MEM 564

MANUFACTURING PROCESSES LABORATORY

PREPARED BY:
NAME STUDENT ID
NURUL FATHIN BINTI AHMAD ZAINUDIN 2019 541 979
NUR EZZAH EZATY BINTI MOHAMAD FADZIL 2019 530 219
NUR MAIZATUL AIDA BINTI ABDUL WAHAB 2019 530 299

LECTURER’S NAME: DR. MUHAMAD B OTHMAN

SUBMISSION DATE: 21 APRIL 2020
Table of Content

CONTENT PAGE NO

1.0 Tittle 5

2.0 Objective 5

3.0 Introduction (Background and Theory)

5- 7
3.1 Theory

4.0 Apparatus

4.1 Apparatus 8 - 11

4.2 Industrial Apparatus

5.0 Experimental Procedures 12

6.0 Safety Precautions 12

7.0 Results and Data Analysis 13 - 15

8.0 Discussions

 Nurul Fathin binti Ahmad Zainudin (2019541979)

16 - 18
 Nur Ezzah Ezaty binti Mohamad Fadzil (2019530219)

 Nur Maizatul Aida Abdul Wahab (2019530299)

9.0 Conclusions

 Nurul Fathin binti Ahmad Zainudin (2019541979)

19 - 21
 Nur Ezzah Ezaty binti Mohamad Fadzil (2019530219)

 Nur Maizatul Aida Abdul Wahab (2019530299)

10. Recommendation 22

11.0 References 23

2
List of Tables

CONTENT PAGE NO

Table 1: Table of experimental equipment 8 - 10

Table 2: Table of industrial equipment 10 - 11

Table 3: Table of comparison specimens between speed and 15

time

3
List of Figures

FIGURES PAGE NO

Figure 1: EDM Wire Cut illustration 7

Figure 2: Graph of Desired Pattern 14

Figure 3: Result of Coding Programmed EDM Wire Cut 14

Figure 4: Specimen A 14

Figure 5: Specimen B 15

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1.0 TITTLE

Non Traditional Machining (Electro-discharge machining, EDM wire cut)

2.0 OBJECTIVE

1) To produce the NC programming for machining the specimen using EDM wire cut.

2) To machine and produce the specimen using the developed NC programming.

3) To make a comparison the product produce using different cutting parameters.

4) To understand the wire cutting process and programming CNC.

5) To illustrate the Non- Traditional Machining (NTM) process using EDM wire cut the
machine features, process capabilities and limitation.

3.0 INTRODUCTION (BACKGROUND AND THEORY)

Electrode Discharge Machining (EDM) is a machining method primarily used for

hard metal for those that would be impossible to machine with traditional techniques. EDM
process was invented by two Russian scientists, Dr. B.R. Lazarenko and Dr. N.I. Lazarenko
in 1943. First numerically controlled EDM was invented by Makino in Japan. EDM can cut
small or odd-shaped angles, intricate contours or cavities in pre-hardened steel without the
need for heat treatment to soften and re-harden them as well as exotic metals such as
titanium, Kovar and Inconel. There are two main types of EDM machines which is sinker
EDM, also known as Conventional EDM and RAM EDM and another type is wire cut.

Conventional EDM uses a tool to disperse he electric current. The tool, also called
cathode, runs along the metal piece, the anode and the electrical current reacts to melt or
vaporize the metal. As a result of the dielectric fluid, what little debris produced washes away
from the piece?

There are two main types of EDM which conventional and wire. Wire cut EDM
equipment is run by computer numerically controlled (CNC) instruments, which can control
the wire on a three –dimensional axis to provide greater flexibility. While conventional EDM
cannot always produce tight corners or very intricate patterns, the wire EDM’s increased the

5
precision allows for intricate patterns and cuts, and additionally wire cut EDM is able to cut
the metal as thin as 0.004”.

Wire cut EDM discharges the electrified currents by means of a taut thin wire, which
acts as the cathode and guided along the desired cutting path. A dielectric fluid submerges
the wire and work piece, filtering and directing the sparks. The thin wire allows precision
cuts, as wide as three inches and a positioning accuracy of +/- 0.0002”. This heightened
precision allows for complex, three dimensional cuts, and produces highly accurate punches,
dies, and stripper plates.

It is important to remember that wire in the process is constantly moving, and cannot
be reused. The wire which copper, brass or other metallic wire can be kilometres long, adding
to the cost. The possibility of thermal stress can present while the process uses no force and
thus does not cause burrs and can be used on delicate items.

(Thomas t.t)

3.1 Theory

Wire cut is one of the Electrode Discharge Machining (EDM) process in which tool
discharges thousands of sparks to the metal work piece. Wire EDM works on parts resistant
to conventional machining processes, if only these parts are electrically conductive, usually
non-ferrous and include steel, titanium, brass and many other metals. EDM melts or
vaporizes the material leaving very little of debris and providing a very accurate line, instead
of cutting the material. A wide variety of EDM applications has been accepted by industry, as
it is highly versatile, can cut hard metals and utilizes a relatively compact amount of
workspace.

The wire for wire EDM units emits sparks on all sides, which means the cut must be
thicker than the wire itself. In other words, the wire is surrounded by a ring of current the
smallest and most precise cutting path possible is the added diameter of the ring and wire.
The technicians easily account for this added dimension. Manufacturers continue to produce
thinner and thinner wires to allow for smaller and even finer precision.

6
 Wire cut EDM process uses CNC to cut involve the movement of work piece along X
and Y axes in horizontal plane toward vertically moving wire electrode. Electrode does not
have any contact with work piece but operates in stream of dielectric fluid which is directed
to spark the area between work and electrode. When in operation, dielectric fluid in spark
area breaks down, forming gas that permits spark to jump between work piece and electrode.

(Shah 2017)

Figure 1: EDM Wire Cut illustration

7
4.0 APPARATUS

4.1 Apparatus
Table 1: Table of experiments equipment

No Figure Name

EDM Wire Cut Machine

1.

Remote Control
2.

EDM Control Panel

3.

8
 Clamp
4.

Working Table
5.

Waste Wire Container

6.

9
 EDM Pump System
7.

4.2 Industrial Apparatus

Table 2: Table of industrial equipment

No Figure Name

1. Feeler Gauge

2. Allen Gauge

3. Vernier Caliper

10
4. Stainless Steel Ruler

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5.0 EXPERIMENTAL PROCEDURE
1. The power button is turned on.
2. The manual movement has been made.
3. The electrode pins and nozzles have being checked before putting the work piece
on the working table.
4. The wire and work piece are being mounted.
5. The program is input.
6. After that, the drawing is being checked by inserting the coding into the program.
7. Then, the machining condition is selected.
8. The wire is positioned according to the work piece.
9. Next, the preparation is being made for machining.
10. The machining is started.
11. The machining is stopped when the program is completed.
12. The product is being examined and inspected.
13. After that, the machine is cleaned.
14. Lastly, the power is turned off it is completed.

6.0 SAFETY PRECAUTIONS

There it is safety precautions when handling EDM wire-cut machines as shown below:
1. Make sure there are no leaks in the tank dielectric liquid, tank hose and pipe
connections.
2. Make sure a fire extinguisher near the machine for use in emergencies.
3. Make sure the materials are installed in areas where the right job.
4. Make sure the electrodes are not touching the thing work.
5. Make sure each cable there is no leakage.
6. Clear oily liquid that is in place the working substance during the installation
process.
7. Clear all dirt in the tank desk and storage tanks.
8. Wear appropriate clothing while using machines.

There it is safety precautions after using EDM wire-cut machines:

1. Switch off the machine.

2. Leave the machine and work area in a safe, clean and tidy state.

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7.0 RESULT AND DATA ANALYSIS

In this experiment, a metal block with a thickness of 0.8 mm is used.

NC PROGRAMMING
N100 G00 G21 G90;
N102 G92 X0. Y25. I8.;
N104 M60;
N106 M83;
N108 M81;
N110 S101 D2;
N112 G41 G01 X5. Y25.;
N114 Y35.;
N116 X30.;
N118 Y40.;
N120 X45. Y35.;
N122 Y30.;
N124 G03 X45. Y20. I0 J-5.;
N126 G01 Y15.;
N128 X30. Y10.;
N130 Y15.;
N132 X5.;
N 134 Y25.;
N136 X0.;
N138 M50;
N140 M45;
N142 M30;

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 Figure 2: Graph of Desired Pattern

Figure 3: Result of Coding Programmed EDM Wire Cut

Figure 4: Specimen A

14
 Figure 5: Specimen B

Table 3: Table of comparison specimens between speed and time

Specimen Speed run (mm/min) Time taken (min)

A 17.17 9
B 16.27 10.5

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8.0 DISCUSSION

NURUL FATHIN BINTI AHMAD ZAINUDIN (2019541979)

In the experiment conducted, two specimens having the same shape, dimension
and types of material are produced. Different range of speeds applied to both specimens.
Specimen A and specimen B are produced using speed of 17.17 mm/min and 16.27
mm/min. The time taken by specimen A and specimen B took 9 minutes and 10.50
minutes. Specimen B applied lower speed compared to specimen A and resulting longer
period for the process to be done. As the speed of the cutting increase, the time taken to
finish the product decreases.

The products were then measured and it is proven that EDM wire cut machine
could produce accurate product base on the drawing since the result showed the same
measurement as the drawing of the desired shape. EDM Wire Cut is unaffected by
material hardness. Any hard and tough materials are able to be machined as long as they
are conductive to electricity. Compared to other material, aluminum is easy to cut at
higher speeds. Using naked eyes, the two specimens discovered no differences on the
surface finish but in order to achieve better EDM finish quality is to cut slower.

Wire EDM cutting can provide high dimensional accuracy for close fitting parts.
EDM Wire Cut machine uses a thin brass wire for an electrode that can make sharp
inside corners. Since both products are small with dimension of 40mm x 30mm as the
machine could cut it, this showed that the machine is capable to cut small and complex
shape. EDM-wire cut have slow material removal rate and less flexible compared others
machine. The type of wire also will impact performance. The angle of the wire cut and
the speed will affect the result for example, when the wire is break if the angle is too
narrow of the speed movement of the work piece is too fast.

From this experiment, the material removed is carried away by a flowing

dielectric fluid and filtered out in the EDM machine. The pump will supply water, which
act as coolant, flows at the bottom of the jig and flushes away all the discarded metal
particles from the product. The weakness of this machine are the machine cannot make
blind holes but only through holes and only the wire can only be used once at on time.

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NUR EZZAH EZATY BINTI MOHAMAD FADZIL (2019530219)

For the process of using Electrical-Discharge Machining (EDM) wire cut

machine, a brass wire of 0.2 mm diameter is used to cut Aluminium plate which has
thickness of 8 mm. At the end of the process, the desired shape from results above is
required. The time taken to cut the work piece took only 9 minutes with a speed of 17.17.
The product shape obtained is accurately the same of the drawing, which means that
EDM wire cut machine could produce the accurate product base on the drawing. The
machine is capable to cut a small and complex shape. Wire EDM cutting uses rapid,
controlled and repetitive sparks discharges from the wire to the work piece, thereby
eroding the metal away. Wire EDM can provide a high dimensional accuracy for close
fitting parts and wire cut EDM can optimize cost options that include reducing cut surface
area, minimizing the number of holes and cut-outs, stacking parts during cutting. Wire cut
EDM movement is much faster than EDM. It can cuts intricate shape, narrow slots and
small products. Furthermore, no burrs generated during the process and wire electrodes
much cheaper than shaped electrodes in EDM. In term of environment, the wire cut EDM
machine is more environmental friendly as it is not exiting any dangerous gases to
environment. Also, there are no burrs produce when using this machine. For safety factor,
this machine is safe as it has a full cover around the machine and only produces a small
spark between work piece and electrode.

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 NUR MAIZATUL AIDA BINTI ABDUL WAHAB

The Wire Electrical-discharge Machine (EDM) is used to cut sheet metal into
desired shape by using the Numerical Control (NC) programming. The G-code and M-code
used for programming. The G-code that be used are G00, G21, G90, G92, G41, G01and G03.
While for M-codes be used are M60, M83, M81, M50, M45 and M30. M-code stands for the
coding of the machine while G-codes stand for the coding of the cutting tools. The EDM
Wire machine uses 0.25mm diameter of brass wire as the cutting tool to cut aluminium plate
of thickness 0.8mm.

From the result in table the two specimens have be conducted, having the same
shape, dimension and types of material are produced. The different of range speed are applied
to both specimens. Specimen A and specimen B are produced using speed 17.17 mm/min and
16.27mm/min. The time taken by specimen A and specimen B took 9 minutes and 10.50
minutes. The both specimens have good close tolerances and good surface finish. The
machine also can cut most any simple or complex 3D shape including cut outs and thin walls,
intricate openings and sharp inside corners.

The work piece must be electrically conductive and that’s why aluminium used as
the base metal. Because EDM Wire Cut creates microscopically small particles during the
cutting process, removing these “chips” becomes a key factor in maximizing cutting speed as
well as attaining part accuracy and surface finish. To be an effective flushing agent, the
dielectric fluid must flow freely into the zone where the cutting action occurs. Because each
spark melts away a microscopic bit of the work piece, the fluid helps solidify the molten
particle and keep it from adhering to the wire or the work piece surface.

The dielectric fluid, or coolant, used in the EDM Wire process, is deionized water. It
acts as a semiconductor between the energized wire and the work piece to maintain stable and
controlled conditions for ionization in the spark gap. Next, it can be chilled to keep the wire,
work piece, worktable and fixtures at a steady temperature. This limits the thermal growth of
the work piece and machine in order to hold tight tolerances. Then, it acts as a flushing agent
to wash away the ashy debris created as cutting occurs.

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9.0 CONCLUSION

NURUL FATHIN BINTI AHMAD ZAINUDIN (2019541979)

In conclusion, the objective for this experiment is successfully accomplished which to

produce NC programming for this process by making a coding code as command
depending on the desired product. The second objective is to produce and machine the
specimen using NC programming as the result obtained is same as the designed product
that has been drafted before proceeding with the experiment. As technology advances in
speed, work piece size, geometry complexity and accuracy, new machine technology and
EDM wires are helping to improve machine performance and productivity. The wire-cut
electrical discharge machining plays an important role in manufacturing sectors especially
industries like aerospace, ordinance, automobile and general engineering. Since the speed
of the cutting increase, the time taken to finish the product will decrease. So, with the
right application, cutting speeds, the process could be done faster and it is possible to
increase the productivity of parts.

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NUR EZZAH EZATY BINTI MOHAMAD FADZIL (2019530219)

As conclusion, the desired objectives in this experiment have been successfully

achieved. Wire cut machine that used electrode wire to cut through work piece which
include the knowledge on how to enter the program and how to apply the program to
form G-code are also part of this machine process working. The entire step is required to
produce the obtained product in the result. Wire cut EDM able to cut any material
regardless of its hardness but only conductor materials and also due to its high accuracy
that can produce a high quality product. This will reduce overall production cost and
increase profit of the company.

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NUR MAIZATUL AIDA BINTI ABDUL WAHAB

As conclusion, the desired objectives have been successfully implemented. The

experiments have been successfully EDM Wire Cut machine with skill and know how to
enter the program and run machine for the design of the products made. EDM Wire
cutting process based on the principal energy mode is thermal with the electrical
discharge. It is also similar to contour cutting with a band saw, a slowly moving wire
travels along a prescribed path, cutting the work piece, with the discharge sparks acting
like cutting teeth. This process is used to cut plate as thickness 0.8mm and for making
punches, tools, and dies from hand metals. It can also cut intricate components for the
electronic industry. Special brass wires are typically used and usually performed in a bath
of water. As technology advances in speed, work piece size and geometry complexity,
accuracy, ease of use, unattended operation, industry education and affordability. In the
case of complicated shapes requiring cuts or angled, conical, or other unusual surface, the
upper and lower wire guide systems carry out differing movements accordingly.

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10.0 RECOMMENDATIONS

One of the recommendations for the best EDM wire cut is to have the ability to cut
any conductor material by neglecting its hardness. Besides that, the absence of all-mechanical
forces makes it possible to machine fragile parts without distortion. It is so recommended due
to its high accuracy thus producing a high quality product. Furthermore, the process is cost
effective for low quantity projects, can prove to be beneficial in prototype manufacturing,
even if the actual project is carried out by different means.

The cleanliness of the dielectric fluid must be maintained to get the best performance
from a wire electrode. Otherwise if it gets too dirty, some materials will start to rust in the
tank, and surface finish may deteriorate. For example, cutting aluminium will quickly
increase the conductivity of the dielectric fluid. Besides that, the wire rethreading mechanism
should be checked and adjusted periodically.

When handling the EDM-Cut machine, the setup of the machine must be assured for
example, the clamp of the work piece is tightened firmly. Any carelessness will result to
serious injury since the machine is supplied by high current. Last but not least, if the machine
suddenly hanged or running awkwardly, immediately press the emergency button to stop it
and shut down the power supply. Any incident happened must be reported to the technician.

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11.0 REFERENCES
I. Manufacturing Processes Laboratory. (2015).
Non Traditional Machining (Electro-discharge machining, EDM wirecut).
Permatang Pauh, Pulau Pinang: Universiti Teknologi Mara cawangan Pulau Pinang
Kampus Permatang Pauh.

II. Thomas. (n.d.).

Wire Cut EDM (Electrical Discharge Machining).
Retrieved from https://www.thomasnet.com/articles/custom-manufacturing-
fabricating/Wire-Cut-EDM/

III. Dhruv, S. (2017, August 3).

Wire cut EDM.
Retrieved from https://www.slideshare.net/DhruvShah121/wire-cut-edm-78552400

IV. Tanimura T, Isuzugawa K, Fujita I (1989)

Development of EDM in the mist.
In: Proceedings of 9th international symposium electromachining (ISEM IX), pp
313–316

V. Rotella G, Lu T, Settineri L, Dillon OW Jr, Jawahir IS (2012)

Dry and cryogenic machining: comparison from the sustainability perspective.
In: 9th global conference on sustainable manufacturing. Springer, Berlin, pp 95–100

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