STUDY OF WIRE ELECTRICAL DISCHARGE MACHINING

Objectives

1. To understand the mechanics of material removal in electrical discharge machining

2. To realize the function of various machine elements
3. To assimilate some important process parameters that affect the machining process

Scope

1. Theoretical explanation of (i) the process of material removal and (ii) process parameters
associated with EDM
2. Brief explanation of the various functional elements of the machining system
3. Demonstration of WEDM

Guidelines to conduct the study and to prepare the report

(Use Schematic diagrams and Flow chart to explain the following)

Introduction

1. Identify EDM as an unconventional material removal process by distinguishing it from

conventional material removal processes and bring out the need for such a process.

2. Clearly distinguish it from other unconventional material removal processes and identify
the various applications of the process.

Mechanism of Material Removal and Process Parameters

1. Explain the process of material removal through a sequence of schematic diagrams

representing the following
a. Basic electrical connections between the electrode and workpiece
b. The formation of an ionized column and plasma channel
c. Process of sparks occurring between the closest points
d. Formation of vapourised cloud of electrode and material during spark on
e. Flushing of the vapourised material at spark-off and material removal

2. Explain the following parameters with suitable diagrams

a. Spark-on
b. Spark-off
c. Voltage
d. Current
e. Overcut

Functional Elements of Wire Electrical Discharge Machining System

The following Figure 1 gives the overall view of the various functional elements of a WEDM system.
Identify these with respect to the demonstrated WEDM machine.

Figure 1 Overall view of various functional elements of a WEDM system

Schematic diagram of WEDM

With a neat schematic diagram and brief description, show the various elements of the WEDM system
as observed in the demonstration. The schematic diagram should include the following elements.

1. Machine Frame
2. Work Holding System
3. Electrode Head Assembly
4. Wire Feed Mechanism
5. Dielectric Pumping System
6. Control Panel and various modes of operation like Auto, Dry, Single Block
7. PC – WEDM system Interface

REFERENCES

1. E. C. Jameson, 2001, Electrical Discharge Machining, Society of Manufacturing Engineers,

USA.

2. H. A. G. El-Hofy, 2005, Advanced Machining Processes – Nontraditional and Hybrid

Machining Processes, McGraw-Hill Publishers, USA, pp. 115-139.

3. J. A. Mcgeough, 1988, Advanced Methods of Machining, Kluwer Academic Print, USA,

pp. 128-152.

STUDY OF ULTRASONIC MACHINING

Objectives
 1. To understand the mechanics of material removal in ultrasonic machining
2. To realize the mechanism of various machine elements
3. To assimilate the various parameters that affect the machining process

Scope

1. Theoretical explanation of (i) the process of material removal and (ii) process parameters
associated with EDM
2. Brief explanation of the various functional elements of the machining system
3. Demonstration of WEDM

Guidelines to conduct the study and to prepare the report

(Use Schematic diagrams and Flow chart to explain the following)
Introduction

1. Identify USM as an unconventional material removal process by distinguishing it from

conventional material removal processes and bring out the need for such a process.

2. Clearly distinguish it from other unconventional material removal processes and identify
the various applications of the process.

Mechanism of material removal

Explain the process of material removal through a sequence of schematic diagrams representing the
following

1. Formation of ultrasonic vibration – magnetostriction mechanism

2. Constriction of the vibrations from horn to tool – mechanical amplification

3. Transfer of the force to the abrasive particle – process in between the tool and workpiece

4. Mechanism of material removal – crack initiation, propagation and network of cracks

5. Mechanism of Grain hammering and Grain throwing

Functional elements of the USM system

The following Figure 2 gives the overall view of the various functional elements of a USM system.
Identify these with respect to the demonstrated USM machine.
 Figure 2 Overall view of various functional elements of a USM system

Plot the graph Load Vs Time from the readings obtained during the experiment

REFERENCES

1. H. A. G. El-Hofy, 2005, Advanced Machining Processes – Nontraditional and Hybrid

Machining Processes, McGraw-Hill Publishers, USA, pp. 115-139.

2. J. A. Mcgeough, 1988, Advanced Methods of Machining, Kluwer Academic Print, USA,

pp. 128-152.