INDUSTRIAL TRAINING

STEPTOOLS
SHIVANSHU SINGH
ROLL NO. 20357
DEPARTMENT - ME 1
 ABOUT THE COMPANY
STEPTOOLS
◦ Founded by Mr.Virender ,in 2009.
◦ Currently situated at Kadipur industrial area , Gurgaon
◦ Deals in tools and dies.
◦ Certified manufacturing partner of MINDA GROUPS , JET TECH LTD
, BEST AUTO LTD.

FACILITES AND TECHNOLOGIES

◦ Product and toll design
◦ Tool room
2
 PRODUCTS

Fig 1- Die
Fig 2- Bending die

Fig 3- Punch Fig 4-Punch 3

 NON-CONVENTIONAL MACHINING
◦ A special type of machining process in which there is no direct contact between the tool and the
work piece. In unconventional machining ,a form of energy is used to remove unwanted material
from a given work piece.

◦ Material removal may occur with chip formation or even no chip formation may take place. For
example in AJM, chips are of microscopic size and in case of Electrochemical machining material
removal occurs due to electrochemical dissolution at atomic level.

◦ In NTM, there may not be a physical tool present. For example in laser jet machining, machining is
carried out by laser beam. However in Electrochemical Machining there is a physical tool that is
very much required for machining.

◦ In NTM, the tool need not be harder than the work piece material. For example, in EDM, copper is
used as the tool material to machine hardened steels.
4
Why unconventional machining processes
are used
◦ In several industries, hard and brittle materials like tungsten carbide, high
speed steels, stainless steels, ceramics etc., find a variety of applications.
◦ If such materials are machined with the help of conventional machining
processes, either the tool undergoes extreme wear (while machining hard
work piece) or the work piece material is damaged (while machining brittle
work piece).
◦ This is because, in conventional machining, there is a direct contact between
the tool and the work piece. Large cutting forces are involved and material is
removed in the form of chips. Huge amounts of heat is produced in the work
piece. This induces residual stresses, which degrades the life and quality of the
work piece material.
◦ conventional machining produces poor quality work piece with poor surface
finish .To overcome all these drawbacks, we use unconventional machining
processes to machine hard and brittle materials.

5
 Classification of non-traditional
machining processes
Classification of NTM processes is carried out depending on the nature of
energy used for material removal. The broad classification is given as follows:

• Mechanical Processes
◦ Abrasive Jet Machining (AJM)
◦ Ultrasonic Machining (USM)
◦ Water Jet Machining (WJM)
◦ Abrasive Water Jet Machining (AWJM)

• Electrochemical Processes
◦ Electrochemical Machining (ECM)
◦ Electro Chemical Grinding (ECG)
◦ Electro Jet Drilling (EJD) 6
◦
• Electro-Thermal Processes
◦ Electro-discharge machining (EDM)
◦ Laser Jet Machining (LJM)
◦ Electron Beam Machining (EBM)
◦ Ion Beam Machining (IBM)
◦ Plasma Arc Machining (PAM)

• Chemical Processes

◦ Chemical Machining (CHM)

◦ Photochemical Machining (PCM) etc

7
 ELECTRIC DISCHARGE MACHINING
◦ EDM is one of the important non-traditional machining processes.
◦ EDM is also known as “spark machining” as it uses repetitive
electrical discharges to remove metal.
◦ The EDM machine uses spark discharges that are fast, repetitive,
and controlled for cutting.
◦ This process works with electrically conductive metals.
◦ Process is specially suited for contours and cavities that are not
possible with other cutting tools.

8
Different types of EDM:
◦ Ram EDM-
In ram EDM, a graphite electrode is used along with traditional tools. This electrode is
connected to the ram with the help of a power source and is fed into the work piece.
The whole process is carried out in a fluid bath. The fluid helps to flush away the
material, serves as a coolant to reduce the heat, and acts as a conductor for passing
current between the work piece and the electrode.

◦ Wire EDM –
In this method, a thin wire is used as an electrode. The wire is fed in the metal
and the discharges are used to cut the material. The process is carried out in a
bath of water. When closely observed, you can see that the wire does not
touch the metal. All the cutting work is done by the electrical discharge.

9
4- AXES WIRE CUT EDM
Model: SUPERCUT 734 (ELECTRONICA M/C TOOLS LIMITED)

10
 SPECIFICATIONS
◦ Travel Range:
Longitudinal - Y-axis - 400 mm V-axis - + 40 mm

Lateral - X-axis - 300 mm U-axis - + 40 mm

Vertical - Z-axis – 225 mm

◦ Table Size: 110 X 450 X 650 mm

◦ Maximum work piece size: 400 X 300 X 200 mm
◦ Maximum work piece weight: 400 kg
◦ Wire diameter (Standard): 0.25 mm
◦ Maximum taper angle: + 150 /100mm

11
Feed:

• Main table feed rate: 170 mm/min

• Resolution: 0.001 mm

• Wire feed rate: 0-10 m/min

• Wire tension: 1.5 kgf

Dielectric: Distilled water

12
Parts of Wire cut machine
1. Machine tool
2. Power supply
3. Dielectric Supply
4. Part programming

13
 Machine tool

◦ machine tool unit comprises of a main work table (called X-Y table) on which the work
piece is clamped,
◦ an auxiliary table (called U-V table) and wire drive mechanism.
◦ U & V are parallel to X & Y axes respectively.
◦ When X-Y table moves along the predetermined path, the U-V table is kept stationary
as stationary cut with the predetermined pattern is formed.
14
Power supply
Power supply unit comprises of

electric pulse generator

motor drive unit for X-Y, U-V axes
controller

CONTROLLER

15
Dielectric Supply

While the machining is continued, the machining zone is

continuously flushed with chilled distilled water through the nozzle
on both side of work piece.
The spark discharge across the work piece and the wire
electrode causes ionization of the water which is used as a
dielectric medium.
It is important to note that ionization of water leads to the
increase in conductivity of water.
An ion exchange resin is used in dielectric distribution system in
order to prevent the increase in conductivity of water.
16
Part programming
◦ The geometry of the profile and the motion of wire electrode tool
along the profile are fed to the part programming system using
keyboard,
◦ The profile geometry is defined in terms of various geometrical
definition of points, lines and circles as the wire tool path
elements on graphical screen by using a totally menu driven
software.
◦ After successful profile definition, the profile is recorded by the
computer on a floppy disk which can be used in the controller for
the execution.

17
Work piece material
◦ Any slight dislocation in the work piece material may result distorted job.
◦ It is important to use the material free from residual stresses, arising from various
processes. This may affect the machining accuracy to a very large extent.

Work piece material should be

◦ Electrically conductive (at least 0.1 micro-ohm/cm)
◦ Suitable for clamping
◦ Non-combustible
◦ Non-violent chemical reactions with water, oxygen and hydrogen

18
Wire electrode
◦ The wire electrode is required to have a sufficient tensile strength and should be of
uniform diameter and free from kinks and twist.

The electrode wire material should be

◦ Brass/super alloy (coated)
◦ Diameter variation within + 0.02 mm
◦ Tensile strength more than 50 kgf/mm2
◦ Even winding free from kinks/breaks

Fig 5-Wire Roll

19
WATER DI-ELECTRIC
Characterization & suitability of wire cut medium

◦ The use of water as dielectric permits widening of spark

gap to minimize short circuit, resulting in high cutting
speed.
◦ Water has good wire electrode cooing effect (than
kerosene as example).
◦ It is non flammable and its vapours are non-toxic.

20
SETTING UP AND OPERATIONS
1. Job mounting
2. Dialing
3. Job reference point
a. Edge finding (EF)
b. Center finding (CF)

21
Job mounting & Dialing
◦ Mount the job and damp by maximum possible clamp.
◦ dial the top surface of the job by dial gauge.
◦ The dial gauge can be marked on the upper flushing assembly.
◦ Make the wire vertical with the help of vertical block provided with the machine.

Fig 6- Dialing of block 22

Job reference point
◦ It is always desirable to have a reference point on the work piece for setting the work
co-ordinate system (WCS).
◦ The reference point can be defined by the ground edge of the work piece or the
centre of the bored hole on the work piece.
1. Edge finding (EF):

Fig 7: Edge Distance Fig 8-Edge finding

23
*This function should be used to find the edge for the setting work
co-ordinate system.

*Find the edge of the work piece from a distance of 2-5 mm

*After edge finding the wire system is always from the work piece
edge by a distance equal to wire radius.

24
Center finding (CF):
◦ This function should be used to find the centre of the reference
hole. Centre finding should be repeated at least few times to
verify consistency.

Fig 9-Centre finding 25

Advantages:
◦ Enable high accuracy on tools and dies.
◦ Useful process for metal saving.
◦ It is quicker process for intricate shapes.
◦ Fine holes can easily be drilled.
◦ Any shape can be imparted to the tool can be produced on
work.
◦ Weaker section can be machined.

26
Disadvantages:

◦ Capacity to machine small pieces only.

◦ Unsuitable for machining of non conductors.
◦ Thermal distortion may take place during machining.
◦ Inability to produce sharp corners.

27
APPLICATION
◦ In tool manufacturing industries (hard to machine
metal).
◦ Re sharpening of cutting tools and broaches.
◦ Trepanning of holes with straight and curved curves.
◦ Machining of cavities for dies and re machining of die
cavities without annealing

28