VISVESVARAYA TECHNOLOGICAL UNIVERSITY

"JNANASANGAMA", BELAGAVI- 590 018

Mini Project Report on

“Small-Scale Desktop Wire EDM System for Precision Cutting of

Metals”
Submitted in partial fulfilment of the requirement for the award of the degree of

BACHELOR OF ENGINEERING
in
MECHATRONICS ENGINEERING
by

PRANAV SHARMA 1AY22MT022

SHIV JYOTI KUMARI 1AY22MT027
KRISHN R. BAILURKAR 1AY23MT408
PRATHAMESH MAHESH PATIL 1AY22MT417

Under the guidance of

Dr. Devarajaiah R M
Head of Department
Department of Mechatronics Engineering

DEPARTMENT OF MECHATRONICS ENGINEERING

Acharya Institute of Technology
(Affiliated to Visvesvaraya Technological University, Belagavi)
Acharya Dr. Sarvapalli Radhakrishnan Road, Soladevanahalli,
Bangalore – 560 107
2024-2025
 ACHARYA INSTITUTE OF TECHNOLOGY
(Affiliated to Visvesvaraya Technological University, Belagavi)
Acharya Dr. Sarvapalli Radhakrishnan Road, Soladevanahalli,
Bangalore – 560 107
DEPARTMENT OF MECHATRONICS ENGINEERING

CERTIFICATE

This is to certify that the Mini Project entitled “Small-Scale Desktop Wire EDM System for
Precision Cutting of Metals”, carried out by Ms. Shiv Jyoti Kumari, 1AY22MT027, Mr. Pranav
Sharma, 1AY22MT022, Mr. Krishn Rajesh Bailurkar, 1AY23MT408 and Mr. Prathamesh
Mahesh Patil, 1AY23MT417 are bonafide students of Acharya Institute of Technology, in partial
fulfillment for the award of Bachelor of Engineering in Mechatronics Engineering of the
Visvesvaraya Technological University, Belgaum during the year 2024-25. It is certified that all
corrections/ suggestions indicated for Internal Assessment have been incorporated in the Report
deposited in the departmental library. The mini project report has been approved as it satisfies the
academic requirements in respect of mini project work prescribed for the said Engineering Degree.

------------------------------- --------------------------------
Dr. Devarajaiah R M Dr. Devarajaiah R M
(Guide) (Head of the Department)

i
 ACKNOLEDGEMENT

I wish to express my deep and profound gratitude to our Head of the Department Dr. Devarajaiah R
M for his valuable guidance and suggestions.

I express our sincere gratitude to our guide Dr. Devarajaiah R M Department of Mechatronics
Engineering for their guidance, timely suggestions and encouragement at every step, which helped us
to complete the work successfully.

I thank all the teaching and non-teaching staff of our Mechatronics Engineering department for
their constant support.

I am also thankful to our beloved parents who have motivated and installed confidence in us.

ii
 DECLARATION

We Pranav Sharma (1AY22MT022), Shiv Jyoti Kumari (1AY22MT027), and Krishn Rajesh
Bailurkar (1AY23MT408) and Prathamesh Mahesh Patil (1AY23MT417), students of third year
Mechatronics Engineering, Acharya Institute of Technology, declared that the report entitled “Small-
Scale Desktop Wire EDM System for Precision Cutting of Metals”, has been successfully completed
under the guidance of Dr. Devarajaiah R M, Department of mechatronics Engineering, Acharya
Institute of Technology.

This Mini Project report is submitted to Visvesvaraya Technological University, in partial fulfilment
of the requirement for the award of the degree of Bachelor of Engineering in Mechatronics
Engineering, during the academic year 2024-2025.

PRANAV SHARMA
1AY22MT022

SHIV JYOTI KUMARI

1AY22MT027

KRISHN RAJESH BAILURKAR

1AY23MT408

PRATHAMESH MAHESH PATIL

1AY23MT417

iii
 ABSTRACT

This report outlines the design and construction of a small-scale desktop Wire EDM for precision
cutting of metals for prototyping and small-scale manufacturing applications. The main goal is to
design a portable and cheap EDM system capable of achieving high levels of accuracy suitable for a
desktop environment. They include a CNC based motion control system a wire feed mechanism a
dielectric fluid system and a microcontroller-based control unit for operation of the project. The
designed system does not require the operator to interact with the system frequently during the
cutting process especially when there are complicated operations involved and the system can
monitor and control the process in real time terms. The accuracy, surface finish and performance of
the newly developed system was also assessed through simulation and experimental testing. The
findings show that the system has the capability to deliver clean, smooth and accurate edges to
different metallic workpieces, establishing the system’s prospects as a useful tool for small
businesses, teaching institutions, and prototype manufacturing sector. Possible future improvements
such as enhanced supervisory level control algorithms and first-auto mode that will enhance the
flexibility and performance of the system are given. The project shows how this desktop wire EDM
machine if adopted would be inclusive, efficient and economical for precision machining needs.

Table of Contents

iv
Sl. No Contents Page No.
CHAPTER 1: INTRODUCTION
1.1 Background to the Study 1
1.2 Statement of the Problem 2
1.3 Aim and Objectives of the Study 3
1.4 Significance of the Study 4
1.5 Definition of Terms 5

CHAPTER 2: LITERATURE SURVEY

2.1 Introduction 7
2.2 Wire Electrical Discharge Machining of Advanced Conductive 7
Materials
2.3 A Review: Recent Developments in Wire EDM 7
2.4 Conceptual Design of a High-Speed Wire EDM Robotic end 8
Effector
2.5 Comprehensive Review on Wire Electrical Discharge Machining 9

CHAPTER 3: METHODOLOGY
3.1 Introduction 11
3.2 Working Principle 12
3.3 Flowchart and Block Diagram 12
3.4 Benefits of the system 13
3.5 Manufacturing and Assembly

3.6 Components summary 14

CHAPTER 4: SOFTWARE MODELS

4.1 Introduction 15
4.2 Designing the CAD Model 15
4.3 Designing the Virtual Circuit 15
4.4 Data processing & control mechanism 20

v
4.5 Simulation and Testing 21
4.6 Summary 22

CHAPTER 5: HARDWARE SPECIFICATION

5.1 BIGTREETECH Manta M5P Control 33
5.2 BIGTREETECH CB1 Motherboard 34
5.3 Motor Drive 35
5.4 Stepper Motor 36
5.5 24V/14.6A SMPS 37
5.6 Stainless Steel Road 38
5.7 Spark Generator 39
5.8 DC Gear Motor 40
5.9 Summary 40

CHAPTER 6: RESULT & DISCUSSIONS

6.1 Result 41
6.2 Discussion 42

CONCLUSION
REFERENCES

vi
 LIST OF FIGURES

Fig No. Contents Page No.

Fig.3.1 Flow Chart 11

Fig.3.2 Block Diagram 22
Fig.4.1 CAD Model 23
Fig.4.2 Circuit Flow Chart 23
Fig.4.3 Microcontroller 24
Fig.4.4 Power 24
Fig.4.5 Controls 25
Fig.4.6 Charge Power Stage 25
Fig.4.7 Output Stage 26
Fig.4.8 Monitoring 26

vii
 Fig.4.9 Connectors 27
Fig.4.10 Slope Generator 31
Fig.4.11 Simulation 32
Fig.5.1 BIGTREETECH Manta M5P Control. 33
Fig.5.2 BIGTREETECH CB1 Motherboard 34
Fig.5.3 TMC2209 Motor Driver. 35
Fig.5.4 NEMA17 Stepper Motor. 36
Fig.5.5 24V/14.6A SMPS 37
Fig.5.6 Stainless Steel Road. 38
Fig.5.7 Spark Generator. 39
Fig.5.8 JGY-370 Gear Motor 40

LIST OF TABLES

Sl. No Contents Page No.

Table 1.1 Advancements in Wire EDM 9

Table 1.2 Brief Summary of Components used in WEDM

viii
Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

CHAPTER-1
INTRODUCTION

1.1 BACKGROUND TO THE STUDY

Wire Electrical Discharge Machining (WEDM) is an advanced, non-traditional

machining process that has revolutionized precision manufacturing. WEDM is used
extensively for producing intricate components and complex geometries from electrically
conductive materials. Unlike conventional machining processes that involve physical cutting
tools, WEDM employs a continuously moving wire as an electrode to erode material using
electrical discharges. The ability to achieve extremely tight tolerances and smooth surface
finishes has made WEDM indispensable in industries such as aerospace, medical, electronics,
and mold manufacturing. Over the years, advancements in WEDM technology have
improved its accuracy, speed, and versatility, positioning it as a vital tool for modern
manufacturing.
The WEDM process operates on the principle of controlled material removal through
spark erosion. A thin wire, typically made of brass or copper, serves as the tool electrode, and
the workpiece acts as the second electrode. When a voltage is applied across the wire and the
workpiece, a dielectric fluid maintains a small gap while facilitating the generation of sparks.
Each spark creates a localized thermal effect that vaporizes tiny amounts of material, which
are then flushed away by the dielectric fluid. Unlike traditional cutting tools that wear out
over time, the wire in WEDM is continuously fed, ensuring consistent precision. This
capability allows WEDM to handle hard materials such as titanium, tungsten carbide, and
hardened steel with exceptional accuracy.
One of the significant advantages of WEDM is its ability to produce intricate profiles
and contours without exerting mechanical stress on the workpiece. This makes it ideal for
manufacturing delicate components where precision and material integrity are paramount.
The process also enables the production of parts with fine surface finishes, eliminating the
need for secondary finishing operations. Additionally, WEDM can be used to cut extremely
thin or small features that would be impossible to achieve with conventional machining. As
industries demand greater precision and miniaturization, WEDM has emerged as a critical
solution for meeting these exacting requirements.

Department of Mechatronics, AIT 1

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

In recent years, efforts have focused on enhancing the performance of WEDM

through process optimization, automation, and integration with computer-aided design
(CAD) and manufacturing (CAM) software. The use of intelligent control systems, adaptive
strategies, and real-time monitoring has significantly reduced process time while improving
accuracy and energy efficiency. Innovations such as high-speed WEDM have further
expanded its capabilities, enabling faster machining and better material removal rates. These
developments have made WEDM more cost-effective and accessible to small-scale
manufacturers, research institutions, and educational laboratories.
The growing demand for compact and portable WEDM solutions has led to the
development of desktop Wire EDM machines. These smaller systems are designed to provide
the same level of precision as industrial-grade machines but in a more affordable and space-
efficient form. Desktop WEDM machines cater to small workshops, prototyping facilities,
and academic settings, where space and budget constraints are significant considerations. By
bridging the gap between affordability and high performance, these systems empower users
to manufacture complex parts efficiently while exploring innovative applications. As
industries continue to push the boundaries of design and material capabilities, WEDM
remains at the forefront of modern manufacturing technologies.

1.2 STATEMENT OF THE PROBLEM

Wire Electrical Discharge Machining (WEDM) has become an essential process in

precision manufacturing due to its ability to produce complex geometries with high accuracy.
However, despite its advantages, WEDM still faces significant challenges that affect its
efficiency and adoption, especially in small-scale manufacturing environments. Conventional
WEDM systems are often large, expensive, and require significant infrastructure, making
them inaccessible to small workshops, research labs, and educational institutions. This limits
opportunities for innovation and hands-on learning in advanced machining processes.

Additionally, WEDM processes are susceptible to issues such as wire breakage, low
material removal rates, and surface imperfections, particularly when machining hard and
exotic materials. These issues result in longer machining times, increased operational costs,
and frequent interruptions, which hinder productivity and overall process efficiency. The lack
of affordable, compact, and reliable solutions exacerbates these problems for small-scale
users who cannot invest in industrial-grade WEDM systems.

Department of Mechatronics, AIT 2

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

There is also a growing need for an accessible WEDM system capable of delivering
precision cutting without compromising on performance. Existing machines often fail to meet
the flexibility and cost-effectiveness required for small-scale or prototype-level
manufacturing. A solution that addresses these shortcomings is necessary to bridge the gap
between affordability and high performance, enabling broader access to WEDM technology
for diverse applications.

To overcome these challenges, the development of a Small-Scale Desktop Wire

EDM System is essential. Such a system must be compact, affordable, and capable of
precision cutting while ensuring ease of use and reduced operational issues. By addressing
these problems, the proposed solution can empower small businesses, educational
institutions, and research facilities to leverage WEDM technology effectively for their
machining needs.

1.3 AIM AND OBJECTIVES OF THE STUDY

The aim of this project is to design and develop a small-scale desktop Wire Electrical
Discharge Machining (WEDM) system that offers precision cutting capabilities, is cost-
effective, and suitable for small-scale manufacturing and educational purposes.
The objectives are to:
1. To design a compact desktop WEDM system that can efficiently cut hard and
conductive materials with high precision.
2. To optimize the key parameters of WEDM, such as wire feed rate, pulse duration,
and dielectric fluid flow, for improved cutting efficiency and minimal material
wastage.
3. To integrate basic automation features, such as CNC control and real-time
monitoring, to improve the precision and consistency of the machining process.
4. To develop an affordable WEDM machine suitable for small-scale manufacturers,
research institutions, and educational purposes without compromising on
performance

Department of Mechatronics, AIT 3

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

1.4 SIGNIFICANCE OF THE STUDY

The significance of this study lies in the development of an affordable, compact, and high-
precision desktop Wire Electrical Discharge Machining (WEDM) system, which addresses
the growing need for advanced manufacturing solutions in small-scale and educational
environments. By providing a cost-effective alternative to large industrial WEDM machines,
this project opens up opportunities for small workshops, research institutions, and academic
labs to access precision machining technology previously out of their reach. The ability to cut
intricate shapes and hard materials with high accuracy, without the need for expensive
industrial setups, allows for the creation of complex parts at a lower cost and faster
turnaround time. This system will not only benefit prototype development and small-scale
manufacturing but also offer hands-on learning experiences for students and researchers,
fostering innovation and skill development in the field of mechatronics and manufacturing.
Additionally, the system’s automation and ease of use make it ideal for non-expert users,
enhancing accessibility. With growing demand for precision parts in various industries,
including aerospace, automotive, and medical devices, this project contributes to bridging the
gap between high-performance technology and smaller-scale applications, supporting
sustainable growth in the manufacturing sector.

Advantages of the System

i. Cost-Effective: The desktop WEDM system is more affordable compared to large
industrial-grade machines, making it accessible for small-scale manufacturers,
educational institutions, and research labs.
ii. Compact Size: Its small footprint allows for easy installation in limited spaces,
making it ideal for small workshops and academic settings where space is a
concern.
iii. High Precision: The system provides high-precision cutting capabilities, enabling
the production of intricate and complex geometries with tight tolerances, similar
to industrial machines.
iv. Ease of Use: Designed with user-friendly interfaces and simple control
mechanisms, the system is accessible even to non-expert users, such as students or
small business owners.

Department of Mechatronics, AIT 4

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

v. Versatility: Capable of cutting a wide range of conductive materials, including

metals like steel, brass, and titanium, the system can cater to various industries
such as aerospace, medical devices, and automotive.
vi. Reduced Operational Costs: The compact design and optimized parameters reduce
energy consumption, wire consumption, and material wastage, leading to lower
overall operating costs.
vii. Automation Features: Integration of basic automation (e.g., CNC control and real-
time monitoring) ensures consistent, precise results with minimal manual
intervention, improving efficiency and reliability.
Area of Application
i. Prototyping and Small-Scale Manufacturing: The desktop WEDM system is ideal
for producing small batches of precision parts, prototypes, and components for
industries such as aerospace, automotive, and medical devices.
ii. Tool and Die Making: It can be used for creating intricate molds and dies,
including those used in injection molding, stamping, and casting, where high
precision and complex shapes are required.
iii. Educational Institutions: The system is well-suited for use in educational and
research environments, enabling students and researchers to study and explore
advanced manufacturing technologies and process optimization.

1.5 DEFINITION OF TERMS

i. Wire Electrode: A thin, electrically conductive wire, typically made of brass or
copper, used as the electrode for material removal in WEDM.
ii. Dielectric Fluid: A non-conductive fluid used to cool the workpiece, flush away
debris, and facilitate the electrical discharge process during WEDM.
iii. CNC Controller: A computer-based controller that directs the movement of the
workpiece and wire, ensuring accurate and automated cutting based on
programmed paths.
iv. Workpiece: The material or object being cut or shaped using the WEDM process,
typically made from conductive metals like steel, titanium, or brass.
v. Power Supply: The unit that generates and supplies electrical pulses to the wire
electrode, creating the sparks needed for the material removal process.

Department of Mechatronics, AIT 5

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

vi. Pulse Generator: A device that creates the electrical pulses used to trigger the spark
erosion between the wire electrode and the workpiece.
vii. Wire Tensioner: A component that maintains consistent tension on the wire
electrode to prevent fluctuations, ensuring stable and accurate cuts.
viii. Wire Feeder: A mechanism that continuously feeds the wire through the system at
a steady rate, ensuring the wire is replenished during the machining process.
ix. Cutting Head: The assembly that holds and guides the wire electrode, providing
stability and precision during the cutting process.
x. Flushing System: A system that circulates dielectric fluid around the cutting area
to remove debris and cool the workpiece, preventing overheating.
xi. Stepper Motor: A motor used to precisely control the movement of the workpiece
and wire in all three axes (X, Y, and Z), allowing for detailed and accurate
machining.
xii. Spark Gap: The small, controlled gap between the wire electrode and the
workpiece where sparks are generated, influencing cutting speed and accuracy.
xiii. Worktable: The surface where the workpiece is securely mounted during the
WEDM process, ensuring stable positioning during cutting.
xiv. Surface Finish: The texture and smoothness of the cut surface, which is influenced
by machining parameters such as pulse duration and wire tension.
xv. Electrical Discharge: The spark or burst of electrical energy that occurs between
the wire electrode and the workpiece, eroding the material to create the desired
shape.

CHAPTER-2
LITERATURE SURVEY

2.1 INTRODUCTION

Department of Mechatronics, AIT 6

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Wire Electrical Discharge Machining (WEDM) is a specialized non-traditional

machining process used for achieving precision cutting and complex geometries in
conductive materials. The process utilizes thermal energy generated by controlled electrical
discharges between a thin, continuously moving wire electrode and the workpiece submerged
in dielectric fluid. It has gained significant traction in industries requiring high-precision
machining, such as aerospace, automotive, and medical device manufacturing (Charles Sarala
Rubi, 2024).
WEDM has evolved significantly over the years, addressing the demand for advanced
machining processes that deliver superior accuracy, surface finish, and flexibility. The
process is particularly effective for cutting hard metals, alloys, and intricate shapes that are
challenging to machine using conventional methods (Mahapatra et al., 2014). Innovations in
WEDM systems, including the development of CNC-based control systems and improved
wire electrodes, have enhanced its accuracy and productivity (Kumar & Babu, 2015).
However, challenges such as wire breakage, thermal damage, and limitations in processing
non-conductive materials remain areas of active research. Recent studies have focused on
optimizing machining parameters, improving dielectric fluids, and integrating robotic
systems for automated operation (Rubi et al., 2024; Kumar et al., 2021). The use of AI and
real-time monitoring has also been proposed to improve WEDM's adaptability in modern
manufacturing (Zhang et al., 2023).
In summary, WEDM has proven to be a versatile and essential tool in precision machining.
The following sections explore key aspects such as process optimization, performance
evaluation, innovative applications, and a critical review of recent advancements.

2.2 WIRE ELECTRICAL DISCHARGE MACHINING OF

ADVANCED CONDUCTIVE MATERIALS

Wire Electrical Discharge Machining (WEDM) is a crucial non-traditional method for

machining advanced conductive materials like superalloys and composites. It uses controlled
electrical discharges between a thin, moving wire electrode and the workpiece to produce
precise and complex shapes. This process offers advantages such as high cutting accuracy,
stress-free machining, and improved surface quality, making it ideal for aerospace and
automotive applications (Asgar & Singholi, 2021).

Department of Mechatronics, AIT 7

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Key research highlights include optimizing process parameters like pulse duration,
discharge current, and dielectric fluid flow to improve material removal rates and minimize
defects. WEDM efficiently handles hard-to-machine materials, ensuring minimal tool wear
and enhanced productivity in modern manufacturing (Asgar & Singholi, 2021).

2.3 A REVIEW: RECENT DEVELOPMENTS IN WIRE EDM

Wire Electrical Discharge Machining (WEDM) has witnessed significant

advancements aimed at improving process efficiency, surface quality, and material removal
rate. Recent developments include the use of coated wires, which enhance performance by
improving conductivity and tensile strength while reducing wire breakage. Zinc-coated
electrodes, for example, provide faster cutting speeds and better cooling properties during
machining. Research has also focused on optimizing process parameters like pulse energy,
wire tension, and dielectric flow to improve precision while reducing machining time and
energy consumption (Singh et al., 2013).

Another notable advancement in WEDM involves the integration of adaptive control

systems and hybrid technologies. Adaptive control helps monitor and adjust machining
parameters in real time, reducing wire erosion and improving surface integrity. Hybrid
processes, such as WEDM combined with ultrasonic vibration or cryogenic cooling, further
enhance machining performance on challenging materials like titanium alloys and
composites. These advancements make WEDM a critical technology for industries requiring
high precision and minimal residual stresses in conductive materials (Singh et al., 2013).

Table 1.1 indicates the advancements in Wire EDM technology significantly enhance
its capabilities. Coated and multilayered wire electrodes improve cutting speed, surface
finish, and durability, making them suitable for demanding applications. Optimizing
machining parameters like pulse duration and dielectric flow boosts material removal rates
and precision. Hybrid machining techniques, such as combining EDM with laser or additive
manufacturing, enable complex geometries with reduced processing time. The development
of micro-WEDM has made it possible to fabricate intricate micro-components with high
accuracy, catering to industries like electronics and medical devices. Incorporating smart

Department of Mechatronics, AIT 8

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

technologies like IoT and AI has further enhanced automation, efficiency, and real-time
process monitoring.

Table 1.1. Advancements in Wire EDM

Sl
Parameter Advancement/Development Benefit/Impact
No
.
Wire Electrode Improved cutting speed,
1. Coated and multilayered wires
Materials surface finish, and durability.
Better debris removal,
2. Dielectric Fluids Introduction of eco-friendly
reduced thermal damage, and
fluids.
enhanced sustainability.
Use of finer wires and advanced Fabrication of high-precision
3. Micro-WEDM
control systems micro-components.
Broader application in
4. Workpiece Machining of advanced alloys
aerospace, medical, and
Materials and composites.
automotive industries.
Predictive maintenance,
5. Automation and Incorporation of IoT.
smarter operations, and
Smart Tech
increased productivity.
Real-time optimization of pulse Enhanced material removal
6. Machining
duration, wire tension, and rate and surface quality.
Parameters
dielectric flow rate.

2.4 CONCEPTUAL DESIGN OF A HIGH-SPEED WIRE EDM

ROBOTIC END-EFFECTOR

The research paper titled "Conceptual Design of a High-Speed Wire EDM Robotic
End-Effector Based on a Systematic Review Followed by TRIZ" presents a novel approach to
developing a high-speed wire Electrical Discharge Machining (EDM) end-effector for
industrial robots. The authors conducted a systematic review of existing wire EDM
technologies to identify current limitations and challenges. Utilizing the Theory of Inventive
Problem Solving (TRIZ), they analysed these challenges to generate innovative solutions for
the end-effector design. The proposed design aims to enhance machining speed, precision,

Department of Mechatronics, AIT 9

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

and adaptability in complex manufacturing environments. Key features include an optimized

wire tensioning system, improved dielectric fluid delivery, and enhanced thermal
management to maintain machining accuracy. The study provides a comprehensive
framework for integrating TRIZ methodology into the design process of advanced robotic
end-effectors, potentially leading to significant improvements in automated manufacturing
processes.

2.5 COMPREHENSIVE REVIEW ON WIRE ELECTRICAL

DISCHARGE MACHINING

The research paper titled "Comprehensive Review on Wire Electrical Discharge

Machining: A Non-Traditional Material Removal Process" provides an in-depth analysis of
Wire Electrical Discharge Machining (WEDM), a sophisticated thermo-electric machining
technique. WEDM is renowned for its ability to fabricate components with varying hardness
and intricate designs that are challenging to machine using conventional methods. The paper
traces the evolution of WEDM from a simple tool-making approach to a preferred method for
producing micro-scale components with high dimensional accuracy and superior surface
finish. Despite its advantages, challenges such as wire damage and bending have impeded the
process's full potential, affecting precision and efficiency. The authors review various studies
focused on optimizing process parameters and assessing factors influencing machining
performance and accuracy. They also discuss adaptive monitoring and control strategies
aimed at achieving optimal machining conditions. The paper highlights industrial
applications of WEDM and the development of hybrid machining techniques, concluding
with insights into recent advancements and suggesting directions for future research in this
domain.

Department of Mechatronics, AIT 10

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

CHAPTER 3:

METHODOLOGY

3.1 INTRODUCTION
The development of the Desktop Wire EDM (Electrical Discharge Machining)
machine involves a series of carefully planned steps that bring together mechanical design,
electrical systems, and control integration. Each stage, from the initial concept to simulation,
testing, and final manufacturing, is essential to create a compact, cost-effective, and reliable
machine. Below is a detailed explanation of the methodology, broken down into the sub-
components.

3.2 WORKING PRINCIPLE

The Desktop Wire EDM Machine operates based on the principle of Electrical Discharge
Machining (EDM), which removes material through a series of controlled electrical
discharges (sparks) between a thin wire electrode and the conductive workpiece. The process
involves:
 Spark Generation:
A high-frequency electrical pulse is applied between the wire (electrode) and
the workpiece, creating a spark.
The spark generates intense heat, vaporizing and melting small amounts of the
workpiece material.
 Material Removal:
The molten and vaporized material is flushed away by the dielectric fluid,
leaving a precise cut or cavity.
 Wire Movement:
The wire is continuously fed through the machine to maintain a fresh cutting
edge, ensuring consistent cutting performance.
 Controlled Spark Gap:
The machine maintains a precise gap between the wire and the workpiece
using a servo-controlled mechanism to ensure stable and efficient sparking.
 Dielectric Fluid:

Department of Mechatronics, AIT 11

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Deionized water is used as the dielectric fluid to cool the cutting zone, insulate
the wire and workpiece, and remove debris.
 Precision Control:
The machine’s CNC system controls the wire’s movement and cutting path
based on the programmed design, allowing for intricate and accurate cuts

3.3 FLOWCHART AND BLOCK DIAGRAM

FLOWCHART

The flowchart represents the operational process of a Wire EDM (Electrical

Discharge Machining) machine. The process starts with setting up the machine, followed by
checking the components for readiness. If the components are not in order, they are fixed, and
the check is repeated until the components are satisfactory. Once confirmed, dielectric fluid is
applied to prepare the machine for operation. Next, the power supply is set up, ensuring it is
ready for generating sparks, which are critical for the machining process. If sparks are not
generated, the settings are adjusted, and the spark generation is retried. Upon successful spark
generation, CNC (Computer Numerical Control) movement begins, enabling precise cutting
or shaping of the material. Simultaneously, debris created during the machining process is
flushed out to maintain a clean workspace. The process continues until the desired machining
is complete. Decision points in the flowchart ensure checks at critical stages, such as
component readiness and spark generation, to maintain efficiency and quality. The
rectangular blocks represent process steps, while diamond shapes indicate conditional checks,
and ovals denote the start and end of the process. The entire flow ensures a systematic
approach to operating a Wire EDM machine, emphasizing precision, safety, and
effectiveness.

Department of Mechatronics, AIT 12

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Start

Setup machine

Components
check

Apply Fix
dielectric Components
fluid

Power
Supply
Ready

Spark
Generated

Department of Mechatronics, AIT 13

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

CNC Adjust
Movement Settings

Complete
Process

End
BLOCK DIAGRAM

This block diagram outlines the process of designing, building, and testing a small-
scale Wire EDM machine. The project begins with defining objectives and goals, followed by
research and planning to understand EDM fundamentals and analyze similar designs. After
planning, the required components, such as motors, wire guides, and power supplies, are
procured. Mechanical structure designs are then created using CAD software, and the base
frame, guides, and wire tensioning systems are assembled. Next, the electrical circuits are
developed and integrated with the mechanical components to ensure proper power delivery
and synchronization. Initial tests are conducted to verify the machine's functionality, with
troubleshooting to resolve any issues. Once testing is successful, the final assembly is
completed, and the machine is refined for better performance and portability. Finally, the
project is submitted for evaluation or showcased for demonstration. This systematic approach
ensures a well-structured development process.

Department of Mechatronics, AIT 14

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Research and Planning

Start
Study the fundamentals of
Define project objectives EDM technology.
and goals.
Analyze small-scale EDM
designs.
Identify required
functionalities and
constraints.
Component Design and CAD
Procurement Modeling PCB design
List all required Create mechanical
components (motors, wire structure designs using
guides, power supply, CAD software.
etc.). Design the electrical
Purchase the components circuitry for spark
and materials. generation and control.
Mechanical Structure Electrical Circuit
Assembly Integration
Assemble the base frame Build the control circuit
and guides. for power delivery.
Install wire tensioning Integrate the circuit with
mechanisms and motion the mechanical structure.
systems.

Final Assembly and Testing and

Refinement Troubleshooting
Complete assembly of all Perform initial tests to
components. verify machine
Refine for portability and functionality.
reliability. Debug any issues with
wire alignment, sparks, or
motion control.
End
Submit the project for
evaluation or showcase it.

Department of Mechatronics, AIT 15

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

3.4 BENEFITS OF THE SYSTEM

 Compact Design:
The small footprint makes it ideal for use in constrained spaces such as small
workshops, laboratories, and educational institutions.
 Cost-Effectiveness:
Affordable production and maintenance costs make it accessible to small-scale
manufacturers and researchers.
 High Precision:
Capable of achieving tight tolerances and intricate geometries, suitable for producing
complex components.
 Material Versatility:
Can machine a wide range of conductive materials, including hard-to-machine alloys
like titanium and Inconel.
 Energy Efficiency:
Optimized power consumption reduces operational costs while maintaining
performance.
 User-Friendly Interface:
Intuitive software design simplifies operation, making it suitable for users with
varying skill levels.
 Clean Operation:
The dielectric system effectively removes debris and maintains a clean working
environment.
 Scalability:
The modular design allows for easy upgrades and customization based on user
requirements.

3.5 MANUFACTURING AND ASSEMBLY

The final stage involved fabricating the components, assembling the machine, and
performing real-world testing. The CAD design served as the blueprint for manufacturing,
with parts such as the frame, wire feed system, and workpiece table fabricated using
processes like CNC machining and laser cutting. Materials were carefully selected to ensure
durability and cost-efficiency.

Department of Mechatronics, AIT 16

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Once the parts were ready, the machine was assembled step by step. The mechanical
components were installed first, followed by the wiring of the electrical systems. The control
system, including the microcontroller and sensors, was integrated and connected to the
motors and power supply.
After assembly, the team conducted a series of calibration runs to align the
components and fine-tune the control system. The dielectric fluid system was tested to ensure
smooth flow and cooling during operation.
Finally, the machine was put through extensive real-world testing, cutting various
materials to evaluate its accuracy, speed, and surface quality. Adjustments were made
wherever necessary to optimize the machine's performance.
By the end of this process, the Desktop Wire EDM machine was fully functional,
ready to deliver high-precision cutting in a compact and cost-effective form.

3.6 COMPONENTS SUMMARY

 Frame and Structure: Lightweight and vibration-damping materials like PLA/ABS
ensure stability and precision.
 Wire Tensioning Mechanism: Maintains consistent wire tension for accurate cuts.
 Pulse Generator: Provides controlled electrical pulses for spark generation.
 Dielectric System: Includes a compact reservoir and pump for cooling and debris
removal.
 Wire Feeder: Ensures continuous wire supply during operation.
 Servo Motors: Enable precise control of wire movement and positioning.
 Control Software: Facilitates user-friendly operation with CAD/CAM integration and
real-time monitoring.
 Power Supply Unit: Delivers stable and adjustable power for machining processes.

Department of Mechatronics, AIT 17

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

CHAPTER-4
SOFTWARE PROGRAM

4.1 INTRODUCTION

The software program is an integral part of the Wire EDM machine, designed to
ensure precise control over its various components and seamless integration between
hardware and software. It facilitates key operations such as motor control, spark generation,
and user interaction. The software's primary objective is to deliver accurate machining while
maintaining reliability and user-friendly functionality. This chapter delves into the software's
structure, highlighting its configuration, implementation, and role in achieving the project’s
goals.

4.2 DESIGNING THE CAD MODEL

The project begins with the mechanical design of the Desktop Wire EDM machine. A
well-thought-out CAD (Computer-Aided Design) model forms the foundation, providing a
clear visualization of the machine's structure and components. Using software tools like
SolidWorks, Fusion 360, or AutoCAD, the 3D model of the machine was designed piece by
piece.
The first priority was to create a strong, compact, and rigid frame that would provide
stability during operation. The frame had to accommodate the workpiece table, wire
mechanism, motors, and sensors without compromising space. Aluminum and steel were
chosen as the primary materials for their strength-to-weight ratio and cost-effectiveness.

Department of Mechatronics, AIT 18

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Fig.4.1 CAD MODEL

The next focus was on designing the wire feed mechanism. This involved creating
spools and rollers that could guide and tension the thin cutting wire during the process. Since
wire tension is critical for accuracy, additional provisions were made to integrate real-time
tension adjustments later in the project.
The workpiece table design was another essential aspect. This table needed to move
smoothly along the X and Y axes to guide the workpiece while the wire remained stationary.
The team incorporated motor mounts and bearings to ensure precise, controlled movement. In
addition, the worktable was designed to hold clamps or jigs to secure the workpiece in place
during operation.
By the end of this stage, the CAD model provided a comprehensive blueprint of the
machine, detailing all the parts, their dimensions, and assembly points. It also served as the
reference for the subsequent stages, such as manufacturing and simulation.

4.3 DESIGNING THE VIRTUAL CIRCUIT

Once the mechanical design was finalized, attention turned to the electrical systems-
specifically, the creation of a virtual circuit for the EDM process. Electrical Discharge
Machining relies on high-voltage sparks to erode material without physical contact, which
makes the circuit design crucial.
The team started by designing the power supply and spark generation system. This
circuit needed to produce controlled pulses of high voltage and current at precise frequencies
to ensure smooth, efficient cutting. Using software tools this is KiCAD the team simulated
the circuit to understand how it would behave under load conditions.

Department of Mechatronics, AIT 19

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

The virtual circuit also included motor drivers, which would control the movement of
the workpiece table along the X and Y axes. Stepper motors were chosen for their accuracy
and reliability, and their operation was tested within the simulation environment.
In addition, feedback mechanisms were integrated into the virtual design to monitor
the wire’s position and maintain the correct spark gap between the wire and the workpiece.
This real-time monitoring would allow for adjustments during the cutting process, ensuring
precision.
By simulating the circuit virtually, the team was able to troubleshoot potential issues
before moving to hardware implementation. The outcome was a robust and functional circuit
design ready to be integrated with the machine.

4.4 DATA PROCESSING & CONTROL MECHANISM

The software processes data from sensors and feedback loops to adjust and optimize
machining operations. For example, endstop sensors are used for accurate homing, while
voltage and current sensors monitor the spark generator’s performance. Algorithms
dynamically adjust motor speeds, spark parameters, and wire tension based on this data. Real-
time control is achieved through interrupt-driven routines that synchronize motion and spark
generation.

4.5 SIMULATION AND TESTING

Before full-scale manufacturing, rigorous simulations and testing were conducted to
validate the design and ensure its functionality.
The first step was virtual simulation. Using software tools, the team tested the CAD
model under various conditions to evaluate the machine's structural stability. Stress analysis
and deformation simulations helped identify areas that needed reinforcement.
The virtual circuit was also tested to verify that the power supply, spark generator,
and motor drivers performed as expected. Any issues detected during simulations were
corrected before moving to the physical testing stage.
Once the design passed virtual testing, physical prototypes were developed. The
machine was assembled in its initial form, and each system—mechanical, electrical, and
control—was tested individually. The wire tension, spark generation, and workpiece
movement were calibrated for optimal performance.

Department of Mechatronics, AIT 20

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

The team also evaluated key performance metrics such as cutting speed, accuracy, and
surface finish. By running test cuts on sample materials, they identified areas where
improvements could be made. Adjustments were applied to the programming and physical
components to ensure the machine met the project goals.

CIRCUIT
This schematic represents the flow diagram of a wire EDM (Electrical Discharge
Machining) spark generator circuit, designed for precise cutting using electrical discharges.
The microcontroller manages control signals and system logic, including enabling outputs
and monitoring feedback. The charger power stage generates controlled pulses to charge
capacitors, enabling precise spark generation, with integrated voltage and current sensing.
The output stage delivers high-voltage sparks to the electrodes, essential for the EDM
process, while monitoring current through shunt resistors. The monitoring section oversees
critical parameters like temperature, current, and voltage, ensuring safe and efficient
operation by providing feedback to the microcontroller. The power section distributes power
to the circuit components with safety features, and the connectors provide external interfacing
for USB communication, power input, and system alerts. This modular design ensures easy
debugging, maintenance, and efficient operation of the EDM system.

Fig.4.2 CIRCUIT FLOW CHART

Department of Mechatronics, AIT 21

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Fig.4.3 MICROCONTROLLER

Fig.4.4 POWER

Department of Mechatronics, AIT 22

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Fig.4.5 CONTROLS

Fig.4.6 CHARGE POWER STAGE

Department of Mechatronics, AIT 23

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Fig.4.7 OUTPUT STAGE

Fig.4.8 MONITORING

Department of Mechatronics, AIT 24

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

Fig.4.9 CONNECTORS

Fig.4.10 SLOPE GENERATOR

Department of Mechatronics, AIT 25

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

SIMULATION

Fig.4.11 SIMULATION

4.6 SUMMARY

The software program for the Wire EDM machine serves as the backbone for its
operations, integrating hardware components and ensuring precise control. With features like
dynamic spark adjustment, robust motion control, and an intuitive user interface, the software
achieves high performance and reliability. Challenges during development were met with
effective solutions, resulting in a versatile and efficient system.

Department of Mechatronics, AIT 26

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

CHAPTER-5

HARDWARE SPECIFICATION

5.1 BIGTREETECH MANTA M5P CONTROL

The BIGTREETECH MANTA M5P is a 32-bit control board primarily used in 3D

printing but can potentially be adapted for experimental Wire EDM applications. It features
precise motion control with support for multiple stepper motors, customizable firmware (e.g.,
Klipper), and expandability through GPIO pins. In Wire EDM, it could manage the X-Y axis
motion, wire feed, and peripheral controls like dielectric fluid pumps. Its Wi-Fi and
Raspberry Pi integration allow for remote monitoring and additional customization. However,
the M5P is not natively designed for EDM's high-voltage pulse requirements or real-time
spark gap control, requiring external circuits and sensors for adaptation. While it offers
flexibility and cost-efficiency for DIY projects, significant software customization and
power-handling designs are essential. For professional Wire EDM, industrial CNC controllers
remain more suitable due to their built-in precision and process-specific capabilities.

Fig.5.1 BIGTREETECH Manta M5P Control.

Department of Mechatronics, AIT 27

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.2 BIGTREETECH CB1 Motherboard

The BIGTREETECH CB1 motherboard is a versatile, compact controller
designed for 3D printing and CNC applications, offering a solid foundation for
managing precise machining tasks like those in wire EDM. It features a
powerful ARM Cortex-A53 processor with a 64-bit architecture for fast and
reliable performance. The motherboard supports multiple stepper motors and
various I/O interfaces, allowing for precise movement control, which is critical
for wire EDM applications. Additionally, it provides compatibility with custom
firmware, enabling fine-tuned control over parameters like feed rate, cutting
depth, and speed. With its onboard Wi-Fi and Ethernet connectivity, the CB1
allows for remote monitoring and control, enhancing flexibility in EDM
operations

Fig.5.2 BIGTREETECH CB1 Motherboard

Department of Mechatronics, AIT 28

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.3 MOTOR DRIVER

The TMC2209 is a highly efficient and versatile stepper motor driver widely used in
applications like 3D printers, CNC machines, and robotics. It is known for its silent
operation, precise motion control, and ease of integration. The driver operates in step/dir
mode or through UART communication for advanced control. It supports microstepping up
to 256 steps, ensuring smooth and precise motion for stepper motors. The TMC2209 features
StealthChop2 technology for ultra-quiet operation and SpreadCycle for high torque and
dynamic performance. It also includes StallGuard4, enabling sensorless homing and stall
detection, making it ideal for applications requiring minimal external sensors. Additionally,
the TMC2209 has a compact design, low heat generation, and adjustable current control,
ensuring efficient energy usage and adaptability for various motor sizes. Overall, it’s a
reliable and cost-effective choice for achieving precision and noise reduction in motion
control systems.

Fig.5.3 TMC2209 Motor Driver.

Department of Mechatronics, AIT 29

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.4 STEPPER MOTOR

The NEMA 17 stepper motor is a widely used, high-performance motor in

applications like 3D printers, CNC machines, and robotics. Named after its 1.7-inch (43.2
mm) square faceplate, this motor provides precise control by dividing each revolution into
discrete steps, typically 200 steps per revolution (1.8° per step). It operates through bipolar or
unipolar configurations and is compatible with popular drivers like the TMC2209. Known for
its reliability and affordability, the NEMA 17 delivers excellent torque for its size, typically
ranging from 20 to 50 N·cm, depending on the specific model. It is ideal for applications
requiring accurate positioning and speed control. With proper drivers, it supports
microstepping, improving smoothness and reducing vibration. The NEMA 17’s compact size,
versatile mounting, and high compatibility make it a staple for precision motion control in
various mechanical and mechatronic systems.

Fig.5.4 NEMA17 Stepper Motor.

Department of Mechatronics, AIT 30

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.5 24V/14.6A SMPS

A 24V/14.6A SMPS (Switched-Mode Power Supply) is a compact and efficient
power supply device used to provide a stable 24V DC output with a maximum current of
14.6A. It is commonly used in applications like 3D printers, CNC machines, robotics, LED
lighting, and other industrial or automation systems that require reliable power. The SMPS
operates by converting AC mains power (e.g., 110V or 220V) into regulated DC voltage with
high efficiency, typically over 85%.
Key features include overvoltage, overcurrent, and short-circuit protection, ensuring
safety during operation. Its compact design allows for easy integration into various systems,
while its active cooling mechanism (usually a built-in fan) prevents overheating during high-
load operation. The 14.6A current capacity provides sufficient power to drive multiple
components simultaneously, such as stepper motors, drivers, and other peripherals. This
SMPS is an excellent choice for projects requiring stable and high-capacity 24V DC power.

Fig.5.5 24V/14.6A SMPS

Department of Mechatronics, AIT 31

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.6 Stainless Steel Road

A 304 stainless steel rod with a 12mm diameter and 300mm length is a high-quality,
corrosion-resistant metal commonly used in various industrial, mechanical, and engineering
applications. 304 stainless steel is known for its excellent resistance to oxidation, corrosion,
and staining, making it ideal for environments exposed to moisture or chemicals. With a
12mm diameter, this rod provides a balance between strength and flexibility, while the
300mm length offers versatility for cutting, machining, or fabrication into custom
components. Its non-magnetic properties and good formability make it suitable for
applications in food processing, medical devices, construction, and other fields requiring
durable, rust-resistant materials. Additionally, 304 stainless steels ease of welding and
forming makes it an excellent choice for fabrication and structural components.

Fig.5.6 Stainless Steel Road.

Department of Mechatronics, AIT 32

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.7 Spark Generator

The Spark Generator rated at 65VDC, 2 kHz, and 180 Watts max is a specialized
device designed for applications requiring controlled electrical discharges, such as Wire
Electrical Discharge Machining (WEDM) or ignition systems. Operating at 65V DC, it
delivers stable high-frequency pulses at 2 kHz, ensuring consistent sparking performance.
The maximum power output of 180 Watts enables it to handle medium to high-intensity
operations while maintaining efficiency. Its robust design often incorporates features like
pulse width modulation for precise control, arc suppression to prevent wire or system
damage, and thermal protection for reliable operation under load. This spark generator is
ideal for achieving accurate material removal or efficient energy transfer in industrial and
precision machining applications.

Fig.5.7 Spark Generator.

Department of Mechatronics, AIT 33

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.8 DC Gear Motor

The JGY-370 12V DC Gear Motor is a versatile and compact motor widely used in
robotics, automation, and DIY projects for applications requiring high torque and controlled
speed. Operating on a 12V DC power supply, it delivers optimal performance with low
current consumption, typically around 200–300 mA under no load. The motor features a
robust gearbox, available in metal or plastic, which reduces speed and amplifies torque,
making it suitable for tasks like driving wheels, conveyor belts, or motorized blinds. With
speed options ranging from 5 RPM to 600 RPM, it provides flexibility for various use cases,
while its D-shaped or round shaft ensures easy coupling with attachments. The JGY-370 is
prized for its reliability, efficiency, and ease of use, making it a go-to choice for both
hobbyists and professionals in the field of mechatronics and automation.

Fig.5.8 JGY-370 Gear Motor

Department of Mechatronics, AIT 34

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

5.9 SUMMARY

Table 1.2. Brief Summary of Components used in WEDM

Sl Component Description Key Features Quantity
No.
1. BIGTREETECH A 32-bit control board - Motion control for
MANTA M5P primarily used in 3D multiple stepper motors
Control printing, adaptable for - Customizable firmware
experimental Wire EDM. (e.g., Klipper)
- Wi-Fi and Raspberry Pi
integration
2. BIGTREETECH A versatile controller for - ARM Cortex-A53
CB1 3D printing and CNC processor
Motherboard applications, suitable for - Multiple stepper motor
precise machining like support
Wire EDM. - Wi-Fi and Ethernet
connectivity
3. TMC2209 Motor Stepper motor driver - StealthChop2 (quiet
Driver known for silent operation, operation)
precision, and versatility in - SpreadCycle (high
various motion control torque)
systems.
4. NEMA 17 A widely used stepper - 1.8° per step (200 steps
Stepper Motor motor providing precise per revolution)
control in motion systems. - Compatible with
TMC2209 driver
- Torque range 20-50
N·cm
5. 24V/14.6A A compact, efficient power - High efficiency (>85%)
SMPS supply providing stable - Over voltage, over
24V DC output at 14.6A, current, and short-circuit
ideal for power-hungry protection
systems like CNC and 3D - Active cooling (fan)
printers.
6. Stainless Steel A corrosion-resistant 304 - Non-magnetic
Rod (304) stainless steel rod used in - Corrosion-resistant
various industrial and - Easy to weld and form
mechanical applications.
7. Spark Generator A device designed for - 65V DC output
controlled electrical - 2 kHz frequency
discharges in applications - 180W max power output
like Wire EDM. - Pulse width modulation,
arc suppression
8. DC Gear Motor A 12V DC gear motor - Low current
(JGY-370) providing high torque and consumption (200–300
controlled speed, used in mA)
robotics and automation - Speed range: 5 RPM to
projects. 600 RPM

Department of Mechatronics, AIT 35

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

CHAPTER-6

RESULT & DISCUSSION

6.1 RESULT
The results obtained from the Wire EDM project highlight significant achievements
and provide a comprehensive understanding of the system’s performance. The input power is
calculated as 216 W, and the output power is determined to be 924.75 W, yielding an
efficiency of 42.8%. These findings are indicative of the system's current operational status
and provide a foundation for optimization. The calculated efficiency reflects power losses
primarily attributed to resistive elements and heat dissipation, underscoring the importance of
refining the electrical design. The data further highlight areas requiring adjustments,
particularly in reducing thermal resistance and enhancing power delivery efficiency through
optimized circuitry.

Circuit simulation tests confirmed that the system operates effectively within the
designated parameters. The output voltage range of 65–72 V ensures stable performance,
while the peak output current of 200 A demonstrates the system’s capacity to handle high
loads. Furthermore, the RMS output current of 13.5 A meets the operational requirements,
enabling efficient cutting processes. These parameters align with the theoretical expectations,
validating the reliability of the design. The tests also showed a consistent spark generation,
essential for precision cutting, even under variable load conditions, confirming the robustness
of the circuit design.

The PCB layout is completed with meticulous attention to minimizing

electromagnetic interference and ensuring optimized current flow. The design incorporates
robust insulation and appropriate trace widths to manage high current levels effectively,
thereby enhancing operational safety and system longevity. Shielding techniques were also
considered to further reduce noise and improve system stability under varying operating
conditions. The layout supports efficient thermal dissipation and allows for better component
placement, ensuring accessibility and ease of future upgrades.

Department of Mechatronics, AIT 36

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

The CAD model is successfully developed, integrating all mechanical and electrical
components seamlessly. Key elements, such as the wire feed mechanism, dielectric fluid
system, and workpiece holder, are modeled to align with operational requirements. This
ensures that the mechanical design complements the electrical system for optimal
functionality. The design emphasizes precision and robustness, ensuring that all components
work in unison to achieve high-quality cutting results. By considering ergonomic placement
and minimizing structural vibrations, the model ensures operational stability and reliability.

Component selection is validated against the system’s operational demands. All

chosen components demonstrated the ability to withstand the specified voltage and current
levels without compromising performance. Future iterations of the design may consider
utilizing higher-grade materials to further enhance durability and reliability. This will be
especially important for handling prolonged high-current operations without degradation.
Additionally, the inclusion of fail-safes and diagnostic systems can further ensure operational
security and reduce downtime.

Simulation results demonstrate the system’s stability under a range of load conditions.
Output voltage and current remained within acceptable tolerances, validating the reliability of
the design in theoretical scenarios. However, real-world testing will be necessary to confirm
these results under practical operating conditions. This step is crucial for identifying
unforeseen variables that may influence the system’s performance in an industrial setting.
Key areas for real-world evaluation include wire wear rates, cutting precision consistency,
and adaptability to varying material properties.

The system achieved a moderate efficiency of 42.8%, which is a baseline for future
improvements. Power losses attributed to resistive elements and switching mechanisms were
identified as areas for enhancement. Incorporating advanced switching technologies and
reducing resistive losses will be crucial for achieving higher efficiency. The efficiency
analysis also provides valuable data for selecting alternative materials and improving circuit
designs. This insight will aid in achieving better resource utilization and lowering operational
costs in the final design.

Overall, the prototype’s performance demonstrates that the design meets the
fundamental requirements for Wire EDM applications. While the results are promising,
further refinements and testing are necessary to elevate the system to industrial-grade

Department of Mechatronics, AIT 37

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

performance standards. The successful integration of electrical and mechanical systems

highlights the robustness of the initial design and lays a solid foundation for future
improvements. The results showcase the feasibility of achieving high precision and reliability
in a compact and cost-effective design framework, paving the way for broader applications.

6.2 DISCUSSION
The proposed small-scale Desktop Wire EDM Machine represents an exciting
innovation in the field of precision manufacturing, offering a compelling combination of
affordability, versatility, and high-performance capabilities. This section will delve into the
key aspects of the machine's design, exploring both its potential benefits and challenges, as
well as its place within the broader context of modern machining technologies.
Precision and Accuracy:
The heart of any EDM machine lies in its ability to deliver high-precision cuts, and
this small-scale system is no exception. With a dimensional accuracy of ±0.01 mm, it can
cater to a wide range of applications, particularly in fields like aerospace, electronics, and
medical device manufacturing, where tight tolerances are crucial. The level of precision
achievable with this machine opens up possibilities for micro-machining, a growing trend in
various high-tech industries. However, while the accuracy target is ambitious, achieving this
consistently in a small-scale machine may pose challenges in terms of thermal stability and
mechanical rigidity. The system’s design will need to account for these factors to ensure that
such high precision is maintained during extended use.
Surface Finish Quality:
The fine surface finish achievable with an average roughness (Ra) of 0.8 µm is
another important feature that sets this machine apart. A smooth surface finish is essential in
many industries, as it reduces the need for additional finishing processes and enhances the
overall quality of the part. Achieving this level of finish in a small-scale machine is a
significant advantage, as many lower-cost systems tend to produce rougher results. However,
factors such as material type, wire tension, and machining parameters will affect surface
finish, and users will need to carefully adjust settings for optimal results. It will also be
important for the machine to handle complex geometries without compromising surface
quality.
Cutting Speed and Material Versatility

Department of Mechatronics, AIT 38

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

The cutting speed of 10-12 mm/min is competitive for small-scale EDM machines,
offering a balance between speed and accuracy. This allows for relatively fast production of
parts while maintaining high-quality results. The machine’s ability to handle a wide range of
conductive materials further broadens its appeal. Materials such as aluminium, mild steel, and
titanium are commonly used in industries like automotive, aerospace, and electronics, so the
ability to machine these effectively in a small, cost-efficient machine is a significant
advantage. However, cutting speed and material versatility will depend heavily on the
specific characteristics of the materials, including their conductivity and hardness. The
machine’s software and control systems will need to be adaptable to optimize cutting
parameters for different materials, ensuring the best performance across various use cases.
Compact Design and Cost-Effectiveness
One of the most appealing aspects of the proposed Wire EDM Machine is its compact
and portable design, which allows it to be used in smaller spaces, such as research labs, small
workshops, and educational institutions. The small footprint makes it a practical solution for
environments where space is limited, and the lightweight frame further enhances its
portability. This makes it an ideal option for users who need high-performance capabilities
but lack the space for larger industrial machines.
In addition to its compact size, the machine's cost-effectiveness makes it a valuable
tool for smaller businesses, hobbyists, and educational institutions. Traditional industrial
EDM systems can be prohibitively expensive, making them inaccessible to many potential
users. By simplifying the design and using cost-efficient components, the proposed machine
lowers the financial barrier, making precision machining more accessible. However, there
may be concerns about the trade-off between cost and performance, particularly when it
comes to durability and long-term reliability. While the goal is to keep costs low, it will be
essential to strike a balance between affordability and ensuring the machine can withstand
continuous use.
User-Friendly Operation and Accessibility:
The user-friendly operation of the machine, facilitated by intuitive CAD/CAM
software, makes it accessible to a wide range of users, from beginners to seasoned
professionals. This ease of use is especially valuable in educational settings, where students
can gain hands-on experience with precision machining without the need for extensive
training. The software's support for real-time parameter monitoring also allows users to fine-
tune machine settings and optimize the cutting process. However, while user-friendly
controls and programming ease are attractive features, the complexity of the tasks being

Department of Mechatronics, AIT 39

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

undertaken will still require users to have some foundational knowledge of EDM principles
and machining techniques.
Energy Efficiency and Environmental Impact:
The energy efficiency of the machine is a notable consideration, particularly as
manufacturing processes become increasingly focused on sustainability. By incorporating
low-energy pulse generators and efficient dielectric fluid management, the machine reduces
its power consumption, making it eco-friendlier and more cost-effective in the long run. The
use of eco-friendly dielectric fluids and waste collection systems further enhances the
machine’s environmental credentials. However, the energy savings may not be as significant
in the initial phases of development, and the machine will need to be thoroughly tested to
ensure that these systems function optimally under various conditions.

Reliability and Long-Term Durability:

Reliability and durability are essential for any manufacturing equipment, and while
the machine is designed to offer consistent performance, the small-scale nature of the
machine may introduce challenges in maintaining long-term operational stability. Smaller
machines are often subject to wear and tear more quickly than their larger counterparts, and
ensuring that the components remain robust and functional over time will be crucial. With
proper maintenance, however, the machine’s quality components and durable construction
should offer reliability, making it a valuable investment for users looking for consistent
results.

Department of Mechatronics, AIT 40

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

CONCLUSION

A small-scale desktop Wire EDM system is a revolutionary tool designed to deliver

precision cutting capabilities in a compact and affordable package. It caters to industries,
researchers, and hobbyists requiring intricate cuts and exceptional surface finishes for metals
and alloys. With advancements in control systems and fine wire electrodes, the system offers
unparalleled accuracy, making it ideal for applications in micro-fabrication, prototyping, and
small-batch production.

The compact design and cost-effective nature of the system make it highly suitable for
small workshops, research labs, and educational institutions. It eliminates the need for
expensive industrial-grade equipment while maintaining reliable performance for complex
machining tasks. Furthermore, its user-friendly interface and low maintenance requirements
enhance accessibility, encouraging broader adoption of precision machining technology.

By bridging the gap between affordability and high precision, the desktop Wire EDM
system empowers users to achieve professional-grade results in a wide range of applications.
It supports innovation and creativity in metalworking, enabling the production of intricate
components for fields like electronics, medical devices, and jewelry. This system signifies a
significant step toward democratizing precision machining technology for diverse user
groups.

Department of Mechatronics, AIT 41

Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

REFERENCES

[1].Kumar, A., & Batra, U. (2019). Electrical Discharge Machining: Principles and
Applications. Springer.
[2].Li, L., & Guo, Y. (2020). Advances in Wire EDM Technology. Journal of Manufacturing
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[3].Masuzawa, T. (2000). State of the Art of Micromachining. CIRP Annals, 49(2), 473-488.
[4].McGeough, J. A. (1988). Principles of Electrochemical Machining. Chapman & Hall.
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[10].Prakash, R., & Senthilkumar, P. (2021). Recent developments in wire EDM: A review
on advances and challenges. Materials Today: Proceedings, 45, 2164-2170.

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Small-Scale Desktop Wire EDM System for Precision Cutting of Metals 2024-2025

[11].Singh, H., & Garg, R. K. (2009). Effects of process parameters on material removal rate
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materials. Procedia Manufacturing, 48, 1110-1118.

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