EDM NOTE ASSIGNMENT EDM-DIE SINKING

1. Spark Gap = Ø work piece - Ø electrode

2
= ____ mm
= ____ µm
E-Cu (Ø25mm)
2. Refer to Technology Table (VDI : 37 for 240 µm)
3. From Table, take the initial VDI start for machining process
Δ VDI = ?
Ø25.5mm
4. Form the VDI sequences Table

VDI SPARK GAP (mm) CUT POINT (mm)

37 0.24 -1.76 3 mm-axes (z)
(Depth)
36 0.225 -1.775
35 0.195 -1.805
ΔΔ VDI = ? 90 mm-axes (y)
5. Cut point = Spark Gap (Every VDI) – Depth

Example : 50 mm-axes (x)

Cut Point = 0.24 – 2
= -1.76 mm ( -ve is for direction)

6. The EDM program for machining process Based on the diagram above, the students need to be prepared one EDM
program using G00, G69, G11 and G74 for machining process.
G00 (Rapid Traverse)
G00 Z=20.0 X=30.0 Y=20.0 EDM – ELECTRICAL DISCHARGE MACHINE

G69 (Selection of Erosion Setting) X (VDI) U(Criterio) Electric Discharge Machining (EDM), sometimes colloquially also
W(Techno) referred to as spark machining, spark eroding, burning, die sinking or
G69 X 37 U3 W0 wire erosion, is a manufacturing process whereby a wanted shape of an
object, called work piece, is obtained using electrical discharge (sparks).
G11 (Erosion) X -1.76 The material removal from the work piece occurs by a series of rapidly
recurring current discharges between two electrodes, separated by a
G74 (SPR) Start Point Return dielectric liquid and subject to an electric voltage. One of the electrodes
is called tool-electrode and is sometimes simply referred to as ‘tool’ or utilization almost in all fields, such as education, engineering,
‘electrode’, whereas the other is called work piece-electrode, commonly fabrication and other field.
abbreviated in ‘work piece’. When the distance between the two
electrodes is reduced, the intensity of the electric field in the volume Started since 1940
between
2.0 TYPE OF EDM
CNC (Computer Numerical Control) is the computer machine that been
used in controlling the various machine in the industrial environment SINKING A) DRILLING
today. Its function is to control others machines, coz of this situation B) DIE SINKING
mostly of the workers is not been used anymore to operate the machine.
CUTTING A) SLICING (ROTARY DISC,RIBBON/BLADE)
CNC mostly been used in the steel works to control all the mechanical B) CUTTING WITH WIRE (WIRE-CUT)
system for machining and cutting the metal. The thickness and length of
the metal sheet could be manipulated and set up by the CNC machine. GRINDING A) EXTERNAL
B) INTERNAL
1.0 HISTORY OF CNC & EDM C) SURFACE

CNC stand for Computer Numerical Control, CNC system is been
implemented and operated to automatic control the industrial world
today. Its function is to control other machine simultaneously coz of
this, CNC machine used less worker to operate many machine. Many
CNC machine been used in the metal industrial to control the
mechanical system of the applied machine and metal cutter. This CNC
machine could be programmed with suitable instruction such as G00 for
Rapid Traverse or G69 for Erosion Setting.
Started as early 1952 by John Pearseon from Institution Technology of
Massachusetts, or US Air Force. Since 1973, the CNC Machine is still
too expensive. That situation affected the usage of this technology and
retarded the development process.
In year 1973, CNC machine is still very expensive until some industry
that have courage in leading with this technology. From year 1975,
CNC machine's production developed so fast. This development is
speed up by microprocessor development. Today, CNC machine
3.0 EDM PRINCIPLE
THE DEFINITION:
EDM is the system that used the electrical energy to discharge the metal
from work piece in melting or vaporization method for the selected area.
Also been known as electro discharge or spark erosion based on erosion
of metals by spark discharge.
BASIC PRINCIPLE:
In EDM process, the metal will disperse from the work piece coz by the
reaction of electrical charge that react in continuous mode between
electrode (cutting tool) and work piece inside dielectric fluid.
In this process, electrode acting as negative source (cathode) and work
piece as positive source (anode) will make interaction between these
sources. The work piece will melt coz by spark and will make a mould
on the work piece surface, the mould will appear like electrode surface.
 The Advantages and Disadvantages of EDM
THE MAJOR COMPONENTS OF EDM
The Disadvantages
1. Low material removal rates compare to metal cutting
2. Electrode smaller than 0.07mm are impractical
MOVABLE
ELECTRODE
3. The material to be machined must be electricity conductor
4. Rapid electrode wear are costly
CURRENT
POWER CONTROL The Advantages
SUPPLY
TANK 1. Burr free edge are produced
WORKPIECE 2. Broken drill and tap can be easily removed
DIE ELECTRIC FLUID 3. One person can operate many machine
4. Better dies and mould can be produced
5. Secondary process can be eliminated

How EDM cuts Metal

The basic features of Electric Discharge (ED) machine are;
i. Bed 1. During machining process sparks occur at
ii. Table
iii. Slides
iv. Dielectric system
v. Servomechanism

Power Supply Unit: Its function is to convert the AC Electric Supply to

DC Electric Supply to ignite the sparks. To control current voltage and
electrode polarization.

Work Table : Is mounted on orthogonal slide-ways is complimented

with optical scales for positioning the work piece to an accuracy
approaching. Located in the Worked Tank, its function is to hold the
work piece and sinking in die electric fluid during machining process.