Aditya Kurhade

DISSERTATION SYNOPSIS
ON
“TO STUDY THE DESIGN AND DEVLOPMENT OF
EDM AND WEDM”
Submitted in partial fulfillment of requirement of University of Mumbai
For the Diploma of
(Mechanical Engineering)
By
1601. AKASH SINGH
1602.AKSHIT KHUPTE
1603. ADITYA KURHADE
Sub:Advanced manufacturing process
Sub code; 22562
Department of Mechanical Engineering
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

NAVJEEVAN EDUCATION
SOCIETYPOLYTECHNIC
(Affiliated to University of Mumbai)
(2021-2022)
i
CERTIFICATE
This is to certify that Mr. ………………………….………………………………………..

Roll no. ……………....…. Of FIFTI Semester of Diploma in Mechanical
Engineering of institute, Navjeevan Polytechnic (code : 0144) has
completed the Project work satisfactorily in course : POWER
ENGINEERING AND PREFRIGERATION for the academic year 2021 to
2022 as prescribed in the curriculum.
Place :Bhandup Enrollment No. :
Date : Exam Seat No. :
Subject Teacher Head of Department Principal
Seal of instruction
ii
ACTION PLAN
Sr. No. Details of Plan Start Plan Names of Group

activity Date Finish Members
Date
1. Introdution Aditya Kurhade
About Project Akash Singh
2. Discussion and Akshit Khupte
Selection of Aditya Kurhade
Project
3. Collection of Akshit Khupte
Data Related to Akash Singh
Project
4. Execution of Aditya Kurhade
Collected Data Akash Singh
5. Report Aditya Kurhade

Precautions Akshit Khupte
Akash Singh
6. Final Aditya Kurhade
Submission Akshit Khupte
Akash Singh
iii
AIM OF MICRO PROJECT:
➢ TO PREPARE A REPORT ON VARIOUS COMPONENT OF EDM AND

WEDM SYSTEM.
➢ TO UNDERSTAND THE APPLICATIONS OF EDM AND WEDM

SYSTEM.
➢ TO WRITE ALL THE INFORMATIONS ON VARIOUS COMPONENT

OF EDM AND WEDM SYSTEM.
iv
ABSTRACT
A Wire-EDM or Electrical-discharge wire cutting is basically a variation

of an EDM process in which a slowly moving wire travels along a
prescribed path, cutting the work piece, by discharge sparks which
occurs in a small gap between wire & work piece and removes
unwanted material from parent metal by melting & vaporization. The
wire should have sufficient tensile strength and fracture toughness, as
well as high electrical conductivity. Creation of extrusion dies,
blanking punches and metal & tool fabrication are performed by
WEDM. The paper reviews of the research work carried out in
different fields related to WEDM such as modeling and simulation,
ultrasonic vibrations, dry machining, composite materials & other key
studies including the effects, investigations, improvements &
developments carried out on the field of WEDM.
v
DESIGN AND DEVELOPMENT OF EDM & WEDM
Chapter 1
INTRODUCTION
Wire electrical discharge machining (WEDM) is a special form of the

traditional EDM process in which material is eroded from the work
piece by a series of discrete sparks between the work piece and the
wire electrode separated by a thin film of dielectric fluid. The
movement of the wire is controlled numerically to achieve the desired
three-dimensional shape and accuracy for the work piece. WEDM is
used in tool and die making industries, automobiles, aerospace,
nuclear, computer and electronics industries. The average cutting
speed, relative machining costs, accuracy and surface finish have been
improved since the commercial inception of the machines; much more
improvement is still required to meet the increasing demand of
precision and accuracy by different industries. The performance of
WEDM depends much on the wire electrode used. Brass wire is used
extensively as a wire electrode in WEDM. Various high performance
electrodes like zinc coated, diffusion annealed, coated steel core wires
etc. have been developed to satisfy the machining needs. In the
present study, the work related to development phrases of wire
electrode's materials, work related to effect of various input
parameters on the performance measures for WEDM process are
described
7
Chapter 2
LITERATURE SURVEY
• M.T. Antar, S.L. Soo, D.K.

Aspinwall, D. Jones and R. Perez
[2] made a brief review of recent
minimum damage EDM pulse
generator developments,
experimental data is presented for
workpiece productivity & integrity
when WEDM Udimet 720 nickel
based super alloy and Ti-6Al- 2Sn-
4Zr-6Mo titanium alloy, using Cu
core coated wires
• (ZnCu50 and Zn rich brass). Up to
a 70% increase in
• productivity was possible
compared to when using
uncoated
• brass wires with the same
operating parameters. Surfaces
measuring ∼ 0.6 Ïm Ra, with near
neutral residual stresses and
almost zero recast were produced
following two trim
• passes. Cross-sectional
micrographs of specimens
following
• rough machining (∼180mm
• 2
• /min) showed the recast to be <
• 7 Ïm thick (up to 11 Ïm for
uncoated wire), with comparable
8
• results for both alloys. Surface

cracking, when evident, was
• restricted to within the recast
layer. Fuzhu Han, Jun Jiang and
Dingwen Yu [3] gives the
• journal on Influence of machining
parameters on surface
• roughness in finish cut of WEDM,
according to them Surface
• roughness is significant to the
finish cut of wire electrical
• discharge machining (WEDM).
This paper describes the
• influence of the machining
parameters (including pulse
duration, discharge current,
sustained pulse time, pulse
• interval time, polarity effect,
material and dielectric) on
• surface roughness in the finish cut
of WEDM. Experiments proved
that the surface roughness can be
improved by
• decreasing both pulse duration
and discharge current. When
• the pulse energy per discharge is
constant, short pulses and
• long pulses will result in the same
surface roughness but
• dissimilar surface morphology and
different material removal rates.
The removal rate when a short
9
pulse duration is used is much

higher than when the pulse
duration is long. S. S. Mahapatra
and Amar Patnaik [4]- studied
• optimization of wire electrical
discharge machining (WEDM)
• process parameters using Taguchi
method, Wire electrical
• discharge machining (WEDM) is
extensively used in machining of
conductive materials when
precision is of
• prime importance. Rough cutting
operation in WEDM is
• treated as a challenging one
because improvement of more
• than one machining performance
measures viz. metal removal rate
(MRR), surface finish (SF) and
cutting width
• (kerf) are sought to obtain a
precision work. Using Taguchiís
parameter design, significant
machining parameters affecting
• the performance measures are
identified as discharge current,
pulse duration, pulse frequency,
wire speed, wire tension, and
• dielectric flow. It has been
observed that a combination of
• factors for optimization of each
performance measure is different.
In this study, the relationship
10
between control
• factors and responses like MRR, SF
and kerf was established by means
of nonlinear regression analysis,
resulting in a valid mathematical
model. Finally, genetic
• algorithm, a popular evolutionary
approach, was employed to
• optimize the wire electrical
discharge machining process with
multiple objectives. The study
demonstrated that the WEDM
➢ process parameters can be adjusted to achieve better metal
removal rate, surface finish and cutting width simultaneously
11
objectives:-
There are many machining parameters affecting the EDM machine

performance and the real mathematical
models between machining performance and machining parameters
are not easy to be derived because of
the complex machining mechanism. The objectives are as follows:-
1. To achieve the better surface finish, low surface roughness,
better dimensional accuracy and less overall
material wastage .
2. To reduce the size of machine .
3. To significant reduction in the cost of
machine.
14
CHAPTER 4
Electrical discharge machining

Electrical discharge machining (EDM), also known as spark
machining, spark eroding, die sinking, wire burning or wire erosion, is a
metal fabrication process whereby a desired shape is obtained by using
electrical discharges (sparks).[1] 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 workpiece-
electrode, or work piece. The process depends upon the tool and work
piece not making physical contact.
An electrical discharge machine

When the voltage between the two electrodes is increased, the intensity
of the electric field in the volume between the electrodes becomes
greater, causing dielectric break down of the liquid, and produces an
electric arc. As a result, material is removed from the electrodes. Once
the current stops (or is stopped, depending on the type of generator),
new liquid dielectric is conveyed into the inter-electrode volume,
enabling the solid particles (debris) to be carried away and the insulating
properties of the dielectric to be restored. Adding new liquid dielectric
in the inter-electrode volume is commonly referred to as flushing. After
a current flow, the voltage between the electrodes is restored to what
15
it was before the breakdown, so that a new liquid dielectric breakdown

can occur to repeat the cycle.
Principle:
Electrical discharge machining process works on the basic principle of

spark generation and metal removed by spark erosion. EDM spark
erosion is same as electric spark which burn a small hole in a piece of
metal through witch it contacts. The spark generated by this process
produces heat, which remove metal by erosion and evaporation. In this
machining process both the work piece and tool must be made by
conductive material.
16
Equipment’s:
The EDM process contains following equipment’s.
Power Supply:
In a EDM process a high frequency current used to generate spark
between electrode and work piece. This spark generates heat and
remove metal form work piece.
Dielectric fluid supply and flushing system:

The dielectric fluid acts as a vehicle to drive away the chips and thus
preventing them from sticking to the surface. This fluid acts as flushing
system for chips. It also helps in increasing the metal removal rate by
promoting spark between tool and work. This fluid also works as coolant
medium.
Tool and tool holding devices:
In EDM process, tool also erodes due to spark hence the selection of tool
depends on wear ratio, ease to tool fabrication and cost of material. The
most commonly used electrode material are Cu, Tungsten alloy, Cast
Iron, Steel, Silver tungsten alloy, graphite.
Work piece and work holding devices:

In this process only good conductors of electricity can be machined. So
the work piece should have good electric conductivity. This process does
not depend on hardness of work piece so there is no criteria of hardness.
Working:
In this process, work piece should be well electric conductive. Only

electric conductive material can be machined by this method. The
17
working of EDM is as follow.
▪ First both work piece and tool are submerged into dielectric fluid.
The dielectric fluid help to control the arc discharge. This also
removes suspended particles of work piece material and tool from
the work cavity.
▪ A servomechanism is used which maintains a very small gap
between the work piece and the tool. This gap is desirable for
proper arc formation. It is about the thickness of human hair.
▪ The tool is made as the opposite shape of work piece.
▪ A high frequency current supplied to electrode, which produces a
spark between the tool and work piece. This spark generates high
in work cavity.
▪ The metal removed from the work piece due to erosion and
evaporate ion.
▪ The chips or suspended particle between tool and work
pieceshould be removed to prevent them to form bridge that
causes short circuit. This is done by continuous supply of dielectric
fluid.
▪ The EDM produce a cavity slightly larger than the electrode
because of overcut.
Advantages:
➢ Every conductive material can be cut by this process.
➢ It is independent on hardness of workpiece so hardened work
piece can be machined easily.
➢ Complex die section and complex shapes can be produce
accurately.
➢ This process is burr free.
➢ Thin section can be easily machined without deforming the part.
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Disadvantages:
➢ In this machining process high tool wear occurs.
➢ Tool wears limits accuracy and surface finish of metal.
➢ Only good conductors of electricity can be machined by EDM.
19
Electrical Discharge Machining: Principle and

Manufacturing Applications
▪ Manufacturers often turn to electrical discharge machining

(EDM) whenever traditional machining methods reach their
limit. The EDM process involves using thermal energy to
remove excess material from an object, creating the required
shape for a task. It is not the most popular CNC
machining process available. However, engineers rely on it to
create parts that are impossible to machine.
▪ EDM is similar to processes such as laser cutting. It does not

require or use mechanical force to remove the excess
material. This is why many people consider it to be a non-
traditional manufacturing process. This process helps in
molding and tooling for a wide range of industries. In this
article, we will examine how it works, the various types
20
available, as well as its advantages and applications. Let’s dive

right into it!
What is EDM?
▪ You may have come across terms such as spark machining, die sinking,
wire erosion, or spark eroding. Some engineers and manufacturers
use these terms to refer to electrical discharge machining (EDM). But
what is EDM? To simply put, EDM involves removing excess material
from a workpiece with the use of thermal energy.
21
▪
• As mentioned earlier, the EDM process does not require mechanical
force. This fabrication process ensures that engineers arrive at desired
shapes only with the use of electrical discharges. It is a highly precise
process that does not involve using a tool on the workpiece. When you
need to work on hard materials like titanium or form complex shapes,
EDM is often the way to go.
▪ How Does Electrical Discharge

Machining Work?
22
❖ While the definition may seem simplistic, the physical process is a little
bit more complex. The removal of material from a workpiece using
EDM occurs through a series of recurring rapid current discharge
between electrodes. These electrodes are separated using a dielectric
fluid. Then, a voltage is sent through the dielectric fluid. It is important
to note that EDM manufacturing only works for electrically conductive
materials.
❖ One of those electrodes serves to change shape to fit the exact

purpose. This electrode is the workpiece electrode or the “anode.”
The other electrode is the tool-electrode or the “cathode.” The basic
principle behind this process is the erosion of the material with a
controlled electric spark. For this to occur, the two electrodes must
not come in contact.
❖ There is the application of potential difference across the workpiece

and the electrode in pulse form. As the electrode moves closer to the
workpiece, the electric field present in the small gap between them
increases. This continues until it reaches breakdown volume.
❖ The electrical discharge causes extreme heating of the material. The

heating leads to the melting away of some parts of the material. A
steady flow of the dielectric fluid helps to remove the excess material.
The liquid also assists in cooling during the machining process.
Types of Electrical DischargeMachining
▪ The EDM process is unique and conventional. However, this does not
mean that there is only one approach to this process. There are three
23
different types of EDM. This helps to assure that there are alternative
methods if one type does not fit adequately. The different types of
electrical discharge machining include:
▪ Wire EDM
▪ Sometimes referred to as wire erosion or spark EDM, wire EDM is a

popular process. It involves the use of a brass wire or thin copper to
cut the workpiece. Here, the thin wire acts as the electrode. The
dielectric liquid, in this case, is usually deionized water. During the
wire EDM, there is the continuous unfurling of the wire from an
automated feed using a spool.
24
▪
▪ This is because the electrical discharge may become compromised by
the workpiece and the wire. Therefore, there is a need for a new
discharge path in the cut. This approach works very well. However,
engineers must note that the wire must pass through the workpiece
completely. Hence, it essentially creates two-dimensional cuts in
three-dimensional parts. You tend to get results that are similar to the
traditional CNC machining processes.
25
▪ Hole EDM
▪ hole drilling EDM process is another type of electrical discharge

machining. As the name implies, it helps explicitly in fast hole drilling.
The electrodes for hole EDM are tubular, enabling the dielectric fluid
to flow through the electrodes easily.
▪
▪ Unlike the traditional drilling methods, hole EDM can machine very
tiny and deep holes. Furthermore, these holes do not require any
deburring. Regardless of the metal hardness or type, this process
enables effective drilling of precision holes faster than the
conventional methods.
26
▪ Sinker EDM
▪ This is the conventional EDM, also referred to as Ram EDM, die
sinking, or cavity-type EDM. Cavity type because it creates complex
cavity shapes for various casting applications such as plastic injection
molding.
▪
▪ This process uses pre-machined copper or graphite electrodes to form
a “positive” of the required shape. Then, there is the pressing of the
electrode into the workpiece to create a negative of the original
material shape. Some factors may influence the choice of electrode
material in sinker EDM. These include the electrode’s resistance to
erosion and its conductivity, which is usually easier to machine
graphite than copper. However, copper is stronger and more
conducive.
27
Advantages of Electrical Discharge

Machining
▪ There are several unique advantages associated with EDM. Some of
them include:
▪ 1. It Can Work on Any Type of Electrically Conductive

Material
▪ When you think of EDM manufacturing, the first thing that will come
to your mind is its ability to work on a wide range of materials. As long
as your material is electrically conductive, EDM is always the right
process. This makes it possible to machine parts that are difficult for
traditional machining methods. These include parts made from
titanium and tungsten carbide.
▪ 2. No Mechanical Force is Involved
▪ Another crucial benefit of electrical discharge machining is that no

mechanical force is put into the workpiece. Therefore, you don’t have
to worry about producing fragile outlines. This becomes easy because
there is no need for high cutting force before removing the material.
Since no contact occurs between the tool and the workpiece, there is
no issue of mechanical stress.
28
▪ 3. Enables Various Shapes and Depths
▪ With EDM, you can reach shapes and depths that seem impossible
with a cutting tool. It is an effective method for deep processing with
very high tool lengths and diameter ratios. You can easily cut sharp
internal corners, narrow slots, and deep ribs with the EDM process.
▪ 4. Encourages Better Surface Finish

▪
▪ Manufacturers also argue that injection molding surface finish is

often better with EDM than traditional methods. This may be true
because electrical discharge machining gives surfaces with high
precision and fine finishes.
▪ 5. Can Be Used on Hardened Material

▪ Other conventional machining processes need to be done before
hardening the workpiece. On the other hand, EDM works perfectly on
hardened material. Therefore, it is easy to avoid any potential
deformation from heat treatment.
Applications of Electrical Discharge Machining
▪ EDM is particularly famous in small-volume production. Several

processes are possible using electrical discharge machining. These
processes include milling, turning, small hole drilling, and more. This
unique process is also valuable for a wide range of industries ranging
from automotive to the aerospace industry.
▪ Being able to create unique and precise shapes, EDM helps in the
following applications:
29
▪ Injection Molding
▪ Achieving the right dimension, depth, and shape of a mold is usually
dependent on EDM. It is the major injection molding process used by
mold manufacturers. Wire EDM is the main type used in this case.
▪
▪ Since injection molding requires various delicate and complex
workpieces, so this is usually the best method to use. Moreover, it
often produces high precision and fine EDM surface finish.
▪ Small Hole Drilling
30
▪ Electrical discharge machining is a quick and unique way to create

accurate deep small holes drilling in materials, regardless of their
hardness.
▪
▪ The hole drilling process involves using a brass electrode tube to
channel the electrical discharges onto the material. This helps to
create holes of various small dimensions. The exciting thing is that it
can make holes on inclined faces and other challenging positions.
31
Die Casting
▪ EDM is also very suitable for die-making applications. Manufacturing

highly tailored dies require extreme accuracy. These dies feature
sharp internal corners, deep ribs, and other intricate features.
▪
▪ Also, dies are often made from very hard steel alloys. These alloys are
usually harder to machine with traditional methods. The hard steel
alloys may require finishing prior to heat treatment, which may reduce
the accuracy of details. Therefore, employing the EDM process is more
appropriate.
32
WIRE EDM
• Wire EDM (Vertical EDM's kid brother), is not the new kid on the block.
It was
• introduced in the late 1960s', and has revolutionized the tool and die,
mold, and
• metalworking industries. It is probably the most exciting and diversified
machine tool
• developed for this industry in the last fifty years, and has numerous
advantages to offer.
33
• It can machine anything that is electrically conductive regardless of the

hardness,
• from relatively common materials such as tool steel, aluminum, copper,
and graphite, to
• exotic space-age alloys including hastaloy, waspaloy, inconel, titanium,
carbide,
• polycrystalline diamond compacts and conductive ceramics. The wire
does not touch the
• workpiece, so there is no physical pressure imparted on the workpiece
compared to grinding
• wheels and milling cutters. The amount of clamping pressure required
to hold small, thin and
• fragile parts is minimal, preventing damage or distortion to the
workpiece.
• The accuracy, surface finish and time required to complete a job is
extremely
• predictable, making it much easier to quote, EDM leaves a totally
random pattern on the
• surface as compared to tooling marks left by milling cutters and grinding
wheels. The EDM
• process leaves no residual burrs on the workpiece, which reduces or
eliminates the need for
• subsequent finishing operations.
• Wire EDM also gives designers more latitude in designing dies, and
management
• more control of manufacturing, since the machining is completed
automatically. Parts that
• have complex geometry and tolerances don't require you to rely on
different skill levels or
34
• multiple equipment. Substantial increases in productivity is achieved

since the machining is
• untended, allowing operators to do work in other areas. Most machines
run overnight in a
• "lights-out" environment. Long jobs are cut overnight, or over the
weekend, while shorter
• jobs are scheduled during the day. Most workpieces come off the
machine as a finished part,
• without the need for secondary operations. It's a one-step
process.
35
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
36
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.
Wire Cut EDM

Applications
Because of its versatility, manufacturers use EDM wire cutting machine

operation for an extensive range of applications. Because the process
can cut very small pieces, it is often an ideal choice for the production of
small, highly detailed items that would normally be too delicate for
other machining options. Additionally, the process is cost-effective for
low quantity projects and can prove to be beneficial in prototype
manufacturing, even if the actual project is carried out by different
means.
It is important to remember that the wire in the process is constantly

moving, and not to be reused. As a result, the copper, brass, or other
metallic wire can be miles long, adding cost to the process. And, while
the process uses no force and thus does not cause burrs and can be used
on delicate items, the possibility of thermal stress is certainly present.
37
Most machining operations using wire EDM begin with a rough pass with
a fairly fast feed rate and high dielectric flow. Successive skim passes
take smaller cuts with a reduced dielectric flow to bring finished surfaces
into tolerance. The reduced dielectric flow avoids distorting the wire
during these skim passes.
Cuts that do not begin along an edge of a part (such as holes) require
predrilling to allow the wire to thread through. Many wire EDM
machines are fitted with small hole drilling electrodes for this purpose,
permitting starting holes to be made in hardened steels without the use
of conventional drills. Small hole drills usually employ an EDM electrode
mounted in a spinning mandrel with dielectric pumped through the
electrode to flush the hole. The process of making small holes in
hardened material using standalone EDM drills is sometimes referred to
as hole popping
Advantages
A major advantage of wire EDM over conventional EDM is that the
continuous supply of wire minimizes the wear that occurs with a fixed
electrode. A wire EDM machine can consume a lot of wire, however,
adding expense. Many wire EDM machines are self-threading so that if
a wire breaks the process can be continued almost without
interruption.
Another major advantage is that parts may be cut after heat treatment
which eliminates the possibility of distortion arising from post-
machining treatments. Also, because the wire EDM method exerts no
tooling pressure upon the workpiece, small, delicate parts are easily
machined. Fixturing requirements are minimal compared to
conventional machining methods. Very fine surfaces are possible.
Limitations
38
o Compared with many machining methods, wire EDM is a slow

process although speeds have increased over the years due to
technological advances. Throughputs can be increased by
stacking identical parts and cutting them all at once. Multi-head
machines are available to cut multiple identical parts
simultaneously. Because wire EDM is a thermal process, some
stresses can be imparted to the workpiece.
o Although relatively straightforward to perform, maintenance of
wire EDM machines can be more demanding than that required
for conventional machine tools. Consumables can be more costly,
too. These costs can sometimes be softened by the fact that
almost all wire EDM machines are designed to operate
unattended, save for loading and unloading. The absence of burrs
on the finished parts can also save by labor or time by eliminating
the deburring step.
CONCLUSION
❖ WIRE EDM HAS A BROAD RANGE OF APPLICATIONS THAT
ARE CONTINUING TO GROW
❖ . Parts with complex geometry’s
❖ . Parts requiring "tenths" tolerances
❖ . Parts where burrs can’t be tolerated
❖ . Thin or delicate parts that are susceptible to tool pressure
❖ . Progressive, blanking and trim dies
39
❖ . Extrusion dies
❖ Precious metals
❖ . Narrow slots and keyways
❖ . Mold components
❖ . Tooling for forging, or injection molding operations.
❖ . Medical and dental instrumentation
❖ . Cutting hardened materials such as carbide, C.B.N. and

P.C.D.
❖ Cutting difficult to machine materials like hastaloy, inconel

and titanium
❖ . Aerospace, defense and electronic parts
❖ . Prototypes parts
❖ Production parts
❖ Form tools and inserts
❖ Electrodes (graphite or copper) for vertical EDM
❖ The above list of application represent only a fraction of

areas where wire EDM is being
❖ used. "The wire EDM process is only limited by your

imagination!"
40
REFERENCE
➢
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Aditya Kurhade

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DISSERTATION SYNOPSIS

Department of Mechanical Engineering

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

This is to certify that Mr. ………………………….………………………………………..

Subject Teacher Head of Department Principal

Sr. No. Details of Plan Start Plan Names of Group

5. Report Aditya Kurhade

➢ TO PREPARE A REPORT ON VARIOUS COMPONENT OF EDM AND

➢ TO UNDERSTAND THE APPLICATIONS OF EDM AND WEDM

➢ TO WRITE ALL THE INFORMATIONS ON VARIOUS COMPONENT

A Wire-EDM or Electrical-discharge wire cutting is basically a variation

Wire electrical discharge machining (WEDM) is a special form of the

• M.T. Antar, S.L. Soo, D.K.

• results for both alloys. Surface

pulse duration is used is much

There are many machining parameters affecting the EDM machine

Electrical discharge machining

An electrical discharge machine

it was before the breakdown, so that a new liquid dielectric breakdown

Electrical discharge machining process works on the basic principle of

Dielectric fluid supply and flushing system:

Work piece and work holding devices:

In this process, work piece should be well electric conductive. Only

working of EDM is as follow.

Electrical Discharge Machining: Principle and

▪ Manufacturers often turn to electrical discharge machining

▪ EDM is similar to processes such as laser cutting. It does not

available, as well as its advantages and applications. Let’s dive

▪ How Does Electrical Discharge

❖ One of those electrodes serves to change shape to fit the exact

❖ There is the application of potential difference across the workpiece

❖ The electrical discharge causes extreme heating of the material. The

Types of Electrical DischargeMachining

▪ Sometimes referred to as wire erosion or spark EDM, wire EDM is a

▪ hole drilling EDM process is another type of electrical discharge

Advantages of Electrical Discharge

▪ 1. It Can Work on Any Type of Electrically Conductive

▪ 2. No Mechanical Force is Involved

▪ Another crucial benefit of electrical discharge machining is that no

▪ 3. Enables Various Shapes and Depths

▪ 4. Encourages Better Surface Finish

▪ Manufacturers also argue that injection molding surface finish is

▪ 5. Can Be Used on Hardened Material

Applications of Electrical Discharge Machining

▪ EDM is particularly famous in small-volume production. Several

▪ Small Hole Drilling

▪ Electrical discharge machining is a quick and unique way to create

▪ EDM is also very suitable for die-making applications. Manufacturing

• It can machine anything that is electrically conductive regardless of the

• multiple equipment. Substantial increases in productivity is achieved

PRINCIPLE OF WIRE ELECTRICAL DISCHARGE

▪ The Spark Theory on a wire EDM is basically the same as that

the surface finish required.

Wire Cut EDM

Because of its versatility, manufacturers use EDM wire cutting machine

It is important to remember that the wire in the process is constantly

o Compared with many machining methods, wire EDM is a slow

❖ . Parts with complex geometry’s

❖ . Parts requiring "tenths" tolerances

❖ . Parts where burrs can’t be tolerated

❖ . Thin or delicate parts that are susceptible to tool pressure

❖ . Progressive, blanking and trim dies

❖ . Narrow slots and keyways

❖ . Tooling for forging, or injection molding operations.