ME 308 Experiment Report

Experiment 4

Non-Conventional Machining Process Electric Discharge Machining(EDM)

Name-Ashutosh Garg

Entry Number- 2018MEB1213

Mobile Number- (+91)-83608-75243

Email ID- 2018meb1213@iitrpr.ac.in

Date of sharing- 11th July 2021

Date of submission- 18th July 2021

1
Summary of the experiment

AutoCAD and ELCAM were explored through this experiment to demonstrate and understand the
Wire EDM cutting operation on a metal sheet and to make 3 x (10 mm square sided) plates.
Cutting operation on the metal workpiece was performed with the continuous wire (of diameter
usually 2 microns) feed rate and deionised water was taken as a medium. Wire cuts the materials
by melting and vaporising it after the formation of plasma when it gets close to the metal. This
method is considered good and clean as no residue is left and also at microscopic level, the
deformation is minimal and almost negligible residual stresses are present in the workpiece.

AutoCAD was used to generate 2D drawing of 3 adjacent rectangles and ELCAM was used to
generate the respective GM codes. Other materials used were Controller, Brass wire(0.25 mm
thick), medium used was deionised water and chillers were also used.

Procedure followed in the experiment:

1. Using AutoCAD, 3 squares of side 10 mm were cut with relaxation of 0.3 mm and then
GM codes were generated with the help of ELCAM software. After generating its file, it
was fed to the NC EDM machine. Format of the file wa .dxf.
2. Program was set up and a file was opened and verified its accuracy with the software
present. Final checks were done and the machine was started.
3. Change coordinates to the home place and clamp the workpiece and put a mark on the
start point of cutting on edge manually and reset coordinates to 0.
4. Load the program finally and make sure to check on the display screen for starting
position of tool and after all the safety checks, move machine in -ve Z direction and
process is started by pressing the START button and the final product will be obtained.

Figure 1: Simulation of product(right) and final product obtained(left)

2
 Advantages and disadvantages:

Advantages Disadvantages

1. Complex geometries are possible. 1. EDM is an expensive and slow

2. Good finish on products is possible.
3. Minimal deformation in the workpiece
as the wire makes no contact while
cutting.
4. Materials which are hard to shape and
cut by manual methods can be done
easily via EDM.
process.
2. The type of material is limited as
conduction is the prerequisite for this
process.
3. Wire is not reusable.

Assignment Question:

GM code to write A is as follows:

Figure 2: “A” written with GM codes.

GM CODES FOR THE SAME:

N01 G21 G90 X0 Y0 Z0

N02 G00 X0 Y1
N03 G00 Z-10
N04 G01 X7 Y20
N04 G01 X11 Y20
N05 G01 X17.5 Y1
N06 G01 X15 Y1
3
N07 G01 X13 Y8
N08 G01 X5 Y8
N09 G01 X2.5 Y1
N10 G01 X0 Y1
N11 G00 X0 Y0 Z0
N12 M00