Experiment # 02

EDM:
Electrical discharge machining (EDM), also known as spark machining, spark
eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing process
whereby a desired shape is obtained by using electrical discharges (sparks). Material is
removed from the workpiece by a series of rapidly recurring current discharges between
two electrodes,separated by a direact liquad 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 workpiece-electrode, or "workpiece." The process depends upon the
tool and workpiece not making actual contact.

MAJOR COMPONENTS:
A Wire EDM system is comprised of four major components.
(1) Computerized Numerical Control (CNC) Think of this as “The Brains.”
(2) Power Supply Provides energy to the spark. Think of this as “The Muscle.”
(3) Mechanical Section Worktable, work stand, taper unit, and wire drive mechanism.
(This is the actual machine tool.) Think of this as “The Body.”
(4) Dielectric System The water reservoir where filtration, condition of the water
(resistivity/conductivity) and temperature of the water is provided and maintained. Think
of this as “The Nourishment.”
PRINCIPLE OF WIRE ELECTRICAL DISCHARGE MACHINING
The Spark Theory on a wire EDM is basically the same as that of the vertical EDM
process. In wire EDM, the conductive materials are machined with a series of electrical
discharges (sparks) that are produced between an accurately positioned moving wire
(the electrode) and the workpiece. High frequency pulses of alternating or direct current
is discharged from the wire to the workpiece with a very small spark gap through an
insulated dielectric fluid (water). Many sparks can be observed at one time. This is
because actual discharges can occur more than one hundred thousand times per
second, with discharge sparks lasting in the range of 1/1,000,000 of a second or less.
The volume of metal removed during this short period of spark discharge depends on
the desired cutting speed and the surface finish required. The heat of each electrical
spark, estimated at around 15,000° to 21,000° Fahrenheit, erodes away a tiny bit of
material that is vaporized and melted from the workpiece. (Some of the wire material is
also eroded away) These particles (chips) are flushed away from the cut with a stream
of de-ionized water through the top and bottom flushing nozzles. The water also
prevents heat build-up in the workpiece. Without this cooling, thermal expansion of the
part would affect size and positional accuracy. Keep in mind that it is the ON and OFF
time of the spark that is repeated over and over that removes material, not just the flow
of electric current.
Short Interval Item:
Short interval items vary in occurrence from weekly to monthly.
Automatic Wire Threading System: The automatic wire threading
(AWT) system performs the threading of the wire via a water jet column. It is the single
most important automated feature on a wire EDM machine. Utilization of an AWT
system will extend the unattended operation of the machine. AWT units typically require
cleaning and alignment checks of mechanical components and sensors to ensure
reliable operation.
Power Contacts: These two contacts deliver the electrical cutting power to the
wire. These contacts—both on the upper and lower machine heads—will erode over
time, resulting in a significant decrease of machining speed. They require a simple
indexing and cleaning, and eventual replacement.
Belts and Rollers: These items make up the wire transport system. They require
either cleaning indexing, or replacement to prevent wire slippage or wire tension
problems that can result in part inaccuracies.
Brake/Clutch Roller: This roller is the most critical item in the wire transport
system. Its function is to create and control the proper tensioning of the wire. If wire
tensions are not held to within certain parameters, workpiece inaccuracies, exces-
sive wire breaks and excessive wire lines on the workpiece may result. This unit is
typically maintained with the aid of an OEM (original equipment manufacturer) supplied
procedure or calibration cycle.
Wire Guides (2): These guides—either diamond or sapphire—are located in
both the upper and lower machine heads. They are used to align and locate the wire
within the machine. The guides are the most important item within the machine because
they deliver and transfer the machine tool accuracy into the workpiece. They require
cleaning to prevent misfeeding, clogging, part inaccuracies and failure.
Wire Alignment: This procedure is typically required after wire guide cleaning
with the aid of an OEM supplied jig or fixture, and is performed to calibrate and align the
wire within the machine for verticality. If the wire is not properly aligned for verticality,
machined results will contain tapers and positional part locations will be inaccurate.
Wire Collection Box: The wire is only used once within the machine, and will
accumulate in a box or bin that will need to be emptied periodically. The spent or used
wire should be routinely checked and emptied per manufacturer recommendations. The
spent material can typically be recycled through an industrial materials scrap recycler.
Machine Seals: Many machine designs require cleaning of a door and tank seal
to ensure seal integrity and longevity. Seals will need to be replaced once they become
degraded beyond their service life and can no longer sufficiently prevent or control
water leakage.
General Cleaning: With the intricate wire EDM process, debris is typically
scattered evenly throughout the work tank. Over time, this debris can accumulate and
build up into a hard scale that is difficult to clean. Scheduling a monthly machine
cleaning using a standard cleaner will prevent large buildups of debris. Less overall time
will be required the more frequent the cleanings. Generally, the cleaner a machine is
kept, the less likelihood there is for unsuspected problems to arise. This also may
extend the life of some long interval consumable items.
Long Interval Items
Long interval items vary from bi-monthly to yearly.
Machine Filters: Replacement of the main water filters will be required and
should be performed as needed (most machines will typically generate an alarm when
the filters are depleted). Replacement intervals are purely dictated by the type of work,
workpiece material and thickness, and applications being performed. Many machines
also contain a safety filter for the AWT system that will need replacing periodically (six to
12 months). The filtration system on a wire EDM is fundamentally necessary because it
controls the amount and size of particles/debris that can exist and be circulated through
the flushing system during machining. If this debris is excessive and of a large
particulate size, machining will be very unstable and inefficient.
De-ionization Resin: This is a special resin that is used to control the
conductivity of the water within the machine. If the conductivity or resistivity of the water
is not controlled and sustained at a certain level that the machine requires, machining
will become very unstable, and final results will be inaccurate. The de-ionizing (DI) resin
is replaced when needed (most machines will typically generate an alarm when the
resin is depleted). There also is a conductivity/resistivity probe that requires cleaning to
ensure proper level readings.
Water Level: Over time, the water level in the machine reservoir will become low
from evaporation and will need to be replenished. The quality of the incoming water (tap
water is typically used) can affect the life of the DI-resin.
Belts, Rollers and Pulleys: Certain machine designs require periodic
replacement of some belts, rubber rollers and pulleys. Replacement may be required
due to physical wear of the component or from wear of replaceable bearings. It is very
important that these items be maintained, checked and/or replaced by specific
procedures and intervals suggested by your machine tool manufacturer. Failure to keep
these items within operational specifications will result is part inaccuracies and machine
downtime.
Wire Choppers: Some machines contain a wire chopping unit that cuts the used
or spent wire into small pieces. Maintenance on this unit will include the sharpening or
replacement of cutting blades and dies. The results of allowing these cutting edges to
become excessively dull will lead to workpiece inaccuracies, excessive wire lines on the
workpiece and machine downtime.
Cabinet Filters: Some machine designs require the changing or cleaning of an
air filter element. Such filters are commonly found on intake fans of the
electrical/generator cabinets and water chiller units. These filters should be inspected,
cleaned and replaced at regular intervals specified by the OEM. If these filters become
excessively clogged, air flow will be restricted, which will lead to overheating and failure
of the equipment.
Machine Seals: Due to specific seal designs, some seals and/or gaskets may
require a yearly replacement to ensure proper machine operation. The seals/gaskets
that typically require the most attention are the work tank door gasket and the lower arm
tank seal plate. Proper maintenance and care of the lower arm sliding seal plate is
especially important because as this seal wears and friction increases, machining
accuracies also may be degraded.
Machine Floats: Most manufacturers recommend a yearly inspection and
cleaning of machine operational and safety float switches. If these floats become
excessively dirty, their operation may fail, resulting in damaged machine electrical
components and water spillage.
Water Reservoir: The quality level of the water within the machine can become
degraded over time and heavy sediments also can build up in the water holding tanks.
Contaminants from cleaning agents also can change the pH levels of the water, all of
which can affect the performance of the machine. Most wire EDM manufacturers
recommend that the water be drained and the water reservoir cleaned yearly.
Insufficiently monitoring and maintaining the reservoir system may result in excessive
machine corrosion, sedimentary buildup and machine component/pump failure.
Machine Lubrication: Check with your machine’s OEM on recommended
intervals and access points for machine lubrication. The most common items that
require attention are the ball screws and linear guide way systems. Be sure to use the
proper lubricants that are specified by the OEM. Improper lubrication of the machine will
lead to workpiece inaccuracies and the eventual replacement of costly machine
mechanical components.
General Cleaning Importance
Good cleaning habits and care of a wire EDM machine is highly recommended. Regular
and systematic cleaning of the machine also can extend the life of some consumable
items.
Care should be taken when selecting a cleaner. It is recommended that a general, all-
purpose household cleaner/degreaser be used for general cleaning. A mild, watered-
down solution of acid (typical EDM acid cleaners are phosphoric acid based) is used for
the cleaning of more heavily soiled machine components.
When using any cleaner, it is best to apply the cleaner to a rag and not directly spray
cleaners into the machine. This will result in using less cleaner as well as controlling the
contamination of the water reservoir.
Do not allow caustic or acidic cleaners to sit on some surfaces too long as they may
etch, bleach or damage surfaces. And avoid getting cleaners on attachment points
where power cables connect to the machine heads, as cleaners can act like a corrosive
agent and degrade the power cables.
After cleaning, be sure to wash and rinse cleaned surfaces with water. This will ensure
that the cleaners are properly removed prior to operation.
Keep in mind, the underlying concept and operating strategy for wire EDM is to
maximize the unattended machining time. With a properly maintained wire EDM
machine, the goals of maximizing machine up-time and greater overall process
efficiency can be more easily achieved and realized.
Due to machine design differences, the type and time intervals of machine maintenance
can vary. It is highly recommended to check with and follow the maintenance
specifications, intervals and procedures supplied by your machine OEM. If maintenance
requirements, procedures or intervals are in question, contact your OEM or refer to your
machine’s maintenance manual for more information.