EDM-Electrical Discharge Machining MODULE 1

The EDM process involves a controlled erosion of electrically conductive materials by the initiation of Rapid and
repetitive spark bbvvh Alain yeah that star dies to remove that thing we want to remove those kinds of of sweets
discharges b/w the tool and W.P separated by a small gap of about .01 to .50mm.[DC power supply]

 Capacitor discharge range 50KHz

to 500KHz
 Volt -50v to 400v,current -0.1 to
500A
 Fluid-Dielectric fluid{Functions-Act
as a insulator,cooling medium}.
[kerosene,mineral oils,silicon
based oil,Transformer oil]
 Properties of Dielectric fluid
1.Strong dielectric resistance.
2.Easily available 3.Economic
Characteristics of electrode

 1.High Electrical coductivity

 2.Higher density
 3.High melting point
 4.Easy manufacturing

Chara of EDM

 Mechanism of process-controlled
 erosion through series of electric spark.

MRR .1 to 1.0mm

Limitations

 High specific energy consumption

 Non conducting material cannot be machined.

Advantages

 1.Hardness is never a limitation

 2.Complex shapes can be Easily machined
 3.There is no cutting Force acting on tool and W.P.

Application

 1.Die cavities for large automobile-body components.

 2.Narrow slots
 3.Turbine blades
 4.Small dia deep hole
EDG-Electric Discharge Grinding

The grinding wheel in Electrical Discharge Grinding is made of graphite or brass and contains no
abrasives.material is removed from the surface of the W.P by repeatitve spark discharges B/W the rotating wheel
and the W/P.

ECM-Electro Chemical Machining

ECM is a method of removing metal by an electrochemical
process. It is normally used for mass production and is
used for working extremely hard materials or materials
that are difficult to machine using conventional methods.
ECM can cut small or odd-shaped angles, intricate
contours or cavities in hard and exotic metals, such as
titanium aluminides, and high nickel, cobalt.

In the ECM process, a cathode (tool) is advanced into an

anode (workpiece). The pressurized electrolyte is injected
at a set temperature to the area being cut. The feed rate is
the same as the rate of "liquefication" of the material.

The gap between the tool and the workpiece varies

within 0.003–0.030 in. As electrons cross the gap, material
from the workpiece is dissolved, as the tool forms the
desired shape in the workpiece. The electrolytic fluid
carries away the metal hydroxide formed in the process.
Applications

• Die-sinking operations
Advantages • Drilling jet engine turbine blades
• Multiple hole drilling
• This method works even on very hard and brittle workpieces
• the tools can be made from any cheap and easily machined
• Machining steam turbine
• the tool can be repeatedly used. blades within close limits.

• Disadvantages
• Only electrically conductive materials can be machined.
• High Specific Energy consumption.
 AJM-Abrasive Jet machining Abrasive jet machining (AJM), also known as
abrasive micro-blasting, pencil blasting and
micro-abrasive blasting,it is an abrasive
blasting machining process that uses
abrasives propelled by a high velocity
gas to erode material from the workpiece.
Material is removed by fine abrasive
particles, usually about 0.001 in (0.025 mm)
in diameter, driven by a high velocity fluid
stream; common gases are air or inert gases.
speeds can be as high as 300 m/s.

nozzle dia - .2 to .8mm

gases –nitrogen ,carbon dioxide
Advantages
Disadvantages
• slow material removal rate. • High flexibility
• produces a tapered cut. • low heat production
• Compressor needed. • ability to machine hard and brittle
Application materials.
• Remove machine marks .
• Used to cut optical fibers without altering wavelength.
• Removal of Laser Slag from Components.

LBM-Laser Beam Machining

LBM) is an nonconventional machining process in which a laser is
directed towards the work piece for machining. The rays of a laser
beam are monochromatic and parallel it can be focused to a very
small diameter and can produce energy as high as 100 MW of
energy for a square millimeter of area.

LASER stands for Light Amplification by Stimulated Emission of Radiation.

Application
• Laser can be used in wide range of manufacturing
applications
– Material removal – drilling, cutting
– Welding
– Cladding
Disadvantages
– Alloying • High initial cost
– Used to drill micro sized Holes. • High maintanance cost
Advantages • Skilled operators needed.
• Tool wear and breakage are not encountered Limitations
• Very small holes with a large aspect ratio can • High equipment cost.
• A blind hole of precise depth is difficult to
be produced.
achieve with a laser.
• The setup times are economical. • The thickness of the material that can be
WC • Holes can be drilled at difficult angles.
laser drilled is restricted to 50 mm.
Wave length- .5 to 7 micron
Power density -1MW/mm2
EDM-WIRE CUT EDM
In this process, which is similar to
contour cutting with a band saw,a
slowly moving wire travels along a
prescribed path,cutting the W.P,with
the discharge sparks acting like cuttig
teeth.
 Wire electrode-copper,brass,
tungsten.{.25mm dia}
 Travel velocity-.15 to 9m/min

Application Advantages Disadvantages

• Die making
• Small hole EDM is used to
drill rows of holes into the
leading and trailing edges of
turbine blades used in jet
engines .
• Aerospace, automobile and
electronics parts
• very fine holes can be
attained.
• tapered holes may be
produced.
• a very good surface may
be obtained by redundant
finishing paths
• Extremely hard material to
very close tolerances
 Power consumption is
high
 The slow rate of
material removal.
 Initial cost is high
 Maintanance cost
is high

ULTRASONIC MACHINING

USM is a machining operation in which a

vibrating tool oscillating at ultrasonic
frequencies is used to remove material
from the workpiece, aided by an abrasive
slurry that flows freely between the
workpiece and the tool. The hammering of
the abrasive particles on the work surface
by the tool.
Advantages
 Virtually any hard material can
be machined
 good surface finish
 higher structural finish is obtained.
Disadvantages
 Low mat removal rate
 High tool wear
 Power consumption is high
Application
 Brittle mat like glass, ceramics can
be machined.
 Abrasives-silicon carbide,
boron carbide
 Tool vibration-20 to 30 Hz
 MODULE 2
N. C. MACHINE

Numerical control is a form of programmable automation in which the processing equipment is controlled by a set
of instructions called as program (which contains numbers, letters, and symbols)

When the job changes, the program of instructions changed.

Basic components of NC

Program of Instructions

Machine Control Unit

Processing Equipment.

 Program of Instructions

The program of instructions is the detailed step by step commands that direct the processing equipment.
 Machine Control Unit (MCU)
MCU consists of the electronics control and hardware that read and interpret program of instruction and convert
it into mechanical actions of the machine tool or other processing equipment.
 Processing Equipment
It is the component that performs useful work
The machine tool consists of worktable and spindle to hold tools, motors and controls necessary to drive them.

NC Procedure
 Process planning
 Part programming
 Tape preparation
 Tape verification
 Production
Process Planning
The engineering drawing of the workpart must be interpreted in terms of the manufacturing processes to be used
It consists of preparation of route sheet.
Part Programming
A part programmer plans for the portions of the job to be accomplished by NC.
There are two ways to program for NC
Manual part programming
Computer-assisted part programming
Tape Preparation
A punched tape is prepared from the part programmer’s NC process plan.
Production
This involves ordering the raw workparts, specifying and preparing the tooling and any special fixturing that may
be required.
CLASSIFICATION OF NC MACHINES
1) Based on feedback control
2) Based on control system.

 Based on feedback control

1) Open loop nc system
an open-loop NC system is one that does not use feedback signals to indicate the table position
to the controller unit.
2) a closed loop system
uses position sensors attached to the machine tool table to measure its position relative to the
input value for the axis. The function of the feedback loop in a numerical control system is to
assure that the table and work part have been properly located with respect to the tool.

 Based on control system.

1) point to point
Point to point (PTP) is also called a positioning system. In PTP, the objective of the machine control unit is to
move the cutting tool to a predefined location.
2) Straight cut
Straight cut control systems are capable of moving the cutting tool parallel to one of the major axis at a
controlled rate suitable for machining.
3) Contouring system
Contouring is most complex, the most flexible and most expensive type of machine tool control.
It is capable of performing both PTP and straight cut operations

contouring
Preparation of Punched Tape
• There are two methods for preparing punched tape
• The first method associated with manual part programming and involves the use of typewriter like device.
• The operator writes directly from the part programmer’s hand written list of coded instructions.
• This produces a typed copy of the program as well as the punched tape.
• The second method used with Computer assisted part programming.
• By this approach, the tape is prepared directly by the computer using a device called a tape punch.
• During production, the tape id fed through the tape reader once for each workpiece.
• It is advanced through the tape reader one instruction at a time.
• While the machine tool is performing one instruction, the next instruction is being read into the controller unit’s
data buffer.
• After last instruction has been read into the controller, the tape is rewound back to the start of the program
to ready for next workpart.
Absolute and incremental positioning
 Absolute positioning means that the tool locations are always defined in relation to the zero point.
 Incremental positioning means that the next tool location must be defined with reference to the
previous tool location.

COORDINATE MEASURING MACHINE

A coordinatemeasuringmachine
(CMM) is a device that measures the geometry of physical objects by sensing points on the surface of the object with
computer controlled.
Scanning and Digitization

It refers to the process of scanning paper documents and converting them to electronic documents, capturing
important information and saving the document in a central repository for easy retrieval later.

FLEXIBLE MANUFACTURING SYSTEM (FMS)

It is a manufacturing system in which there is some amount of flexibility that allows the system to react in case of changes,
whether predicted or unpredicted.

Flexible Manufacturing Cell (FMC)

It is the manufacturing system, created by grouping several NC machines, determined for the certain group
of parts with the similar sequence of the operations or for the certain type of operations.

Advantages Disadvantages
 Reduced manufacturing cost
 Lower cost per unit produced,
 Greater labor productivity,  Initial set-up cost is high,
 Substantial pre-planning
 Greater machine efficiency,
 Improved quality,  Requirement of skilled labor
 Increased system reliability,  Complicated system
 Reduced parts inventories,  Maintenance is complicated
 Adaptability to CAD/CAM operations.
 Shorter lead times
 Improved efficiency
 Increase production rate
AGV’S

An automated guided vehicle or automatic guided vehicle (AGV) is a portable robot that follows
along marked long lines or wires on the floor, or uses radio waves, vision cameras, magnets, or lasers for
navigation. They are most often used in industrial applications to transport heavy materials around a large
industrial building, such as a factory or warehouse.

Flexible manufacturing transfer line

It is a manufacturing system which consists of a predetermined sequence of machines connected by an

automated material handling system and designed for working on a very small family of parts.

Advantages
 Easy management: low work in progress
and scheduling without simultaneous processing of different
products
 Low need for manpower
 Less space needed (compare with job shop)
 Less output variability: no alternative technological
cycles and quality control is more effective (less WIP and
easier to automate)
 High system saturation: less production mix variability
 Fast lead time.
 High volume of production is possible.

Disadvantages
 Very low flexibility
 Risk of obsolescence: due to new product introduction
 High vulnerability to failures: a failure in a single
machine blocks the whole system in very short time

COMPUTER NUMERICAL CONTROL (CNC)

Today, NC means computer numerical control. Computer numerical control CNC is defined as an NC system whose
MCU is based on a dedicated microcomputer rather than on a hard-wired controller.
Features of CNC
 Storage of more than one part program
 Various forms of program input
 Program editing at the machine tool
 Using programming subroutines and macros.
 Interpolation.
 Positioning features for setup
 Cutter length and size compensation 8.Acceleration and deceleration calculations
 Communication interface
 Main Parts of CNC Machine
The main parts of the CNC machine are
(i) Input Devices: These are the
devices which are used to input
the part program in the CNC
machine. There are three
commonly used input devices and
these are punch tape reader,
magnetic tape reader and
computer via serial data
communication.
(ii) (ii) Machine Control Unit (MCU): It
is the heart of the CNC machine. It
performs all the controlling action
of the CNC machine.

ADVANTAGES OF CNC MACHINES

1. It can produce jobs with highest accuracy and precision than any other manual machine.
2. It can be run for 24 hours of a day.
3. The parts produced by it have same accuracy. There is no variation in the parts manufactured by a
CNC machine.
4. Highly skilled operator is not required to operate a CNC machine. A semi-skilled operator can also
operate accurately and more precisely.
5. Operators can easily make changes and improvements and reduces the delay time.
6. It has the capability to produce complex design with high accuracy in minimum possible time.
7. The modern design software, allows the designer to simulate the manufacturer of his/her idea. And
this removes the need of making a prototype or model and saves time and money.
8. Fewer workers are required to operate a CNC machine and saves labour cost.
DISADVANTAGES TOO
1. The cost of the CNC machine is very high as compared with manually operated machine.
2. The parts of CNC machines are expensive.
3. The maintenance cost in the case of CNC is quite high.
4. It does not eliminate the need of costly tools

Direct Numerical Control (DNC)

a forerunner to CNC, is similar to it. Initially, DNC utilized a large mainframe computer connected to several
N/C machines, controlling the operation of all of them simultaneously. A program for each N/C machine is
loaded into the mainframe computer, and the computer feeds the instructions to each N/C machine as
needed.
 MODULE 3
NC words
Following are the different types of words in formation of block. Not every NC uses all the words
• Sequence number (N-words): This is used to identify the block
• Preparatory words (G-words): This word is used to prepare the controller for instructions that are to follow e.g.
g02 is used for circular interpolation along an arc in the clockwise direction . The preparatory words are needed
so that the controller can correctly interpret that follow it in the block
• Coordinates (X-, Y-, and Z-words): This give the coordinate positions of the tool. In two axis system only two of
the words would be used. In four or five axis, additional a-words and/or b-words would specify the angular
positions
• Feed rate (F-words) : this specifies the feed in the machining operation
• Cutting speed (S-words) : This specifies the cutting speed of the process, the rate at which the spindle rotates.
• Tool selection (T-word) : This control would needed only for machines with a tool turret or automatic tool
changer. The t-word specifies which tool is to be used in the operation.
• Miscellaneous words (M-words): The m-word is used to specify certain miscellaneous or auxiliary functions
which may be available on machine tool E.g. m03 used to start spindle rotation. This word is last in the block.

APT (Automatically programmed Tools)

• This is most widely used and most comprehensive part programming language available. • APT is a three-
dimensional system which can be used to control upto five axes.
• In programming , it is assumed that the workpiece remains stationary and cutting tool does all the movements.
• APT consists of four types of statements
1. Geometry statements: These are also called definition statements and are used to define geometric elements
like point, circle. Arc, plane, etc.
2. Motion statements : The motion statements are used to define cutter path
3. Post processor statements : These statements are applicable to specific machine tools and are used to define
machining parameters like feed, speed, coolant on/off, etc.
4. Auxiliary statements : These are miscellaneous statements used to identify the part, tools, tolerances, etc

INTERPOLATION The method by which contouring machine tools move from one programmed point to the next is
called interpolation. This ability to merge individual axis points into a predefined tool path is built into most of today’s MCUs.
There are five methods of interpolation: linear, circular, helical, parabolic, and cubic.
Linear Interpolation Linear Interpolation consists of any programmed points linked together by straight lines,
whether the points are close together or far apart . Curves can be produced with linear interpolation by breaking them into
short, straight-line segments.
EG :-GO1
Circular Interpolation The development of MCUs capable of circular interpolation has greatly simplified the process of
programming arcs and circles. To program an arc , the MCU requires only the coordinate positions (the XY axes) of the circle
center, the radius of the circle, the start point and end point of the arc being cut, and the direction in which the arc is to be
cut (clockwise or counterclockwise)
EG:- GO2 ,GO3

GCODES
Canned Cycle
A canned cycle is a way of conveniently performing repetitive CNC machine operations. Canned cycles automate
certain machining functions such as drilling, boring, threading, pocketing, etc...Canned cycles are so called because
they allow a concise way to program a machine to produce a feature of a part. A canned cycle is also known as a
fixed cycle. A canned cycle is usually permanently stored as a preprogram in the machine's controller and cannot
be altered by the user.
ADVANTAGES
 The canned cycles allows quicker and easier development of programs at the machine.
 As canned cycles reduce the number of blocks in a program, the storage space occupied by the program
is less and the programmer escapes the tedium of writing the same instructions again and again.
 This reduces the potential for errors, and locating any errors that do exist is easier in a shorter program.
 Job setup is also facilitated by canned cycles. Some canned cycles exist which are designed for use by
machine tool operators for simple job set-up and measuring tasks.
G80 –G89 CANNED CYCLES

Subroutines
It may be defined within programs, or separately in libraries that can be used by many programs. In different
programming languages, a subroutine may be called a procedure, a function, a routine, a method, or a
subprogram. The generic term callable unit is sometimes used.
 MODULE 4

Computer aided design (CAD)

It can be defined as the use of computer systemsto assist in creation, modification, analysis and optimization
• Computer aided machining (CAM)
It can be defined as the use of computer systems to plan, manage and control a manufacturing plant through
either direct or indirect computer interface with the plant’s production resources.
Computer-integrated manufacturing (CIM)
CIM is the integration of total manufacturing enterprise by using integrated systems and data communication
coupled with new managerial philosophies that improve organizational and personnel efficiency.
Computer-Aided Engineering (CAE)
Computer-aided Engineering analysis (often referred to as CAE) is the application of computer software in
engineering to analyze the robustness andperformance of components and assemblies.
Analysis tools are available for
• static stress-strain,
• deflection,
• thermal,
• flow,
• motion,
• vibration

Benefits of CAD
• Productivity improvement in Design
• Shorter lead times
• Reduced engineering personnel requirement
• Customer modifications are easier to make
• Rapid response of the design analysis
• Improved accuracy ofdesign
• Avoidance of subcontracting to meet schedules
• Provide better functional analysis to reduce prototype testing
• Avoidance of subcontracting to meet schedules
• Assistance in preparation of documentation
• Minimized transcription errors
• Designs have more standardization
• Fewer errors in NC part programming
• Better communication interfaces and greater understanding among engineers,
designers, drafters, management and different project groups.
 ROBOTICS
 A robot is a programmable, multi function manipulator deigned to move material,
parts, tools or special devices through variable programmed motion for the
performance of a variety of tasks.
 An industrial robot is a general purpose, programmable machine possessing
certain humanlike characteristics.
What are the parts of a robot?
• Manipulator
• Pedestal
• Controller
• End Effectors
• Power Source
Manipulator (Mimics the human arm)
• Base
• Appendages
o Shoulder
o Arm
o Grippers
Pedestal (Human waist)
• Supports the manipulator.
• Acts as a counterbalance.
Controller (The brain)
• Issues instructions to the robot.
• Controls peripheral devices.
• Interfaces with robot.
• Interfaces with humans.
End Effectors (The hand)
• Spray paint attachments
• Welding attachments
• Vacuum heads
• Hands
• Grippers
Power Source (The food)
• Electric
• Pneumatic
• Hydraulic

ROBOT PHYSICAL CONFIGURATION (Classification of Robots)

1. Cartesian configuration 2. Cylindrical configuration
3. Polar configuration 4. Joint-arm configuration
Cartesian Configuration
 Robots with Cartesian configurations consist of links connected by
linear joints (L). Gantry robots are Cartesian robots (LLL).
Cartesian Robots
 It consists of three orthogonal slides.
 Three slides are parallel to x, y and z axes of the Cartesian coordinate system
Commonly used for:
1. pick and placework
2. assembly operations
3. handling machine tools
4. arc welding
 Cylindrical Robot

Advantages:
a. ability to do straight line insertions into furnaces.
b. easy computation and programming.
c. most rigid structure for given length.
Disadvantages:
 requires large operating volume.
 exposed guiding surfaces require covering in corrosive or dusty environments.
 can only reach front of itself
Cylindrical Configuration
 Robots with cylindrical configuration have one rotary ( R) joint at the base
and linear (L) joints succeeded to connect the links.
Cylindrical Robots
 In this, the robot body is a vertical column that swivels about vertical axis
 The arm consist of several orthogonal slides which allow the arm to be moved
up and down and in or out w.r.t. to body
Commonly used for:
 handling at die-casting machines
 assembly operations
 handling machine tools
 spot welding
Advantages:
 can reach all around itself
 rotational axis easy to seal
 relatively easy programming
 rigid enough to handle heavy loads through large working space
 good access into cavities and machine openings
Disadvantages:
 linear axes is hard to seal
 won‟t reach around obstacles
 exposed drives are difficult to cover from dust and liquids

Page 3
Spherical/Polar Robots
A robot with 1 prismatic joint and 2 rotary joints – the axes consistent with a polar coordinate
system.
Commonly used for:
• handling at die casting or fettling
machines
• handling machine tools
• arc/spot welding

Advantages:
 large working envelope.
 two rotary drives are easily sealed against liquids/dust.
Disadvantages:
 complex coordinates more difficult to visualize, control, and program.
 exposed linear drive.
 low accuracy

Jointed Arm Configaration

 The jointed-arm is a combination of cylindrical and articulated configurations.

 The arm of the robot is connected to the base with a twisting joint.
 The links in the arm are connected by rotary joints. Many
commercially available robots have this configuration.

Page 4
Advantages and Disadvantages of 4 Robot Types

Configuration Advantages Disadvantages

Cartesian 3 linear axes, easy to visualize, Can only reach front of itself,
coordinates rigid structure, easy to program requires large floor space, axes
hard to seal
Cylindrical 2 linear axes +1 rotating, can Can’t reach above itself, base
coordinates reach all around itself, reach and rotation axis as less rigid, linear
height axes rigid, rotational axis axes is hard to seal, won’t reach
easy to seal around obstacles
Spherical 1 linear + 2 rotating axes, long Can’t reach around obstacles,
coordinates horizontal reach short vertical reach
Joined-arm 3 rotating axes can reach above or Difficult to program off-line, 2
Revolute below obstacles, largest work area or 4 ways to reach a point, most
coordinates for least floor space complex manipulator
Basic Motion Systems
Six degrees of
freedom
 It provides the robot the capability to move and perform predetermined task
 These six degrees of freedom are intended to follow the versatility
of movement possessed by the human arm
 The six basic motions consists of three arm and body motions and three
wrist motions
Page 5