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Production Technology on Non-Traditional Machining

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2.0 OBJECTIVES

 To design a basic NC program for Electrical Discharge Machining (EDM) wire cut.
 To learn how to write a basic NC program,
 To learn type of coding in NC program.

 To machine a product using the Electrical Discharge Machining (EDM) wire cut.
 To learn how to fabricate a product by using the Electrical Discharge Machining
(EDM) wire cut.
 To learn how to put the coding manually in the EDM wire cut machine.

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3.0 INTRODUCTION (BACKGROUND & THEORY)

In today’s world science and technology, traditional edged cutting tool-based

machining processes are now being continuously replaced by non-traditional machining
(NTM) processes so as to generate complex and intricate shapes on advanced and harder
materials, like titanium, stainless steel, high-strength temperature-resistant alloys, fibre-
reinforced composites, and engineering ceramics. These NTM processes, while using energy
in its direct form for removing materials from the work piece surfaces, have the capabilities
of meeting some higher level requirements, such as low tolerance, high surface finish, higher
production rate, automated data transmission, miniaturization, and are also quite suitable in
the areas of micro-machining and nano-machining. Selection of the most appropriate NTM
process to generate a desired shape feature on a given work material is often a challenging
task as it involves consideration of diverse machining characteristics and performance of the
NTM processes.

Figure 1: Types of Non-Traditional Machining

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 In this NTM lab, students learnt Electrical Discharge Machining (EDM). Electrical
Discharge Machining (EDM) is a process of metal machining in which a tool discharges
thousands of sparks to a metal work piece. A non-conventional process, EDM works on parts
resistant to conventional machining processes, but only if these parts are electrically
conductive; usually, they are non-ferrous, and include steel, titanium, super alloys, brass, and
many other metals. Instead of cutting the material, EDM melts or vaporizes it, leaving little
debris and providing a very accurate line. Industry-wide acceptance has led to a wide variety
of EDM applications, as it is highly versatile, can cut hard metals, and utilizes a relatively
compact amount of workspace.

However, there are two main types of EDM which are conventional and wire.
Conventional EDM is as described above. It uses a tool to disperse the electric current. This
tool, the cathode, runs along the metal piece, the anode and the electrical current reacts to melt
or vaporize the metal. Wire cut EDM (or WCEDM) discharges the electrified current by means
of a taut thin wire, which acts as the cathode and is guided alongside the desired cutting path,
or kerf. A dielectric fluid submerges the wire and work piece, filtering and directing the sparks.
The thin wire allows precision cuts, with kerfs as wide as three inches and a positioning
accuracy of +/- 0.0002”. This heightened precision allows for complex, three dimensional cuts,
and produces highly accurate punches, dies, and stripper plates.

Wire cut EDM equipment is run by computer numerically controlled (CNC)

instruments, which can control the wire on a three-dimensional axis to provide greater
flexibility. Whereas conventional EDM cannot always produce tight corners or very intricate
patterns, wire EDM’s increased precision allows for intricate patterns and cuts. Additionally,
wire EDM is able to cut metals as thin as 0.004”. At a certain thickness, wire EDM will simply
cause the metal to evaporate, thereby eliminating potential debris. The wire of a WCEDM unit
emits sparks on all sides, which means the cut must be thicker than the wire itself. In other
words, because the wire is surrounded by a ring of current, the smallest and most precise cutting
path possible is the added diameter of the ring and wire; technicians easily account for this
added dimension. Manufacturers continue to produce thinner and thinner wires to allow for
smaller kerfs and even finer precision.

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 Because of its versatility, manufacturers us wire cut EDM functions for an extensive
range of applications. Because the process can cut very small pieces, it is often an ideal choice
for the production of small, highly detailed items that would normally be too delicate for other
machining options. Additionally, the process is cost effective for low quantity projects, and can
prove to be beneficial in prototype manufacturing, even if the actual project is carried out by
different means.

It is important to remember that the wire in the process is constantly moving, and not
to be reused. As a result, the copper, brass or other metallic wire can be kilometres long, adding
to the cost. And, while the process uses no force and thus does not cause burrs and can be used
on delicate items, the possibility of thermal stress is certainly present.

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4.0 APPARATUS

1) EDM wire cut machine

Figure 2: EDM wire cut machine

2) Plate / work piece

 Material: Aluminium
 Size: 250mm × 250mm
 Thickness: 5mm

Figure 3: Aluminium plate

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3) Wire
 Material: Brass
 Diameter: 0.25mm

Figure 4: Brass wire

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5.0 INDUSTRIAL APPARATUS

1. Wire Electric Discharge Machine (EDM) ALN400G by Sodick Company from

Brazil.

Figure 5: Wire Electric Discharge Machine (EDM) ALN400G

The ALN400G, Rigid Linear Motor Driven High-Performance Wire EDM Machine
incorporates Sodick's next-generation SPW (Smart Pulse Wire) control with the Smart Pulse
Generator and technologies that improve cutting speed and precision. The ALN also
streamlines the control design, combining the best functions of both tablet interface and classic
interface into a highly functional work display, improving processing responsiveness.

Specifications:

X - Axis Travel 15.75" (400 mm)

Y - Axis Travel 11.81” (300 mm)
Z - Axis Travel 9.84” (250 mm)
U, V Axis Travel 5.91” x 5.91” (150 x 150 mm)
Wire Diameter Range (min ~ 0.002” ~ 0.012” (0.05 ~ 0.30 mm) (With Available
max) Options)
Work Tank Dimensions (W x 33.45” x 24.01” (850 x 610 mm)
D)
Maximum Work piece Weight 1,102 lbs (500 kg)
Distance From Floor to Table 39.17” (995 mm)
Top
Machine Tool Dimensions 83.27” x 91.93” x 86.02” (2,115 x 2,954.5 x 2,185 mm)
Machine Weight 7.385 lbs (3,350 kg)

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 2. Wire Electric Discharge Machine (EDM) GE-43F by AccuteX from China.

Figure 6: Wire Electric Discharge Machine (EDM) GE-43F

The GE-43F is GE series general wire cut EDM that produced by AccuteX. The machine is the
best cost and performance ratio machine. Its cutting speed is superior to other competitors. Y-
axis is located on the base and X-axis is located on the top of Y-axis, which is suitable for
precise mold cuttings with small or medium stroke. Machine structure was designed via Finite
Element Analysis (FEA) with high rigidity. Direct motor drive in X/Y axes with high servo
response.

Specifications:

Max. Work Piece Size L x W x H (mm) 750 x 630 x 180

Max. Work Piece Weight (kg) 500 kg
X x Y stroke (mm) 400 x 300
U x V Stroke (mm) 60
Z Stroke (mm) 220
Biggest immersion altitude -
Wire Spool Weigh (kg) 10
Foot Print (mm) 2200 x 2400 x 1990
Machine Weight (kg) 2150
Water System Capacity (L) 360

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 3. Wire electrical discharge machine / precision / CNC DEM Series by Direct Industry
from Germany.

Figure 7: Wire electrical discharge machine / precision / CNC DEM Series

Wire electrical discharge machine / precision / CNC DEM Series that produce by Direct
Industry is high precision and quality plus excellent price/performance ratio. There are many
descriptions about this machine:
 great alternative for wire electrical discharge machines - with excellent cutting
performance and cost-effectiveness
 extra rigid cast-iron frame made with stress-free annealing in T Design
THK Precision Linear Guides (Japan) on all axes
 all machines are measured using laser interferometer systems and subjected to strictest
quality controls
 low-maintenance modular construction
 precision preloaded ball screws for lasting mechanical precision
 the PC-based control system with servo drives is fine-tuned to the manufacturing
process requirements, it is user-oriented and reliable
 the pulse generator uses the newest technology for efficient machining
 the two-directional wire guide system is the heart of the machine, featuring perfect wire
feed even with workpieces with large tapers or heights
 the patented 4BLS system simplifies machining of workpieces with tapers up to ±15°,
without sacrificing accuracy or surface quality
 integrated central lubrication
 handheld control for quick machine setup

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6.0 EXPERIMENTAL PROCEDURE

1) Each group was decided what shape that wanted to do.

2) Each group had to use NC program using by M-Code and G-Code.

M-Code Function
M80 Water jack pressure
M82 Wire fit rotation
M84 Machine ready
M02 Program stop
M00 Machine end
Table 1: M-Code and its function

G-Code Function
G90 Absolute programming
G91 Incremental programming
G40 Tool radius compensation off
G41 Tool radius compensation left
G42 Tool radius compensation right
G02 Circular interpolation, clockwise
G03 Circular interpolation, counter clockwise
Table 2: G-Code and its function

3) The program codes were written.

4) The codes were transferred to EDM wire cut machine manually.
5) The work piece was cut automatically by the machine.
6) Finishing process was run to the work piece.

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7.0 RESULT & DATA ANALYSIS

Coding:
L = (….) [the name/code for product. Acceptance for 4 digit maximum]

H1 = 0.156; [specification for current voltage from manual book based on the wire diameter]

E 937 F24.0 H1; [E for current, F for feed rate]

M80; [water jet system on]

M82; [wire feed on rotation wire]

M84; [machine ready]

G91; [type of program for incremental coordinates]

G40; [wire location at the centre]

G01 X0.0 Y0.0; [the wire starts from (0, 0) coordinate]

G01 X3.0 Y0.0;

G03 X1.0 Y1.0 R1.0;

G01 X0.0 Y1.0;

G01 X1.0 Y0.0;

G02 X1.0 Y1.0 R1.0;

G01 X1.0 Y0.0;

G02 X1.0 Y1.0 R1.0;

G01 X0.0 Y1.0;

G02 X1.0 Y1.0 R1.0;

G01 X1.0 Y0.0;

G02 X1.0 Y1.0 R1.0;

G01 X1.0 Y0.0;

G01 X0.0 Y1.0;

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G03 X1.0 Y1.0 R1.0;

G01 X3.0 Y0.0;

G03 X1.0 Y1.0 R1.0;

G01 X0.0 Y3.0;

G03 X1.0 Y1.0 R1.0;

M02; [function for program stop]

M00; [function for machine end]

Figure 8: Result display

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8.0 DISCUSSION OF RESULT

From the experiment, we know that the EDM process has the ability to machine hard,
difficult-to-machine materials. With EDM process, work piece with complex shape, precise
and irregular shapes for forging, press tools, extrusion dies, difficult internal shapes for
aerospace and medical applications can be made.

At the beginning of EDM operation, a high voltage is applied across the narrow gap
between the electrode and the work piece. This high voltage induces an electric field in the
insulating dielectric that is present in narrow gap between electrode and work piece. This cause
conducting particles suspended in the dielectric to concentrate at the points of strongest
electrical field. When the potential difference between the electrode and the work piece is
sufficiently high, the dielectric breaks down and a transient spark discharges through the
dielectric fluid, removing small amount of material from the work piece surface.

There are many advantages of EDM. However, it also has its limitations.

The advantages of EDM are:

 By this process, materials of any hardness can be machined

 No burrs are left in machined surface
 One of the main advantages of this process is that thin and fragile/brittle components
can be machined without distortion
 Complex internal shapes can be machined

The main limitations of this process are:

 This process can only be employed in electrically conductive materials

 Material removal rate is low and the process overall is slow compared to conventional
machining processes
 Unwanted erosion and over cutting of material can occur
 Rough surface finish when at high rates of material removal

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9.0 CONCLUSION

In conclusion, this experiment taught about how to design basic NC program for
Electrical Discharge Machining (EDM) wire cut. G-Code and M-Code are basic codes in NC
program. Each code has its own function. With EDM wire cut, the product that hard or
impossible to make with traditional machining can be made. More complex the shape of the
product will make more longer of coding in the NC program. There are many manufacturer
produce different types of EDM machines. EDM has many advantages traditional machine but
EDM also has limitations. For example, unwanted erosion and over cutting of material can
occur and rough surface finish when at high rates of material removal. During the collection of
the work piece, our product is not found.

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10.0 RECOMMENDATION

The objective of this laboratory are successfully achieved with the help of assistant engineer
and laboratory technicians. Students can understand and acknowledge how to design a basic
NC program for Electrical Discharge Machining (EDM) wire cut and machine a product using
the Electrical Discharge Machining (EDM) wire. However, few improvements need to be taken
in the future such as:

1. Use different materials such as brass or stainless steel.

2. Use different thickness of the plate.
3. Teach students how to run the cutting operation.
4. Use other NTM machine such as water-jet machining.
5. The laboratory experiments should held longer because the shorter time make students
rushing to complete it.

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11.0 REFERENCES

 Groover, Mikell P. (2007), "Theory of Metal Machining", Fundamentals of Modern

Manufacturing (3rd ed.), John Wiley & Sons, Inc., p. 491–504.
 Todd, Robert H., Allen, Dell K., Al ting, Leo (1994), Manufacturing Processes
Reference Guide, Industrial Press Inc., p. 153.
 Kucukturk, G.; Cogun, C. (2010). "A New Method for Machining of Electrically
Nonconductive Workpieces Using Electric Discharge Machining
Technique". Machining Science and Technology. 14 (2): 189.
 Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994). Manufacturing Processes
Reference Guide. Industrial Press Inc. pp. 175–179.
 Jameson, E. C. (2001). Electrical Discharge Machining.
 What is a CNC machine? (2016). Retrieved July 19, 2016, from CNC Machine Training
 Nguyen, Van Khai; Stark, John (2009), STEP-compliant CNC Systems, Present and
Future Directions, Springer.
 Smid, Peter (2008), CNC Programming Handbook (3rd ed.), New York: Industrial
Press.
 Smid, Peter (2010), CNC Control Setup for Milling and Turning, New York: Industrial
Press.
 Reintjes, J. Francis (1991), Numerical Control: Making a New Technology, Oxford
University Press.

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