Indo-German Tool Room, Aurangabad: Chapter Outline

INDO-GERMAN TOOL ROOM, AURANGABAD
CHAPTER : A4 – CNC EDM – DIE SINKING TG2
CHAPTER OUTLINE
A4.1 – Introduction
A4.2 – Definition, Description of main parts
& features
A4.3 – Calculation of cutting parameters
(structure of machined surfaces)
A4.4 – Operations on CNC EDM
A4.5 – Safety & Maintenance of machine
A4.1 Introduction
TOPIC OUTLINE
a) Classification of EDM
machine
Introduction of CNC EDM
Electrical Discharge machining: Machining of hard material or harden material is not

simple. It is totally difficult & maximum time consuming method, EDM has been solved this
problem. Since it can cut harden electrically conductive material. To cut complicated
shapes & geometrically difficult contours.
A4.1a Classification of EDM Machine
It depends on ampere used.

1) 16 ampere generator
METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

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SUMMARY
At the end of this topic student shall be able to –
 Explain the CNC EDM Process
 Know the classification of the EDM machines
In the next topic students are going to learn about the description of the main parts and
features of CNC EDM Machine.
QUESTION BANK
Questions:
1) Describe CNC EDM process.
2) Explain how CNC EDM Machines are classified.

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A4.2 Definition, Description of main parts & features
TOPIC OUTLINE
a) Definition
b) Description of main parts
c) Tool holding devices
d) Machine parameters
e) Work Holding devices
f) Tools (Electrodes)
A4.2a Definition of the Process
The process is characterized by the fact that removal of material is obtained by a

succession of material is obtained by a succession of non-stationary electrical discharges,
separated from each other in time, i.e. only one spark at a time is created. The discharges
are produced by the voltage source (off-load voltage) EDM process is also known as spark
erosion machining.
A4.2b Description of main parts

The machine
The machine consists of a frame to which the column is attached; these two parts, in
ribbed cast iron, are highly rigid.
The frame supports a crossed table consisting of an intermediate saddle and top saddle
coupled to the work table on which the part to be machined is mounted.
The work tank, which is coupled to the table, contains the dielectric during maching. The
work tank is equipped with the part flushing system.
The column supports the Z slide.

The electrical equipment box is attached to the back of the column.
The remote control unit is used to engage the motors of the three axes manually in the
positive or negative direction (together with the C axis option).
The machine rests on the dielectric reservoir.

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Filtering
The dielectric from the work tank is drained into the reservoir through the drain panel.
When the pump is started, the reservoir dielectric is driven into a filter battery attached to
the back of the reservoir.
A part of the clean dielectric is used to feed the flushing circuits, the rest being directed
towards the cooler, before being returned to the reservoir.
Electrical equipment box
The electrical equipment box contains the machine electronic interfaces.

The box also contains connection points for the various electrical circuits and machining
cables.

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Remote Control
In the manual mode, the remote control unit is used to start the motors of the 4 axes in the
positive or negative directions. The rate of movement can be varied between a minimum
and a maximum of 0 to 15 m/sec.
Work tank
The work tank is used to immerse the part to be machined. The front wall, which is hinged,
is used as a door. Access to the table is thus facilitated for installation and clamping of the
part and for adjustment operations prior to machining.
The work tank is filled and emptied manually.
The dielectric level is set manually by the operator. The temperature of the dielectric in the
work tank is kept constant by means of two thermostats located under the cover, on the left
hand side of the work tank.
Control Cabinet
The control cabinet contains the various control devices. It is fitted with two access doors.
The front door supports the operator-machine diclogue system.

 Control panel
 Key board
The front door provides access to the various PCB’s of the numerical control, to the
generator power units and, at the bottom of the cabinet, to the contractors and thermal
protective devices of the electrical part.
The rear door provides access to the power supply PCB’s, to the various monitoring
boards, to the control and machining cable connectors and to the transformers attached to
the bottom of the cabinet.

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Control Panel
The control panel, which is built into the cabinet front door, contains the operator machine
dialogue system, together with controls for the operation of the machine, i.e.
 Screen
During machining, the operator can display all the information concerning the work
performed by the machine: quality, progress, messages from the machine, etc.
 Diskette drive
The diskette drive is used to enter the programs required for operation of the installation,
part programs or data specific to a machining operation. It is also possible to retrieve data
from the machine memory.
 The <<Dielectric>> function command keys
Starting of the pump is indicated by an indicator light, when:
o The dielectric setting level is reached: the light is on
o The dielectric setting level is not reached: the light flashes
o The pump is off: the indicator is off
 Push buttons
o Power on
o Emergency stop (a 2nd emergency stop button is located on the machine head)
A4.2c Tool Holding Devices
Electrode Mounting System
The electrode mounting system is of primary importance for both the attainable degree of
accuracy and the economy of the spark erosion process. The system should combine
universal applicability with maximum stability and high tool change accuracy. A good
electrode clamping system, also referred to as tool system should comprise a leveling
attachment for precision adjustment of electrodes, a number of highly accurate quick
clamping chucks and different electrode holders which enable the electrode to be
machined on a machine tool and subsequently fitted to the spark erosion machine without
re-clamping. Some tool systems also include equipment for rotary eroding.

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The market offers several tool system which have in part been specially developed for
EDM operations. The relatively high price, which is due to the high standard of quality,
should not keep the users of spark erosion equipment from purchasing such a system. In
practice, such an investment will pay its way very soon by saving in setup time and higher
degrees of accuracy.
Types of accessories with changer

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A4.2d Machine parameters
The machining process is influenced by a number of parameters which will have to be

familiar to the uses of spark erosion equipment if optimum results are to be achieved.
A) Stock Removal Rate:

By definition, stock removal rate is the volume of material removed from a work piece
within a unit time. It is expressed in mm3/min when the same spark frequency is used, the
stock removal rate will be increased by raising the energy level per spark. But on the other
hand, the use of a higher spark energy will result in larger craters and thus greater surface
roughness. Generally speaking, max., stock removal rates can only be achieved at the
expense of surface finish values being below the generally acceptable standard. This
means that roughing operations have to be followed by one or several finishing operations
at reduced spark energy. But it should be appreciated that, in the interest of better surface
finish, the stock removal rate then be substantially lower.
It will, of course, always attempted to use the highest possible stock removal rate also in
finishing operations because this is a decisive factor for the total machining time.
A major advantage of the EDM process lies in the fact that the stock removal rate is
practically independent of the hardness of the material. This makes it possible to machine
hardened work piece thus avoid the danger of heat distortions fissures which are
frequently encountered as a result of heat treatment after the finished cavity has already
been produced. Although the hardness of a material is irrelevant for the stock removal rate
in spark eroding different materials such as steel and sintered carbides nevertheless show
certain differences in behaviour. It should also be noted that the stock removal rate will
decrease with increasing working depth. This is mainly due to reduced flushing action and
thus less efficient removal of the eroded particles, which have a detrimental effect on the
conditions in the spark gap. Flushing conditions can be improved by using a vibrator or by
pulse flushing.
B) Relative Electrode Wear

The second important technological parameter of spark erosion is relative electrode wear.
As pointed out above, surface erosion not only occurs on the work piece but also on the
electrode, although, of course, on a lesser scale. Relative electrode wear is understood to

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mean the ratio between the stock removal from the work piece. It is expressed in percent.
A value of 5%, for example, indicates that an amount of 5mm3 is removed from the
electrode while at the same time, 100mm3 is removed from the work piece. In the course
of eroding operation, the active portions of the electrode will more or less be deformed as
a result of electrode wear. Unfortunately, this electrode wear is not strictly linear, otherwise
it could be compensated fro by an appropriate amount of ‘Predistortion’.
As a matter of fact, sharp edges and corners will be subject to accelerated wear due to the
greater current density at these points. As a result, the volume of wear is greater than the
length of wear.
Recent developments in the field of spark erosion generators have mainly concentrated on
an increase in stock removal rate combined with a reduction of electrode wear. The
successes of these efforts is evidenced by the fact that modern pulse generators, if used in
conjection with copper electrodes, have reduced relative electrode wear to less than 1% in
roughing operations.
It should be emphasized in this connection that the use of graphite for spark erosion
electrodes is particularly advantageous because this material is easy to machine and
provides wear ratings which even may be far below 1%.
C) Accuracy for Reproduction:

Another important factor for the general applications of spark eroding machines is the
accuracy of reproduction of the electrode shape, especially since the general advance of
engineering calls for closer tolerance limits. For this reason, it should be carefully
considered what geometrical and dimensional deviations are permissible, and what
corrections can be incorporated in the electrode, because the final dimensions of a spark
eroded die or mould will never exactly correspond to the dimensions of the electrode
reasons such as electrode wear and the necessary spark gap width, but may also be
attributed to mechanical factors e.g. the stability of the machine and the guidance of the
electrode. The spark gap width, which range from 0.01 to 0.05 mm (0.0005” to 0.02”),
always makes the die cavity in the work piece slightly larger than the electrode. The width
of the gap is dependent or the electrode and work piece materials, the dielectric liquid, the
required surface finish and thus, eventually, on the generator setting. In the case of deep
holes with a small section, it should be borne in mind that, due to unsatisfactory flushing,

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there will be slight taper in a downward direction. Conditions can be improved by using
sufficiently long and ‘stepped’ electrodes or by employing button electrodes. Engraved
patterns can only be produced with a high degree of accuracy by finishing the work piece
with the aid of one or more finishing electrodes after the roughing operation.
It should be noted that electrode wear is greater along the edges than on flat surfaces.
Obviously, the smallest obtainable today is roughly ±0.01mm (0.0005”). This value can
not be appreciably improved except with considerable efforts.
D) Surface Quality:
The surface roughness on a spark eroded work piece is determined by the size of the
overlapping craters.
Since a high stock removal rate requires the use of high energy sparks, such roughing
operations will produce very rough surfaces. A smoother surface can be obtained by a
subsequent finishing operation with a second electrode using substantially lower spark
eroding operations is less than 1 mm CLA fro sintered carbides and about 1mm CLA for
steel. This will probably be sufficient for the vast majority of machining operations. If this
is not the case, spark eroding may afford other advantages, for example in applications
where conventional cutting methods can not be used or where complicated profiles and
contours can be produced much more economically by spark erosion, provided that final
retouching by hand is reduced to a minimum.
E) Effects on Microstructure:
The points of impact of the electrical sparks are exposed to its very high temperatures
which have marked effects on the microstructure of the material. In addition, a certain
amount of carbon from the dielectric as well as traces of the electrode material enter the
work piece surface by way of diffusion. Extensive tests have shown that the surface layer
affected by such processes may have thickness of several hundredths of a millimeter
(approximately a thousand of an inch). Since the effects on microstructure are largely
dependent on the duration and energy of the sparks, it will be no problems to remove such
adversely affected surface layers results especially from roughing work by a suitable
finishing operation.

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A) Material removal rate

B) Electrode wear
C) Surface finish
D) Spark GAP
E) Flushing is the most vital element in the technology of EDM and flushing is used to
remove the unwanted particles from the sparking process. Different types of
flushing are used depending on the application.
All above parameters are inter-related and gave best possible results with appropriate
combination.
1) Pressure flushing – continuous flushing impose flushing combined flushing.
2) Suction flushing – Continuous flushing combined flushing
3) Side set flushing – Where flushing through job or electrode is impossible
4) Motion flushing – Motion flushing gives higher efficiency of flushing with moving
electrode.
 Rotating electrode with rotary device guarantees best roundness, better
surface finish shorter erosion time. Vibratory movement of electrode. Auto
flushing in combination with pressure flushing or impulse flushing.
Flushing improves the efficiency of sparking since it is useful:
A) To insulate the gap
B) To flush wastages
C) Cooling of work pieces and electrode
D) To provide bridge between electrode and work piece.
There are variables like on time, off time current etc. which contributes to achieve best
possible results. With these variables the effects are shown in following table:
Mrp Elec. Wear Surface Finish Gap
Current
 Increase ¯ ¯
 Decrease ¯ ¯
On time
 Increase ¯ ¯
 Decrease ¯ ¯
Off time
 Increase ¯ ¯
 Decrease ¯ ¯

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All above are the variables available in the machine. Since the jobs can be of various
materials like steel, carbide, aluminium, copper etc, various electrode materials are being
used VIZ:
A) Copper electrode grade

B) Graphite
C) Steel
D) Copper Tungsten
E) Copper Graphite
Depending upon the requirement of the job, these electrodes are selected. For electrodes
following properties are considered while selection
Electrical conductivity
 Thermal stability
 Melting point
 Grain structure and size
 Machinability
 Density
 Availability
Normally following combinations are used:
Job Material
Electrode Material
1) Steel Copper
Graphite
Copper Tungsten
Steel
2) Non-Ferrous Metals Copper
3) Carbide / Tungsten Copper Tungsten
Carbide
Copper
With the general convention copper or graphite are used as electrodes being available with
reasonable cost.

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Graphite gives better material removal rate than copper since its thermal stability is more
than copper. Hence more discharges are achieved from the same pulse.
Copper gives better surface finish than graphite since its rain structure is much more finer
as compared with graphite.
Machine features and parameters.
Every machine is divided into three major parts

A) Machine Tool
B) Generator or pulse control unit
C) Dielectric unit
A) Machine Tool:
It consists of parts like
 Work table and work tank
 Slides
 Servo
 Safety interlocks
Work table of work tank – work table is used to keep the job on it. Work tank is used for
filling up the dielectric during sparking operation. It is mounted on slides.
Slides-slides are used of various types like slides with V flat rollers, slides with needle roller
bearings etc. Depending upon the requirements of accuracy the slides are used. Needle
roller dearings give better accuracy and life of slides since wear and tear is less.
These slides are driven by either lead screws or ball screws. Normally the slides are
moved by hand wheel (for table movement). However in few cases motorized movements
are used (Big EDMs, CNC EDM etc.)

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SERVO
SERVO the world itself means precious. It is essential element since every sparking
operations is dependent on the SERVO movement various types of SERVO are use in the
machine like –
A) Electromechanical
 DC Servo
 DC Stepper SERVO
 AC SERVO
B) Hydraulic
In earlier generation machines Hydraulic SERVO was used, due to Non-availability of
electrical motors which can lift higher weight electrodes.
Now a days with the advent of latest technology, various electrical motors are available
and hence are preferred over hydraulic SERVO.
Now a days electromechanical SERVO is used since it has all the advantages of hydraulic
SERVO with less maintenance required. Hydraulic SERVO needs periodical preventive
maintenance against compared to electro mechanical SERVO.
Safety interlocks: Various interlocks are used in the machine like –

A) Low level – it prevents machine from fire. In case level goes down and sparking
appears on the surface the fire accident takes place.
B) Over Temperature- Due to continuous sparking operation the dielectric temperature
increases. Due to increase in the temperature dielectric fires. This inter lock trips
the machine before the flash point of dielectric.
C) Preset depth – this switch ensures the correct sparking depth. This prevents slide
from over travel.
D) Upper limit - This switch prevents the slides from over travel.
Apart from above interlocks other interlocks like over level, antiarc switch etc. Arc used to
ensure the safety of the machine and the operator.

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B) Generator or pulse control unit
It is a control unit, which controls all the functions of the machine. It consists of important
sections like –
Input output section

Which controls the input commands and execution of output commands mainly it is
an electrical section where under voltage / over voltage checking, output
connections, contractors etc.
Current Section
The current is selected through this section. The current is applied with various
devices mosfet, transistors, variac etc in recent times mosfets are used popularly
since it can be operated with very high frequency range which gives better surface
finish.
Oscillator
Oscillator controls all the EDM technology hand in hand with current section.
Oscillator provides settings for on time & off time. Oscillator can be of various types
like EPROM, electronically controlled RC, LC or sometimes combination. In this
EPROM oscillator is best choice since the data fed in does not change whereas in
other cases it changes with duration hence calibration is needed.
Control Section
This section controls the movement of SERVO voltage of sparking antiarcing sensing etc.

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A4.2e Work Holding devices
1) Swivel base vice

May be bolted to the table or sub-plate. The swivel base enables the vice to be
swiveled 3600 in a horizontal plane.
2) Angle plates
Arc L-shaped pieces of cast iron or steel accurately machined to a 900 angle. They
are made in a variety of sizes & have holes or slots which provide a means for
fastening the w/piece.
3) V-blocks
Arc generally used in pairs to support round work piece. A U-shaped clamp may be
used to fasten the work in a V-block.
4) Step Blocks
Arc used to provide support for strap clamps when work is being fastened to the
table or work holding device.
5) Clamps or straps
Arc used to fasten work to the table, angle plate or fixture. They are made in a
variety of sizes and are usually supported at the end by a step block and bolted to
the table by a T-bolt.
6) Support Jacks
Arc used to support the work piece to prevent distortion of work piece during
Clamping.
7) Parallels
Arc flat, square or rectangular pieces of metal used to support the work piece for
set up.
8) Sub-plates
Arc generally flat plates that may be fitted to the machine table to provide quick and
accurate location of work pieces.

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A4.2f Tools (Electrode)
Material Classification
Electrode material generally used can be classified as follows:
1) Metallic materials
a) Electrolytic Copper
b) Tellurium Or Chromium Copper
c) Copper Tungsten
d) Brass
e) Tungsten Carbide
f) Aluminium
2) Non-Metallic: Graphite
3) Combination of metallic & non-metallic materials: Copper Graphite
The Electrode
The purpose of any material used as an electrode in the EDM process is to convey the
electrical machining pulses to allow erosion of work piece to take place with little or no
erosion of electrode. In principle, any electrically conductive material may successfully be
used to fabricate electrode. However, experience shows that depending upon the material
to be machined and the type of generator used, certain materials are more suitable than
others. The performance of electrode materials in any given condition is judged by its
material removal rate, low wear and ability to accurately machine.
The basic requirements for a good electrode material are:

 Good electric conductivity and low resistivity
 Resistance to abrasion
 High melting and boiling points
 Dimensional stability
 High density and high modulus of elasticity
 Good heat diffusion and conductivity

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The selection of proper electrode material is influenced by:
 Size of electrode and volume of material to be removed

 Surface finish required
 Tolerances desired
 Nature of coolant applications
The use of a suitable electrode is one of the main conditions for successful spark eroding.
The selection of electrode material is also governed by the following factors:
a) Availability
b) Reasonable price
c) Ease of machining
d) Minimum wear combined with good stock removal rate
Graphite
Graphite is an easily machinable material and has a very low wear characteristic especially
when used for roughing operations. A variety of different graphite grades have been
specially developed for electrical discharge machining. The cheapest and coarsets grain
material are suitable for roughing work, while the more expensive fine grain material can
be used for finishing. Fine grain graphite provides a much higher heat conductivity and
thus prevents local over heating of the electrode, which might lead to establishment of a
continuous arc.
Copper
Apart from graphite, copper is probably the most frequently used electrode material, either
in the form of electrolytic copper or cast copper. The material is universally used in both
roughing and finishing operations, it is characterized by low wear and high stock removal
and, in addition, is easy to machine on conventional machine tools.

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Copper Tungsten
This material is relativity expensive and thus only on a limited scale. It has excellent wear
characteristics and particularly suitable for finishing operations. Copper Tungsten is
specially used for machining cemented carbides.
Aluminium
Aluminium used to be a very popular electrode material but is now employed very rarely.
Its melting point is so low that the high electrode wear ratio makes most aluminium alloys
uneconomical. Only very large electrodes with a correspondingly low current density
provide for sufficient heat dissipation to reduce electrode wear to an acceptable level.
Brass
This is a very popular and low priced electrode material, which was widely used in
conjection with earlier relaxation generations. Today it has only a limited range of
applications, e.g. in machining titanium components, this requires negative polarity.

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SUMMARY
 Identify the various parts of CNC EDM Machine
 Know the tool mounting systems
 Know machine parameters
 Identify various tool holding devices and work holding devices
 Describe the cutting tool (Electrode)
In the next topic students are going to learn about calculation of cutting parameters
(structure of machine surfaces).
QUESTION BANK
Questions:
1) Explain the machine basic construction.

2) Describe the function of filtering unit.
3) Write the elements present on the control panel on the machine.
4) Explain relative electrode wear.
5) What is the importance of servo in machine?
6) Explain any two types of work holding devices used on CNC EDM Machine.
7)

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8) A4.3 Calculations of Cutting Parameters (structure of machined surfaces)
TOPIC OUTLINE
a) Structure & characteristics
of CNC EDM machined
surfaces
b) Surface finish
A 4.3a Structure & characteristics of CNC EDM Machined surfaces
In EDM machining, removal of material is caused mainly by a thermal phenomenon. It is

known that the temperature in a discharge is of the order of 80000 to 120000 C.
The effect of these high temperature discharges obviously affects the structure of the
material used. This influence varies according to different materials (some do not show
any modification of structure).
A metallographic inspection of the cross section of an eroded surface shows two layers of
a different nature, shown in figure below:
 A heterogeneous white layer, consisting of a mixture of carbon rich solid solutions, this
latter coming on the one hand from steel and on the other hand from break down of the
dielectric fluid (hydrocarbon) due to the effect of heat.
 An intermediate layer located between the white layer and the metal that has not been
subjected to the thermal effect. This layer appears only in heavy rough machining
settings; it has not become molten. However, the metal has been raised to a relatively
high temperature over a very short period of time, then suddenly cooled.

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Depending on the temperature reached locally, this heat treatment produces a modification
of the initial structure for steels susceptible to hardening, which can result:
 Either in hardening (hardening effect due to passage of the steel transformation points)
 Or in softening (super-tempered effect in the case of a hardened and tempered steel, if
the heating is greater than the initial tempering temperature).
Generally, in practice hardening in the intermediate zone is observed, the eventual

softened zone being located in the immediate vicinity of the metal not affected by erosion.
The diagrams below show the relationships which may be established between maximum
temperatures which may be reached during erosion, micrographic structures and
hardness.
Curve of maximum temperatures reached erosion (along a line perpendicular to the

surface).
Hardness curve resulting from temperature curve:

1) Melted area
® white film
2) austenitized area ® hardened layer
3) super-tempered area® only for hardened and tempered
steels

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The thickness of the disturbed layers decreases simultaneously with the machining power
level.
4.3b Surface Finish:
Testing of surface finishes is carried out using apparatus known as roughness meters.
Experience shows that measurement of surface finishes by visotactile comparison with a

standard does not give an error of more than 2 class CH.
The roughness criteria are Ra (Europe) = CLA (UK) = AA (USA).
To obtain a roughness scale, Charmilles Technologies have defined a CH scale (similar to

VDI 3400), which is, however comparable with the standards used.

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Definition of roughness criteria

CH No.20 log (10 Ra) (mm)
Significant rules and figures

1mm Ra = CH20 10mm Ra = CH40
if: Ra = Rax2 CH = CH + 6
1mm Ra = CH20
2mMRA = CH26
The ratio
Between 2 successive CH units is 1.12
The difference
Between 2 successive CH units is 12.2%
Rt.

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Is approximately equal to 8 x Ra. Mean Rt = 5 x value of Ra.

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SUMMARY
 Explain the structure and the characteristics of EDM Machine surfaces
 Classify various surface finishes produce on CNC EDM Machine
In the next topic students are going to learn about various operations and features of the
machine.
QUESTION BANK
Questions:
1) Explain the structure and the characteristics of EDM Machine surfaces.
2) Classify various surface finishes produce on CNC EDM Machine.

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A4.4 Operations on CNC EDM
Features of machine
a. On this machine complicated shapes and geometrically difficult contours

can be made.
b. Threading operation also done on this machine
c. Cutting independently in x, y, z axis
d. Helical cutting
e. Path control
f. Planetary motion
g. Magazine facility

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SUMMARY
 Know the various operations performed on CNC EDM machine.
In the next topic students are going to learn about the safety and maintenance of the
machine.
QUESTION BANK
Questions:
1) Explain the planetary motion on CNC EDM machine.
2) List any two operations, which can be performed on the CNC EDM Machine.

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A4.5 Safety & Maintenance of Machine
TOPIC OUTLINE
a) Safety & Maintenance
b) General recommendations
A4.5a Safety & Maintenance of Machine
Introduction
In order to guarantee healthy and agreeable working conditions for persons working on
EDM machines and for those present in the same premises, it is indispensable that some
elementary hygiene and safety rules related to this machining process be respected.
Operators, foremen and company directors are called upon to respect the rules mentioned
below:
Charmilles Technologies disclaims all responsibility if these rules are not respected.
Training
Only persons trained on this type of machine and its equipment are authorized to use it.
Training sessions concerning hygiene and safety problems are to be held annually.
Premises
Freshening up of the ambient air of the premises must be guaranteed; this is done to
avoid formation of a noxious and dangerous atmosphere, without omitting the volume of air
evacuated by the smoke extractor, which must be replaced.
The premises in which an EDM machine using a dielectric operates, in which the flash
point is lower than 1000C, is considered a fire hazard.

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Therefore, the electrical installation on this premises must comply with the requirements of
the standards in force.
For Germany, standard VDE 0 100 T720.
Smoke
Essentially, emanations from the dielectric consist of gases and smoke produced by the
thermal decomposition of the oil due to the spark erosion process.
These emanations are of different kinds and comprise of:
 Polycyclic aromatic hydrocarbons (PAH) in the solid or gas state,

 Aromatic hydrocarbon and paraffin vapors,
 Metal particles
 Various products which may result from the breakdown of additives
The following instructions must be respected:
 The smoke sensor must be connected to a sufficiently powerful suction system capable
of providing a suction rate, measured at the edge of the work tank, of more than 1
m/sec.
 The smoke suction-conduit must be non-inflammable
 If the smoke suction, conduit has a metal armature the latter must be connected to
ground
Comments
Some machines are equipped with a monitoring device in the smoke sensor, if suction is
insufficient; it is impossible to start machining.
Fire

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Preventive measures
 To avoid any over heating of the dielectric, the cooling system must be permanently in
operation.
 Two safety thermostats control the dielectric temperature in the work tank; these will
stop machining if the temperature becomes too high. (T>450)
 Within a radius of 5 meters around the machine, the presence of flames and named
light bulbs is prohibited.
Similarly, smoking is prohibited (no smoking signs)
 A extinguisher must be located in the immediate proximity of the machine
 In the case of non-supervised machining operations, a fire extinguishing installation is
to be set up
 When machining, the part must be covered with a minimum of 40mm of dielectric fluid,
avoiding immersion of the electrode-holder
 Gases generated by the machining process must not be allowed to form in the hollow
parts of the machined part or the electrode (risk of explosion).
Protections
All covers and protective paneling must be kept in place when working with the equipment.
Protective material must not be neutralized.
After an intervention, all protective devices must be installed before machining.
In the event of an accident, and if the safety instructions have not been respected,
Charmilles Technologies may disclaim all responsibility.
There is no need to wear personal protection equipment when operating this machine.
Dielectric

A4-33
The dielectric used on EDM machines must be identifiable by its designation.
A plate affixed to the front of the work tank is used to inscribe the following information:
 Type of dielectric
 Dielectric flash point
 Dermatological risks
 Safety instructions
Comment
The use of dielectrics of flash point less than 600 C is prohibited.
Hygiene instructions
 To prevent prolonged contact of the skin with the dielectric, gloves must be worn. \
 Wash your hands after any contact with the dielectric
 Protect the eyes against dielectric splashes
 Do not ingest dielectric
A4.5b General Recommendations

A4-34
 If the dielectric overflows, this must not be allowed to soak into the ground or to be
drained off through sewers.
 Contact the competent local authorities to acquaint yourself with the regulatory
instructions concerning storage and elimination of waste.
 It should be noted that, in most cases, storage and elimination of waste imply sorting
according to the nature of the pollutants (plastics, metal, etc.).
 Consult the standards in force concerning heavy, non-recyclable materials.

A4-35
SUMMARY
 Know the various safety precautions followed on CNC EDM Machine
 Know the general recommendations while working on the machine
In the next chapter students are going to learn about CNC High Speed Milling.
QUESTION BANK
Questions:
1) List any two hygienic instructions to be followed while working on CNC EDM.
2) What preventive measures to be taken to avoid fire of the machine?

A4-36

Indo-German Tool Room, Aurangabad: Chapter Outline

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INDO-GERMAN TOOL ROOM, AURANGABAD

CHAPTER : A4 – CNC EDM – DIE SINKING TG2

Introduction of CNC EDM

Electrical Discharge machining: Machining of hard material or harden material is not

A4.1a Classification of EDM Machine

It depends on ampere used.

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A4.2 Definition, Description of main parts & features

A4.2a Definition of the Process

The process is characterized by the fact that removal of material is obtained by a

A4.2b Description of main parts

The column supports the Z slide.

The machine rests on the dielectric reservoir.

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

Electrical equipment box

The electrical equipment box contains the machine electronic interfaces.

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

The work tank is filled and emptied manually.

The front door supports the operator-machine diclogue system.

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A4.2c Tool Holding Devices

Electrode Mounting System

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

Types of accessories with changer

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A4.2d Machine parameters

The machining process is influenced by a number of parameters which will have to be

A) Stock Removal Rate:

B) Relative Electrode Wear

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

C) Accuracy for Reproduction:

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A) Material removal rate

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A) Copper electrode grade

Normally following combinations are used:

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

Machine features and parameters.

Every machine is divided into three major parts

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

Safety interlocks: Various interlocks are used in the machine like –

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

B) Generator or pulse control unit

Input output section

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A4.2e Work Holding devices

1) Swivel base vice

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

A4.2f Tools (Electrode)

Electrode material generally used can be classified as follows:

The basic requirements for a good electrode material are:

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

The selection of proper electrode material is influenced by:

 Size of electrode and volume of material to be removed

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

1) Explain the machine basic construction.

METAL WORKING TECHNIQUE WITH CNC MACHINE TOOLS

8) A4.3 Calculations of Cutting Parameters (structure of machined surfaces)