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WARRANTY CERTIFICATE

M/C Model: Electrical Discharge Machine Model M-25-6040 (25 Amps)


SR.NO:-007/14
NAME: -

IMAX ASSOCIATES

Date:-22/12/2014

Warranty is for 15 months from date of dispatch or 12 months from date of


installation whichever ends early. Warranty is not covered for machines working in
following condition :1. faulty power source
2. Supply voltage variation more than 415 V. AC 3 Phase 10%, 50HZ frequency
0.5 with independent neutral from main incoming supply.
3. Voltage between earth & neutral more than 2 Volts.
4. Machine run on CONVERTED POWER From 1 phase to 3 Phase.
5. Machine placed in unventilated Area.
6. International Abusive Use of machine to malign machine performance.
7. Caused by any terrorist or any person motive.
8. Damages due to natural calamities. Like earth quake, fire, riot, flood, etc.
9. The warranty will automatically gat invalid, if the machine is opened, repaired,
modified by any unauthorized person.

AUTHORIZED SIGNATORY

EDM Principles and Technology


The EDM Process Takes Place In The Work Tank Filled With Dielectric Fluid. The
Object To Be Cut Or Machine Is Called The Work Piece; Where as the Cutting Tool Is An
Electrode. Both Are Submerged In the Dielectric Fluid and separated By a Very Small
Gap.
During Machine, Voltage Applied To The Work Pieces An The Electrode Creates a
Strong Electrical Potential. Due to The gap between the two and the insulator flooding it,
there is no spark or arc. The servomechanism continues to reduce the gap until a spark
occurs. Actually duration of ground one second is long enough for several thousand
spark.
At the point when the spark occurs, the current is converted in to heat and the work
piece is strongly heated. It the current is interrupted, the discharge channel explosively
evaporates, carrying away melted material from the work piece. The leaves a Small crater
should discharge reuse the crater will grow, removing more and more material. Since
there is no contact between cutting tool and work piece and no physical force applied, the
shape being cut will exactly match the shape of the electrode.
Now well try to understand the physical characteristics of EDM. When voltage is
applied to the electrode and the work piece an electrical field forms as the voltage build
up. Conductive Particles present in the fluid collect when the field is strong and form a
bridge of discharge channel. At the same time negative particles are emitted from the
electrode, which impact neutrals, particles on the discharge channel and split forming
positive particles. This Process is Called impact ionization. The negatives flow toward
the positive and the positive flow toward the Negative And Electrical current is
established. The current increases to the maximum, temperature and pressure peak
(temperature are around 3600c ) and the vapor bubble expand greatly.
When the current is interrupted the discharge particles collapse and the vapor bubble
evaporates. The dielectric fluid cools the high temperature metal and flushes away the
particles. Some graphite and gas are produced as break down products from the fluid.
Now we understand the principles and physical characteristics of EDM. There are many
factors that influence EDM efficiency; for example, polarity selection, matching of
amperage and duration. Electrode wear may vary from 0.1% to 200% depending on these
factors. Careful control of these variables, gap, polarity, amperage & duration is essential
for machining at maximum efficiency.

ELECTRODE MATERIAL
Theoretically, all conducting materials can be used. Material with the highest melting
point and the lowest electrical resistively are, in theory, the best. Cost analysis show that,
In EDM, electrode material; the quantity and the method of manufacturing are important
Factor and deserve careful consideration.

Electrode Materials Can be divided as Follows:

Silver tungsten
Copper tungsten
Copper graphites ( combination of metallic and non metallic material )
Chromium Copper
Electrolytic copper
Graphites ( non Metallic material)
Brass
Aluminum alloy
Steel

Of all above, electrolytic copper is most popular. Silver tungsten, copper Tungsten is
both quite expensive, so their use is limited to vary small & high precision parts.
After cost, other important factors in electrode selection are low wear and ease of
electrode manufacturing.
Graphite features low electrode wear and high removal rate but due to low density, it
breaks easily. When fine finish is not required we recommend graphite. Steel can be
used as an electrode but the efficiency is lower than that of copper or graphite. Its
most important EDM application is in the machining of split lines plastic mold and
dies. In these cases, the upper part of the mold or the die is used as the electrode.

1 ELECTRODE MATERIAL CHARACTERISTICS


Electrode Material
Silver tungsten
Copper Tungsten
Copper Graphite
Chromium Copper
Electrolytic Copper
Graphite
bronze
Aluminum alloy
steel

Melting point c

Resistively
mm2/m
0.048
0.055
0.04
0.0236
0.0167
0.085~0.015

1083
3700
1060
~650
1539

0.0971

Density G/mm3
0.016
0.015
0.027
0.0081
0.0089
0.0015~0.0018
0.0082
0.0028
0.0087

2 PRODUCTION METHOD ELCTRODE


Traditional machining methods such as turning, milling, shaping,
grinding, engraving etc
Stamping coining.
Extrusion or drawing.
Galvanic plating.
1.The Above Production Methods are All suitable. Selection of One depends
on Electrode Material. When designing an electrode, special attention should
be paid to the flushing of particles to ensure high removal rate.
2. If the electrode shape is vary complex or convoluted, it may be produced
in two parts.
3. irregular shapes must be centered on easily measured axis.
4. long, thin electrodes must be installed with current supplied to the ends as
well as, the center, there by ensuring even discharge over the whole length.
(Fig.1 )
5. small diameter holes require pipe electrodes to ensure efficiency in
Flushing and draining. ( Fig. 2 )

CHAPTER 3. EDM APPLICATION


EDM application depend on a skilled operator. It is necessary to analyze all EDM factor
to produce high quality work..

Electrodes Material.
Work piece Material.
Surface roughness.
Spark gap.
Electrode Wears.
Removal Rate.

During sparking ( discharge ) the gap area must be flushed continuously to gat rid of
particles and residue.
If Flushing and Draining of the cavity is not good enough, increase the servo to a higher
setting. To get fine finish the vertical movement must be vary fast.
To achieve low or no electrode wear, start with a low discharge amperage, and as soon as
the whole area of the electrode contacts the work piece, increase the amperage. This will
Protect Sharp Corners or Angels.
To Set servo sensitivity bear in mind that sensitivity depends on the current; when the
current is low, servo is of small amplitude but high sensitivity.
Know & understand the discharge process.
3. DISCHRGE OPERATION PROCESS

TURN ON MAIN SWITCH.


SET-UP ELECTRODE, ALIGNMENT.
FIND REFERNCE IN X-Y-Z AXES.
ON PUMP, ADJUST LEVEL CONTROL.
SPARK ON.
CHECK V & A METERS.
MAKE SURE THE PERFORMANCE IS STABLE.

CHAPTER NO.4. POWER SUPPLY OPERATION INSTRUCTIONS


SURFACE / CURRENT TABLE.

SURFACEES AREA

Suggested current (A)


Cu+
( Electrodes )
Cuw+

Gr+
( Electrodes )
Gr-

0 mm~ 10 mm

3A ~ 6A

3A ~ 6A

10 mm ~ 25 mm

6A ~ 12A

6A ~ 12A

25 mm ~ 100 mm

12A ~ 21A

12A ~ 21A

100 mm ~ 400 mm

12A ~ 45A

21A ~ 45A

400 mm ~1600 mm

21A ~ 60A

45A ~ 60A

1600mm ~ 6400mm
6400mm

21A ~ 60A
21A ~ 60A

60A ~ 120A
120A

1. Set the Appropriate duration & amperage to produce the desired finish. Rmax
=0.5~ .8 m can be reached at at = 2 s, Where as at =500s can Produce
Rmax = 90~120m.
2. With The duration longer than 50us, duration & amperage can be Matched in
direct ratio to permit machining with no electrode wear.
When duration is short, and current high, electrode wear increases.
3. Since different material have different characteristics, its Necessary to use
Different duration setting according to the tables in the application note.

4-1.

SPARKS OFF SETTING.

1. Duty cycle is the off time between two pulses when no impact ionization occurs
and dielectric condition are re- established. Usually when the discharge is stable
And interval is short, efficiency is high and a protective coating will form on the
electrode. If the flushing is poor, particles are not removed and machining
efficiency decreases. So, its necessary to set the servo to raise the electrode
periodically to permit flushing.
2. No matter whether the interval is short and the amperage high or the interval is
long and the amperage low, the voltage must not change.
3. The length of the interval must be set according to the material characteristics to
get the highest efficiency.
4. T-OFF ( duty cycle ) Function:
1. T-OFF ( duty cycle ) in 1 for high speed machining.
2. If machining is unstable, adjust T Off ( duty Cycle) manually to increase
off time.
3. when amperage is too high for corresponding electrode frontal area adjust
T-Off ( duty Cycle) to increase off time, use the chart no. -3.
4-2

SERVO SENSITIVITY SETTING.


1. Servos adjustment affects the velocity of electrode movement and must be
synchronized with discharge duration. When the voltmeter pointer is steady
synchronized is Achieved.
2. The servo monitors the discharge gap during discharge. Maintaining the proper
gap is one of the most important factors in EDM. So, we have vary carefully
designed this system to enable the most difficult work.

4-3. DISCHARGE GAP SETTING.


1. Gap voltage about 50V; suitable for finish over large areas or deep holes where
flushing is vary difficult.
2. Gap Voltage about 45V; gap is smaller but the current is higher, efficiency is high,
suitable for normal work
4-4 WORK TIME / LIFT TIME SETTING
1. Use WORK TIME / LIFT TIME SETTING for removing particles and improving
Machining speed.
2. WORK TIME / LIFT TIME SETTING shorter for quick motion when finishing.
3. Set WORK TIME longer for slow motion when roughing/medium roughing. (At 1
WORK TIME / LIFT TIME SETTING Is shorter & at 99 both are longer )

CHART NO. 5: PEAK CURRENT AND REAL MACHINING


A. low sparking, current, slow machining speed . High sparking current,
faster machining speed.
B. Using copper as electrode, the wear will increase according to machining
speed. But if using graphite as electrode, the wear is not exactly same as
copper ( depends on grade of graphite material ). At a same current out put
field, the wear is nearly same.
C. The surface
parameters.

finishing and sparking gap depends on the sparking

Sr
no.

On time Position

Current
maximum

Operation

Material

1.

10 to 20

Full

Roughing

Copper to Steel

2.

25 to 35

10 to 12 Amp

Semi finishing

Copper to Steel

3.

35 to 55

7 to 8 Amp

Finishing

Copper to Steel

4.

65 to 95

1 to 5 Amp

Super finishing

Copper to Steel

Electrode material

Melting point C

Rsistivity
mm2/m

Density G/ mm3

Silver tungsten

0.048

0.016

Copper tungsten

0.055

0.015

Copper graphite

0.04

0.027

Chromium Copper

0.0236

0.0081

Electrolytic Copper

1083

0.0167

0.0089

Graphite

3700

0.085 ~ 0.015

0.0015 ~ 0.0018

Bronze

1060

0.0082

Aluminum Alloy
Steel

1539

0.0971

0.0087

CHART 6 : ELECTRODE MATERIAL CHARACTERISTICS

CHART NO. 7: POWER SUPPLY UNIT.

TYPE
Supply Voltage.

M - 20

M - 35

415V, 3 Phase, 50 HZ

Mains Voltage tolerance.

5%

Open gap output Voltage


(V).
Power Factor.

65 5%

Connected Load (KVA).

Approx. 0.8
2 KVA.

Machining Current Max ( 20 Amps


Amps ).
Current Range Selection. manual
Pulse On Duration
Weight.

M - 50

3 KVA.

4 KVA.

35 Amps

50 Amps

manual

manual

2 to 5000s
70 kg Approx. 80 kg Approx.
10

90kg Approx.

Maruti Machine Tools


Vadodara

EDM Controller Instruction Manual

11

FUNCTION KEYS
1.PUMP : Used To Make Pump On/ Off.
2.SPARK : Used To Make Spark Function On/Off.
3.ATPS

: Used To On Manual Auto Position Function On/Off.

4.UP

: Used To On Manual UP Motion.

5.DOWN : Used To On Manual DOWN Motion.


6. BUZZ : Used To Make Buzzer Function On /Off.
7. AMPS : Used To Select Current .
8. A/f

: Used To Select Auto Flush Mode.

9.RESET : Used To Reset All Function.

12

PERAMETER POT
1. Gap

: Shows The Set GAP Voltage Value.


You Can Set It Between 40V To 55v.

2. SERVO

: Servo Speed In Spark & Auto Positioning Mode.


Can set As Per Electrode Size.

3. FLUSH

: Life Time In Auto Flush Cycle.


Not Effective When A/f Is Off.
Can Set Between 0.12 To 12 Seconds.

4. MAN SPEED : Servo Speed In Manual UP & Down Operation.

5. SPARK

: Work Time ( Spark Time) In Auto Flush Cycle.


Not Effective When A/f Is Off.
Can Set Between 0.25 To 56 Seconds.

6. ANTI ARC

: Can Set When S.S is Used As Work Piece.


Can Set 0 To 2

7. ON TIME

: Machining Time OF Spark Cycle.


Decides The Cutting Rate, Surface Finish, Over Cut etc.
Please Refer Technology Chart For More Details

13

8. T OFF

: Non machining Time Of Spark Cycle.


Please Refer Technology Chart For More Detail

INTERLOCKS

1. LL LOW LEVEL :

LED For Low Level Of Dielectric in Working


Tank. It lights when dielectric Level Is Low in
Working Tank than set Level. Sparking
Function Is disabled If It Lights.

2. UP LIMITS

: This LED Lights When Quill Or A Ram Is At


Limit position

3. DN LIMITS

: This LED Light When Quill or a Ram is at DN


Limit Position.

4. ARK ARCING : This LED Lights Only Is Sparking Function ,


When The Machining process is unstable.
When this LED light it reduces The sparking
current and try to protect the electrode & work
Piece from damages due to arcing.

14

TROUBLE SHOOTING
DESCRIPTION

CHECK POINTS

Switch on the machine. Display is


not glowing.

1.Check input supply RN ,YN , BN


is 240Volt.
2.Check fuse on fuse card
Press manual up switch quill will not 1.Up limit switch is operated .
start moving in upward direction
2.Up limit LED on Operators Panel
is Glowing
Press manual down switch ; quill
1.Down limit switch is operated.
will not start moving in downward
2. electrode and work piece are in
direction.
contact.
ATPS not Working
1. Down limit switch is operated.
2. Servo Speed is 0.
Pump is not Working .
1. Check mechanical point of the
pump .
2. Check fuse on fuse card.
3. check power supply.
Spark Switch Is Not Working.
1. ATPS is On.
2. low Level in The Work Tank.
3. Down/up Limit Switch Is
Operated.
Current selection is not working.
1. Check Fuse on Current Card.
2. Check fuse on fuse card
Low-Level Switch Is Not Working
1.Clean The Float.
IF Electrode ware and cutting
1.provid proper flushing.
speed is normal
2.clean the filter an oil.
3. check fuse on power card 1 & 2.

NOTE : If The Problem Is Beyond This Please Inform To Our


Nearest Office.(chinmay natu M- 09376127521)

15

TECHNOLOGY CHART

Curren
t

T-on

4
8

12
12

duty

00
00

Gap.volt
s

45
45

flushin
g

MRR

%wear

Over
cut

Surfac
e
finish
ra

0.150
0.150

3.667

---------------

0.15
0.16

5
6

--------

0.18

0.221

0.20

1.000

0.22

1.442

0.26

16

1.663

0.28

>20

0.13

4.8

0.14
0.15

5.2
5.9

0.17

6.2

0.20

6.9

0.24

12.1

0.26

15.6

58.507
12

12

00

45

0.150
86.588

16

12

00

45

0.150
97.575

20

12

00

45

0.150
112.62
2

28

12

00

45

0.150
171.12
9

35

12

00

45

0.150
239.32
9

21

00

45

0.150

8
12

21
21

00
00

45
45

0.150
0.150

16

21

00

45

0.150

20

21

00

45

0.150

10.488
36.34

0.105
0.48

68.519

3.045

108.85
4
120

3.408
4.000

28

21

00

45

0.150
156.34

35

21

00

45

0.150
16

4.118

4
8

32
32

00
00

45
45

0.150
0.150

12
16

32
32

00
00

45
45

0.150
0.150

20
28

32
32

00
00

45
45

0.150
0.150

202.33
4

4.224

13.31

0.84

36.778
66.88

3.035
9.45

83.741
133
169.7

10.25
11

0.11
0.13

4.6
5.1

0.14
0.15

5.6
6.3

0.16
0.19

7
9.1

0.23

13.43

0.08

4.3

0.09

4.7

0.12

5.1

0.13

5.6

0.14

0.15

8.7

0.17

10.8

13.035
35

32

00

45

0.150
207.87

54

01

45

0.150

54

01

45

0.150

12

54

01

45

0.150

10.422
35.002
16
20
28

54
54
54

01
01
01

45
45
45

15.65
2.52
8.98

58.406

10.997

71.003
133

13.205

0.150
0.150

15.223
17

0.150
162.87

35

54

01

45

0.150
209.43

19.67

68

02

45

0.150

10

68

02

45

0.150

7.75

10

68

02

45

0,150

20

10

4
0.068
4.6
0.068
5
0.076

75

03

45

0.150

13

2.6
0.053

75

03

45

0.150

13

3.4
0.053

75

03

45

0.150

14

13

4
0.064

86

03

45

0.150

1.5

19

1.7
0.045

86

03

45

0.150

2.5

19

2.4
0.045

86

03

45

0.150

19

3
0.052

17

18