi
mul
ati
on
pr
ogr
am st
art
s,t
her
efor
eanyer
rorcanbeedi
ted.

Anot
herer
rori
sthatdur
ingt
heNumer
ical
Cont
rol
progr
am desi
gn,
wrong
codei
schosen.Forexampl
e,G01i
sforl
i
nearcut
ti
ngandG02i
sforci
rcul
ar
cl
ockwi
secut
ti
ng.

Thenexter
rori
sfai
l
uret
oinputt
hemai
ncommandssuchasM80,
whi
ch

12
i
ndi
cat
eswat
erj
etpr
essur
esy
stem onandM84,
whi
chi
ndi
cat
est
hatt
hemachi
nei
s
r
eadyandsensori
sact
ive.

13
8.
0CONCLUSI
ON

I
nconcl
usi
on,
thr
oughoutt
heEl
ect
ri
calDi
schar
geMachi
ne(
EDM)exper
iment
,
wat
erj
ett
ypeofNumer
icalCont
rolPr
ogr
am wasused.Fr
om gr
oupdi
scussi
on,G90
whi
chi
sabsol
utepr
ogr
am waschosent
obet
hegr
oupt
ypeofpr
ogr
am becausei
tis
easi
ert
oconst
ructcompar
edt
otheG91pr
ogr
am.So,t
hedesi
gnofpr
oductwas
cr
eat
edaccor
dingt
oG90pr
ogr
am.Thedesi
gn
scodi
ngwasent
eredi
ntot
heEDM
machi
nebyusi
ngcont
rol
l
ermachi
ne.

I
nthi
spr
ogr
essofent
eri
ngt
hei
nputcodi
ng,t
heer
rorwi
l
lbedi
spl
ayedi
fthe
i
nputwr
ongl
yent
ered.Whent
hecodeswassuccessf
ull
yent
eredi
ntot
hemachi
ne,
t
hesi
mul
ati
onofpr
oductwi
l
lbedi
spl
ayedont
hescr
eenofmachi
ne.

I
nthi
s exper
iment
,the er
ror
sthatoccur
red ot
hert
han i
nputer
rorwas
sy
stemat
icer
rorwhi
chi
sthei
nst
rumentormachi
newasf
ailt
ooper
atet
hei
nputt
o
pr
oducet
hepr
oduct
.Becauseoft
hiser
ror
,ourgr
oupwasaskt
ofi
nishunt
ilt
he
si
mul
ati
onofpr
oductdi
spl
ayedofscr
een.So,
ourf
inalpr
oductwasact
ual
l
yav
irt
ual
pr
oductdesi
gn.

14
9.
0RECOMMENDATI
ON

Oneoft
hemosti
mpor
tantr
ecommendat
ionst
obuyEDM-
Wir
ecuti
sthatduet
o
t
heabi
l
ityt
ocutanymat
eri
alr
egar
dlessofi
tshar
dnessbutonl
yconduct
ormat
eri
als.
Besi
dest
hat
,theabsenceofal
l
-mechani
cal
for
cesmakesi
tpossi
blet
omachi
ne
f
ragi
l
epar
tswi
thoutdi
stor
ti
on.I
tissor
ecommendedduet
oit
shi
ghaccur
acyt
hus
pr
oduci
ngahi
ghqual
i
typr
oduct
.Lessl
abori
srequi
redt
ooper
ateandhandl
ethe
machi
nebutmustbewel
ltr
ained.Thi
swi
l
lreduceov
eral
lpr
oduct
ioncostand
i
ncr
easepr
ofi
toft
hecompany
.

Wi
reEDM (
elect
ri
caldi
schar
gemachi
ning)hasadv
ancedandbeent
ransf
ormed
i
ntoanev
ery
day
,commonl
yrel
i
eduponpr
ocess.Thecapabi
l
iti
esandper
for
mance
i
ntoday
swi
reEDM machi
nescont
inuet
odev
elopandi
mpr
ovei
nthet
hreemai
n
machi
ning char
act
eri
sti
cs:speed,accur
acy and sur
face f
ini
sh.I
n or
der t
o
accompl
i
sht
hiscapabi
l
ityandl
evelofpr
oduct
ivi
tyonaconsi
stent
,repeat
abl
eand
r
eli
abl
ebasi
s,t
hesemoder
ntechnol
ogymar
vel
smustbemai
ntai
nedonar
egul
ar
schedul
e,accor
dingt
othei
rmanuf
act
urer
sr
ecommendat
ions.Forexampl
e,ahi
ghl
y
-
tunedaut
omobi
l
eraci
ngengi
newi
l
lnotpr
oduceati
tsr
atedhor
sepower
,tor
queor
per
for
mancel
evel
swi
thoutr
egul
arcar
eandschedul
edmai
ntenance.Awi
reEDM
machi
newi
l
lbehav
emuchi
nthesamemanner
,andwi
l
lnotper
for
mtot
hespeeds,
f
ini
shesandaccur
aci
est
heyar
erenownedf
ori
fnotpr
oper
lymai
ntai
ned.Duet
othe
el
ect
ro-
mechani
calnat
ureofwi
reEDM machi
nes,t
her
ear
esev
erali
temsi
nnor
mal
oper
ati
ont
hatr
out
inel
ywearandr
equi
recl
eani
ngand/
orr
epl
acement
.Ifcer
tai
n
machi
necomponent
sar
enotpr
oper
lycar
edf
or,machi
ningspeedsandaccur
aci
es
wi
l
lrapi
dlydecay
.Themosti
mpor
tantr
easont
opr
oper
lyschedul
eandper
for
mthi
s
r
out
inewi
reEDM mai
ntenancei
stoensur
econsi
stentandr
epeat
abl
emachi
ning
r
esul
tsf
ort
heaf
orement
ionedmachi
net
rai
tsofspeed,
accur
acyandsur
facef
ini
sh.
Thi
slev
elofmai
ntenanceal
sopr
event
smachi
nef
ail
ureandunexpect
edmachi
ne
downt
ime.

15
10.
0 REFERENCES

1.ht
tp:
//www.
mol
dmaki
ngt
echnol
ogy
.com/
art
icl
es/
mai
ntai
ning-
a-wi
re-
edm-
machi
ne

2.www.
thomasnet
.com/
art
icl
es/
cust
om.
..
/Wi
re-
Cut
-EDM

3.Todd,
Rober
tH.
;Al
l
en,
Del
lK.
;Al
ti
ng,
Leo(
1994)
.Manuf
act
uri
ngPr
ocesses
Ref
erenceGui
de.I
ndust
ri
alPr
essI
nc.

4.Kr
ar,
StephenF.andGi
l
l,Ar
thurR.(
2003)Expl
ori
ngAdv
ancedManuf
act
uri
ng
Technol
ogi
es,
Indust
ri
alPr
essI
nc.

16