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WIRE EDM Likhith

The document discusses wire electrical discharge machining (EDM). It begins by explaining the basic working principle of EDM, which involves generating electric sparks between an electrode wire and workpiece submerged in dielectric fluid. This causes thermal energy to melt and vaporize material in thin layers. It then focuses on wire wear in wire EDM. The traveling EDM wire passes close to the workpiece, with electric discharges melting small volumes of both surfaces. This introduces flaws into the wire that can cause breakage over time due to the low fracture toughness of EDM wires. Maintaining optimal process parameters is important to minimize wire wear and breaks.

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24 views5 pages

WIRE EDM Likhith

The document discusses wire electrical discharge machining (EDM). It begins by explaining the basic working principle of EDM, which involves generating electric sparks between an electrode wire and workpiece submerged in dielectric fluid. This causes thermal energy to melt and vaporize material in thin layers. It then focuses on wire wear in wire EDM. The traveling EDM wire passes close to the workpiece, with electric discharges melting small volumes of both surfaces. This introduces flaws into the wire that can cause breakage over time due to the low fracture toughness of EDM wires. Maintaining optimal process parameters is important to minimize wire wear and breaks.

Uploaded by

Avengers Assemble
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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WIRE EDM-WIRE

WEAR
ME3101- Machining Processes

A. Likhith Reddy
Roll: ME19B005
REPORT TITLE | 2
Introduction
Electrical Discharge Machining (EDM) is a material removal or fabrication technology. It was first introduced by Joseph Priestly in

1770. However, with the modernization of technology and equipment, the technique is now integrated with computer numerical

control (CNC). The modern EDM machines are integrated with automated CNC operations and are used for metal cutting, material

removal, etc. EDM machining has gotten immense popularity in the CNC machining operations and other production activities.

Despite its popularity, this technology is yet not understood by many.

Electrical discharge machining (EDM) is a process of removing material by exposing it to reoccurring controlled electric discharge. It

works on the thermo-electrical phenomenon. As the electric discharge takes place between an electrode/wire and workpiece, the

thermal energy is generated on a workpiece. This leads to the removal of a material layer. Generally, there are three types of EDM

machines: Die-sink EDM; Small Fast Hole EDM and wire-cut EDM. However, in modern production processes, wire-cut EDM

machines are integrated with CNC. Therefore, automated, EDM machines are commonly utilized in the industry.

Working principle
The following steps are performed during EDM machining. These steps sum up the working principle of EDM machine.

 The EDM electrode and the workpiece are mounted. A small gap of a calculated distance is kept between the electrode
tip and workpiece. This is done using the servo mechanism.

 The supply of dielectric is turned on to immerse the workpiece in deionized water. Then the supply is turned off.

 By giving command through the power generation and control unit, a potential difference is generated between the
workpiece and electrode. As the electrode generates an electric spark, high thermal energy is generated which leads to
the melting and vaporization of metal.

 Although the electric spark generated by the electrode is not continuous, it breaks as the layer of dielectric flushes out.
The immersion of the workpiece, generation of potential difference, and electric spark repeats in short periodic cycles
and keeps removing the layer of material until the required amount of material is cut. Since the control unit of the EDM
machines is integrated with CNC automation, the scope of application of this technique has increased in precision
machining.

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WIRE WEAR IN WIRE EDM
For wire-EDM users, wire breakage poses a constant threat to their productivity. But with a bit of

knowledge about the wire-EDM process and the behaviour of metals when they are subjected to the

process, EDM operators can avoid wire breakage and keep their operations running smoothly and

efficiently.

In the wire-EDM process, a travelling wire passes in close proximity to an electrically conductive

workpiece. The gap between the two is filled with a dielectric fluid, which also flushes away the debris

generated by the process. A voltage is applied, creating an electrical discharge. The consequence of the

discharge is the melting or vaporization of a small volume of the surface of both the workpiece and the

wire by the intense heat generated in the gaseous envelope the discharge creates.

This envelope quickly collapses under the pressure of the dielectric fluid. The collapse allows the dielectric

fluid to rush into the void and quench the liquid/vapour phases of the workpiece and wire inside the

envelope. The cooled materials form solid particulate that must be flushed away to prevent interference

with the electrical discharge.

EDM wires break because their fracture toughness is too low to sustain the flaws that are introduced by the

discharges being generated.

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