LAB SESSION: 06

a) To understand the working Principle and basic operation parameters of a

wire-cut electric discharge machining
b) To analyze the effect of wire feed and rate and wire tension on the cut
quality WEDM of aluminium part

(a)

6.1. Problem Statement:

To study and understand the basic working principle of wire-cut EDM machine
and to study the effect of different operation parameters of Wire-cut EDM.

6.2. Introduction:

6.2.1. EDM Wire-cut Machine:

In wire electrical discharge machining

(WEDM), also known as wire-cut EDM and
wire cutting, a thin single-strand metal
wire, usually brass, is fed through the work
piece, submerged in a tank of dielectric
fluid, typically deionized water. Wire-cut
EDM is typically used to cut plates as thick
as 300mm and to make punches, tools, and
dies from hard metals that are difficult to
machine with other methods. The wire,
which is constantly fed from a spool, is held
between upper and lower diamond guides.
The guides are usually CNC-controlled and
move in the x–y plane. On most machines,
the upper guide can move independently in
the z–u–v axis, giving it a flexibility to cut
tapered and transitioning shapes (example:
square at the bottom and circle on the top). Fig.6.1. EDM wire-cut Machine
6.2.2. Construction:
EDM wire-cut machine is a non- conventional machine
consisting of 5 axis; x and y on table z axis which is height
(w.p thickness) and two axis u and v on wire for taper
cutting)
It consists of following components:
 Water tank (450 litre distilled water)
 Filtration unit (2 jumbo size paper filters)
 Water cooler
 AWT (automatic wire threading) to thread the wire
automatically when it breaks by giving start point
and break point
 Tool (wire 0.15-0.25mm dia)

6.3. Operation Parameters:

Following are parameters for EDM-wirecut
 Kerf width (distance b/w wire and workpiece) the less kerf width we have
lesser material will be wasted
 Open Voltage
 Servo Voltage
 Wire tension
 Wire feed

6.4. Advantages and Disadvantages:

6.4.1. Advantages:
 Complex profiles and intricate part can be machined easily
 Hard material can be cut (e.g. titanium)
 High water pressure removes debris quickly and with ease
 Compressive stresses are very less on workpiece

6.4.2. Disadvantages:
 Temperature of water is up to 1200 o C which effects the surface of
workpiece creating Heat affected Zones (HAZ)
 Process is time consuming (Material removal rate is slow)
 Only cut conductive materials
6.5. Applications of Wire-Cut EDM
Wire EDM is used for cutting aluminium, brass, copper, carbides, graphite, steels
and titanium. The wire material varies with the application requirements.
Example: for quicker cutting action, zinc-coated brass wires are used while for
more accurate applications, molybdenum wires are used.

The process is used in the following areas:

 Aerospace, Medical, Electronics and Semiconductor applications
 Tool & Die making industries.
 For cutting the hard Extrusion Dies
 In making Fixtures, Gauges & Cams
 Cutting of Gears, Strippers, Punches and Dies
 Manufacturing hard Electrodes.
 Manufacturing micro-tooling for Micro-EDM, Micro-USM and such other
micromachining applications.

(b)

6.6. Problem statement:

To study and analyze the effect of wire feed rate and wire tension on the cut
quality WEDM of aluminium part by measuring the surface tension of
workpiece of different cuts at different feed rate and wire tension.

6.7. Operation Parameters

6.7.1. Constant parameters

 On Time= 1sec
 Off Time= 20sec
 Open Voltage=75
 Servo Voltage= 47
6.7.2. Varying Parameters:

Feed rate:

Maximum wire feed rate= 300mm/sec

6.8. Procedure:

 Set up aluminium workpiece on machine table

 Turn on the EDM wire cut machine and give input parameter and feed path
to be followed by the tool
 Pump in the dielectric medium
 Start machining and start stopwatch to measure machining time
 Two sides are machined with different feed rates and two sides are
machined with different wire tension
 At last measure the roughness of each side by using roughness measuring
meter repectively