POLITEKNIK MERLIMAU

DEPARTMENT OF MECHANICAL ENGINEERING

DJJ40142 MECHANICAL WORKSHOP PRACTICE 4

Upon completion of this course, students should be able to:

CLO2: Construct programs for EDM and CNC machining process using ISO codes or any related
machining software. (P5, PL03)

PLO3: Apply appropriate techniques, resources, and modern engineering and IT tools to well
defined engineering problems, with an awareness of limitations (P5)

1.0 Title Computer Numerical Control Electrical Discharge Machine (CNC and EDM Wire Cut)
2.0 Objective To understand the CNC and EDM machines according to prescribed procedures/
manual and write CNC program

3.0 Apparatus CNC Machine, EDM Wire cut, Mastercam 2022-2023 software

4.0 Theory
The CNC milling process begins with the creation of a 2D or 3D CAD part design. The finished design
is then exported to a CNC-compatible file format, where CAM software transforms it into a CNC machine
programme that directs the machine's operations and the tooling's motions over the workpiece. The
workpiece is fixed to the machine's work surface (i.e., worktable) or workholding device (i.e., vise) before the
operator starts the CNC programme, and the milling tools are attached to the machine spindle. Depending on
the specifications and needs of the milling application, horizontal or vertical CNC-enabled milling machines
are used, as well as spinning multi-point (i.e., multi-toothed) cutting tools like mills and drills. The machine
starts spinning the cutting tool at speeds up to thousands of RPM as soon as the CNC milling process is
started. As the tool cuts into the workpiece, the machine will carry out one of the following operations to
create the required cuts on the workpiece, depending on the type of milling machine used and the needs of
the milling application.

Schematic Diagram of CNC

 Schematic Diagram of EDM Wire Cut

The wire-cut EDM is a discharge machine that uses CNC movement to produce the desired contour
or shape. It does not require a special shaped electrode, instead it uses a continuous-traveling vertical wire
under tension as the electrode. The electrode in wire-cut EDM is about as thick as a small diameter needle
whose path is controlled by the machine computer. It removes metal by producing a rapid series of repetitive
electrical discharges.

5.0 Work Procedure

5.1 Machining Procedures

1) The conductive work piece is mounted to the machine and the work piece is secured to the table in such
way that the electrode can make the desired cut path without interference either from the work piece, or
the work holding device.

2) The material needs to be removed and the part should be tightly fastened to table to ensure that it
remains in place during the process.

3) The work piece must be aligned relative to the machine axis that consists of X, Y, Z, U and V axes.

4) The ball indicator is usually attached and the work piece is adjusted until it is vertical and parallel within
the desired tolerance.

5) The machine coordinate system has to be set to the appropriate position after the work piece is
secured to the machine table and aligned to machine axes.

6) The wire electrode is positioned to work piece.

7) The brass electrode while being spooled off and under tension is brought within a close proximity of the
work piece edge.

8) The edge position command and designate is executed to the appropriate axis.

9) The process for the cutting had been program using G and M codes.

6.0 CNC Program Data Analysis

Part 1: Write program code for diagram shown below
Drawing 1 (EDM Wire Cut)

Drawing 2 (EDM Wire Cut)

Written down the Codes obtained by Software into table below.

Program Code Drawing 1 (EDM Wire Cut)

Absolute (G90) Incremental (G91)

Program Code Drawing 2 (EDM Wire Cut)

Absolute (G90) Incremental (G91)

Discussion

1) Explain step by step process of CNC and EDM Wire Cut of both Picture above with photo screenshot and
explanation from start drawing until obtained G-Codes.
2) Explain the function of CNC and EDM Wire Cut machine
3) Determine FOUR (4) main parts / operating system of CNC and EDM Wire Cut machine and its function
4) Describe the program language used for your CNC program
5) Is there any error / mistake during your workshop work? If yes, describe the error / mistake and justify
your recommendation to it.
6) Discuss the advantages of electrical discharge machining compare to other machining process

8.0 Conclusion

Conclude your workshop practice

9.0 Reference

Prepared by, Verified by,

(AKBAR BIN OTHMAN) (KHADIJAH BINTI ZAINUDDIN)

Lecturer Head of Mechanical Engineering Programme
Department Mechanical Engineering Department Mechanical Engineering

Date: 5/09/2023