PROJECT-EXPERIMENTAL INVESTIGATION DURING ELECTRIC

DISCHARGE MACHINE WITH COPPER SILICON CARBIDE POWDER

METALLURGY ELECTRODE

SUBMITTED BY:

GOPAL (1801364)

VAIBHAV MAHAJAN(1810396)

HARSH(1801368)

SHUBHAM (180392)

UNDER THE GUIDANCE OF:

Dr. SANDEEP GANDOTRA

 INTRODUCTION
 Today’s manufacturing industry is facing challenges from advanced difficult-to-machine materials (tough super
alloys, ceramics, and composites), stringent design requirements (high precision, complex shapes, and high surface
quality), and machining costs.

 Advanced materials play an increasingly important role in modern manufacturing industries, especially, in aircraft,
automobile, tool, die and mold making industries.

 Traditional machining is most often based on removing material using tools harder than the work pieces. In
addition to the advanced materials, stringent design requirements also pose major problems in manufacturing
industry.

 More and more complex shapes (such as an aerofoil section of a turbine blade, complex cavities in dies and molds,
non-circular, small, and curved holes), low rigidity structure, and micromechanical components with tight
tolerances and fine surface quality are often needed. Traditional machining is often ineffective in machining these
parts.
 EDM THEORY
 The origin of electrical discharge machining (EDM) dates back to 1770 when English scientist Joseph Priestly
discovered the erosive effect of electrical discharges.
 During the 1930s, attempts were made for the first time to machine metals and diamonds with electrical discharges.
Erosion was caused by intermittent arc discharges occurring in air between the tool electrode and work piece
connected to a DC power supply. These processes were not very precise due to overheating of the machining area
and may be defined as “arc machining” rather than “spark machining”.

 However, it was only in the 1980s, with the advent of Computer

Numerical Control (CNC) in EDM that brought about tremendous
advancement in improving the efficiency of the machining operation. Due
to continuous process improvement, modern EDM machines have
become so stable that these cacontrol sn be operated round the clock
under monitoring by an adaptive ystem. This process enables machining
of any material, which is electrically conductive, irrespective of its
hardness, shape or strength.
 LITERATURE
 EDM can be described as a process for eroding and removing material by transient action of electric sparks on
electrically conductive materials immersed in a dielectric liquid and separated by a small (μm) gap.

 Electrical energy in the form of short duration impulses with a desired shape is supplied to the electrodes.

 It is well known that erosion on the electrode surfaces is mainly due to the thermal effect of an electrical discharge.

 The amount of heat generated within the discharge channel is predicted to be as high as 1017 W/m 2 and thus, could
raise electrode temperatures locally up to 20 000 K even for short pulse durations.
 Therefore, melting, vaporization and even ionization of the
electrode materials occur at the point where the discharge takes
place.
 Applying consecutive spark discharges with high frequencies
and driving one electrode towards the other erode the work
piece gradually in a form complementary to that of the tool
electrode.
 Surface Roughness
 Surface roughness, often shortened to roughness, is a measure of the texture of a surface. It is quantified
by the vertical deviations of a real surface from its ideal form. If these deviations are large, the surface is
rough; if they are small the surface is smooth. Roughness is typically considered to be the high frequency,
short wavelength component of a measured surface (see surface metrology).

 Rough surfaces usually wear more

quickly and have higher friction
coefficients than smooth surfaces (see tribology).
Roughness is often a good predictor of the
performance of a mechanical component, since
irregularities in the surface may form nucleation
sites for cracks or corrosion. On the other hand,
roughness may promote adhesion.
 TALYSURF STYLUS TYPE SURFACE ROUGHNESS CHECKER

 A diamond stylus is moved vertically in contact with a sample and then moved laterally across the sample for
a specified distance and specified contact force. A profilometer can measure small surface variations in
vertical stylus displacement as a function of position. A typical profilometer can measure small vertical
features ranging in height from 10 nanometres to 1 millimetre.

 The radius of diamond stylus ranges from 20

nanometres to 50 μm, and the horizontal resolution
is controlled by the scan speed and data signal
sampling rate. The stylus tracking force can range
from less than 1 to 50 milligrams.
 PROBLEM FORMULATION
 To fulfill the objective of present experimental investigation will be performed on EDM using mixer of copper &
silicon carbide as electrode. Electronica make smart ZNC Electric Discharge Machine tool will be used for
conducting the experiments. The existing dielectric circulation system of the EDM machine needs about 60 liters of
dielectric fluid in circulation.

 We perform 22 experiments on EDM with by varying different perimeters like value of peak current, voltage ,
pulse on time and by changing the polarity of electrode.

 We perform these all 22 experiments with the electrode which have 20% composition of silicon carbide in copper.

 Experiments are performed by varying the process input parameters and the observations are recorded for
each experiment. The output parameters are calculated using these observations and mathematical relations.

 The surface roughness is also checked at the end of all experiments using Talysurf Stylus Type Surface
Roughness Checker
 EDM Processing Parameters

Electrical parameters:
• Peak current
 
• Supply voltage
 
• Pulse on time

Electrode based parameters:

• Material of electrode
 
• Size of electrode
 PROBABLE RESULTS
1. EFFECT OF CURRENT:-

2. EFFECT OF VOLTAGE:-
3. +VE POLARITY:-
4. -VE POLARITY:-
5. EFFECT OF PULSE ON TIME:-

i. FOR WORKPIECE:-

ii. FOR ELECTRODE:-

6. EFFECT ON SURFACE ROUGHNESS:-

i. EFFECT OF CURRENT:-

ii. EFFECT OF VOLTAGE:-

 REFERENCES
BOOKS:-

1. MODERN MACHINING PROCESSES: by Dr. P.C Pandey and Dr. H S Shan In 1980.
 
2. POWDER METALLUGY TECHNOLOGY By G. S. Upadhyaya in 1997

3. EDM Manual By Carl Sommer, Steve Sommer in 19992

 

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