Discussion 1. What is the meaning of EDM?

Electric discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark eroding, burning, die sinking or wire erosion, is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). Material is removed from the workpiece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-electrode, or simply the tool or electrode, while the other is called the workpiece-electrode, or workpiece. When the distance between the two electrodes is reduced, the intensity of the electric field in the volume between the electrodes becomes greater than the strength of the dielectric (at least in some point(s)), which breaks, allowing current to flow between the two electrodes. This phenomenon is the same as the breakdown of a capacitor (condenser) (see also breakdown voltage). As a result, material is removed from both the electrodes. Once the current flow stops (or it is stopped depending on the type of generator), new liquid dielectric is usually conveyed into the inter-electrode volume enabling the solid particles (debris) to be carried away and the insulating proprieties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is commonly referred to as flushing. Also, after a current flow, a difference of potential between the two electrodes is restored to what it was before the breakdown, so that a new liquid dielectric breakdown can occur. 2. What is the limitation of EDM machining center? 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 material removal.

3. Explain about axes for EDM wirecut machine? EDM wire cut does the machining process in 5 different axes noted as X, Y, Z, U and V. However, the cutting process is only two dimensional (2-D) that is control-X and Y. The X axis controls motion of the work piece table along a horizontal axis from left to right when facing the front of the unit. The Y axis defines horizontal motion from front to back. The Z axis, which consists of the vertical distance between the upper and lower wire guides, is manually adjusted on all but the most sophisticated machines. The next higher level of CNC and possibly the most common-is programmable 4-axis control. Here the X, Y, U, and V axes are under computer control. The U axis corresponds directly to the X axis but represents motion of the upper wire guide rather than the work piece table. Similarly, the V axis of motion in the wire guide is parallel to the Y axis. The 4-axis machine enables the top wire guide to be displaced relative to the lower wire guide and the work piece. This allows generation of tapered or contoured surfaces, such as cones, cylinders, and other similar shapes. 4. Explain about EDM cutting process completely( from start to end process) Wire EDM machining (Electrical Discharge Machining) is an electro thermal production process in which a thin single-strand metal wire in conjunction with de-ionized water (used to conduct electricity) allows the wire to cut through metal by the use of heat from electrical sparks. Due to the inherent properties of the process, wire EDM can easily machine complex parts and precision components out of hard conductive materials. Wire EDM machining (also known as "spark EDM") works by creating an electrical discharge between the wire or electrode, & the workpiece. As the spark jumps across the gap, material is removed from both the workpiece & the electrode.

To stop the sparking process from shorting out, a non conductive fluid or dielectric is also applied. The waste material is removed by the dielectric, and the process continues. In [wire EDM machining], a thin single-strand metal wire, usually brass, is fed through the workpiece. The wire, which is constantly fed from a spool, is held between upper and lower guides. The guides move in the X-Y plane, and sometimes the upper guide can also move independently giving rise to transitioning

shapes (circle on the bottom square at the top). This gives the Wire EDM the ability to be programmed to cut very intricate and delicate shapes. The wire-cut uses water as its dielectric with the water's resistivity and other electrical properties carefully controlled by filters and de-ionizer units. 5. Comment on safety aspect that you have seen concerning this EDM wirecut machine? Some precaution step for EDM wirecut machine:  Set up of the machine must be right such the clamp of the work piece is tightening securely and firmly  Make sure that all tools and machine parts are clear before starting the machine.  If the machine suddenly hanged or running awkwardly, press the emergency button to stop it immediately and suddenly shut down the power supply.  Do not wear rings jewellery when operating the machine. Long sleeve shirts need to be rolled above the elbows.  Make sure work piece, fixturing and table are properly grounded.  The area around the machine must be free of oil to avoid slippery.  Do not use compressed air to clean chips from the table machine surface.  Use the proper hand tools for each job.  Applying guard to cover the moving part so that there is no possible way an operator can create physical contact to it.  Daily maintenance check before each operation on host and fluid tank. The host should be replace according to it maintenance schedule. The floor around the machine area should be keep dry and clean from all excessive fluid  Personal protective equipment such Goggles, face shields and protective clothing can help reducing machine operator expose to hazard.  Warning such as posted sign, signals and instruction shall warn the worker about the hidden hazards, danger-control method or non-obvious consequence. Although they can be inconsistence actual use, the format, size and color of warning have been prescribed by industry standard and governmental codes

Conclusion

The objective of this product is successfully achieved. We learn how to carry out the EDM wirecut process. This machine exposed student to the Numerical Control (NC) programming. We can know the code that use in NC programming. The different code has a different axis to cut. From this experiment we also exposed to the EDM cutting process completely, from stat to the end of process. Students can know the function of every part of machine during the process and this experiment also exposed student to the principle of operation of EDM wirecut. EDM wire cut process is important in automative industry.