MME 2122 MANUFACTURING PROCESS 2

EXPERIMENT 4:

INTRODUCTION TO WIRE CUT ELECTRICAL DISCHARGE MACHINING & FUSED DEPOSITION MODELING WITH THE FDM 2000

Prepared by:

NORLIYANA ZAINUDDIN 0436700

Group name:

Ibn Sina

Prepared for:

Br Radzi bin Hj Che Daud

Date of submission:

23 MARCH 2007

2 EXPERIMENT 4 (part a): INTRODUCTION TO WIRE CUT ELECTRICAL DISCHARGE MACHINING (EDM) OBJECTIVES OF THE EXPERIMENTS To introduce the wire EDM process and its application. APPARATUS Wire EDM Sample workpiece PRINCIPLE OF EDM The principal of electric-discharge machining (EDM), also called electro discharge or spark erosion machine is based on erosion of metals by spark discharges. When two current conducting wires are allowed to touch each other an in arc is produced and upon close observation it is noticed that small portion of metal from the wire has been erode away leaving a small crater. When the potential difference between the tool and the workpiece sufficiently high, the dielectric breaks down and a transient spark discharges through the fluid.. The sparks removes a very small amount of metal from the workpiece surface. The capacitor discharge is repeated at rates between 200 and 500 kHZ with voltages usually ranging between 50 and 380 V and currents from 0.1 to 500 A. The volume of material removed per spark discharge is typically in the range of 10-6 to 10-4 mm3. The EDM process has become one of the most important and widely used production technologies in manufacturing. OBSERVATION

From the observation, we can see that EDM is automatically conducted by the computer. In EDM, tool are functioning as cathode while work material as anode. As user, we just put the coding or instructions suitable for our product. While

3 running the operation, EDM need to submerge the work material in dielectric fluids. We also can see the lighting sparks occurs. DISCUSSION EDM is a cutting operation that based on erosion of metals by spark discharges. EDM uses a charged electrode, and then brings the electrode near a workpiece (oppositely charged). As the tool (cathode) and the workpiece(anode) get close enough, a spark will occur in dielectric fluid. The spark then creates a hole in both the electrode and the workpiece. The EDM process can be used on any materials that is an electrical conductor. Graphite is the most commonly used material as an electrode because it is less affected and warn from the process. Graphite also is machined very easily, conducts electricity, and does not vaporize. There are also others materials used for electrodes such as copper and tungsten. During the operation, the workpiece is fixture within the tank containing the dielectric fluid, and its movements are controlled by numerically controlled system. EDM operation also needs the presence of dielectric fluids such as hydrocarbon oil, kerosene and water. In determine the dielectric fluid, it depends on material and electrode used and type of work done. The functions of the dielectric fluid are: (a) Act as an insulator until the potential is sufficiently high. (b) Provide a cooling medium. (c) Act as a flushing medium and carry away the debris in the gap. Therefore, to ensure that the dielectric fluids play it roles, it must have the following properties: The dielectric fluid should have sufficient and stable dielectric strength It should deionize rapidly after the spark discharge It should have low viscosity and good wetting capacity Its flash point should be sufficient high to avoid any fire hazard It should not emit any toxic vapours or have unpleasant odours It should maintain its properties under all working conditions It should be chemically neutral to the workpiece, electrode or the work table It should be easily available at a reasonable price .

In EDM, as value of current density increase, the depth of cut also increases. To get the maximum depth of cut, it depends on size of the workpiece, length of the electrode and size of the work table. Increasing the depth of cut will decrease the machining time but will increase the roughness of machined surface. Modern wire EDM machines are capable of producing three-dimensional shapes and are equipped with such features as: (a) Computer controls to control the cutting path of the wire. (b) Automatic self-threading features in case of wire breakage. (c) Multithreads for cutting two parts at the same time. (d) Features such as controls for preventing wire breakage. (e) Programmed machining strategies to optimize the operation. Advantages of wire EDM o Since the tool does not touch the workpiece, there are no cutting forces generated; therefore, very fragile parts can be machined. o The EDM process leaves no burrs and the material is flushed away by the dielectric fluid. o Wire EDM is an efficient and economical choice in many applications. o Easy to use and reduced cycle time and labor hours. o Wire EDM can reduce or eliminate fixture and tooling costs. o It introduces very little stress if done with the correct settings. o EDM allows for cutting complex shapes with out distortion. Disadvantages of wire EDM o Difficult to do deep slots and narrow openings.
o

The bulk of material removal should be done by conventional process.

o The work material must be electrically conductive.

EXPERIMENT 4 (part b): FUSED DEPOSITION MODELING WITH THE FDM 2000 OBJECTIVES OF THE EXPERIMENTS To introduce the fused deposition modeling process using FDM 2000 modeler and its application To produce a part using FDM 2000 modeler To design and convert to STL file, creating SSL file and download to FDM hardware PRINCIPLE OF EDM The FDM 2000 uses Fused Deposition Modelling
TM

(FDM) to turn computer

aided design (CAD) geometry into models that can be used for design reviews, manufacturability studies, investment casting patterns, and marketing. It features the Break Away Support System (BASS), allowing the designer to create models with greater speed and precision. The support tip extrudes a material that supports any overhanging portions of the models geometry. When the model is completed, the support is easily broken off leaving behind the final product. Each CAD file is converted to an STL format. The STL file is read into Stratasys slicing software called Quickslice. Quickslice breaks the model into individual slices, with each slice representing one layer of material. Quickslice then generates tool paths to fill the slices. These tool paths form the SML file. DISCUSSION The first step in operating the FDM machine is to prepare an appropriate solid model. Keep in mind that the FDM has limited space, or envelop size. Material filament is pulled into the FDM head by the drive wheels. It enters the liquefier where it is heated until the material reaches a near-liquid state. As the material comes out the FDM tip, it bonds to previously deposited material. The modeling envelope temperature is regulated to aid in the bonding process. The head movement and material flow information (SML code) for each slice curve is downloading to the FDM 2000. The FDM head deposits material as it

6 follows the part geometry for each curve. It starts from the bottom curve and builds up the model to the top curve. Then, prepare an appropriate solid model as the first step to operating FDM 2000.PRL recommends using Solid Works purpose. The part of size and complexity will directly affect the amount of time required for building. The designer must be aware of the part size relative to the machines envelope size inherently dangerous. The Solid Works part the designer must keep the following considerations in mind: The FDM 2000 is equipped with a 10in x 10in x 10in envelope. Parts larger than a 10in cube may be made from assemblies of several smaller parts. The separation of adjacent beads of deposited material (road width) may be varied from 0.0103in to 0.0396in. The height of successive slices (rod height) may be set at 0.007in, 0.010in, or 0.014in. Most often, users will set the road height at 0.010in. Remember that extremely thin sections will have comprised structural integrity. Where possible, the tips of extremely pointed sections should be rounded or chamfered. Overhanging sections can be produced by the FDM 2000. The FDM will generate supportive scaffolding under any overhanging sections. The software provides options for scaffold growing. The scaffolding will be made out of plastic but will be more brittle than the material used for structural sections of the part. Scaffolding material will be removed from the model during finishing stages. Build times on the FDM may vary considerably depending on size, complexity, and software configuration. Keep in mind that the FDM is shared resource and that users will be charged for material costs. RECOMMENDATIONS/SUGGESTIONS: 1. To increase student understanding about FDM, introduce to all students about FDM practically not just theoretically.

CONCLUSION: As conclusion, in this experiment I learn how to deal with EDM machine. Although the technician just shows only one operation, at least it gives me some knowledge about the machine which already used widely in the industries. I do hope in future, there was a demonstrator about FDM. REFERENCES: 1) 2) 3) 4) Manufacturing process 2 lab manual. Slide note from Dr. Ahsan After M. C. Shaw, P. K. Wright, and S. Kalpakjian. Fundamentals of Modern Manufacturing, Mikell P.Groover , 3rd edition.