ELECTRICAL DISCHARGE MACHINING

Name: Anil Chejara Roll no. : 9003022 Group no. : 5

BACKGROUND: EDM is a non traditional process by which a desired shape is obtained using electrical discharges (sparks). Material is removed from the work piece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-electrode, while the other is called the work piece-electrode. When the distance between the two electrodes is reduced, the intensity of the electric field in the volume between the electrodes becomes greater than the strength of the dielectric (at least in some point(s)), which breaks, allowing current to flow between the two electrodes. This phenomenon is the same as the breakdown of a capacitor (condenser). As a result, material is removed from both the electrodes. Once the current flow stops new liquid dielectric is usually conveyed into the inter-electrode volume enabling the solid particles (debris) to be carried away and the insulating proprieties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is commonly referred to as flushing. Also, after a current flow, a difference of potential between the two electrodes is restored to what it was before the breakdown, so that a new liquid dielectric breakdown can occur. It is commonly used in producing complex shapes, Extremely hard material, a good surface finish product, very fine holes easily drill. AIM: The aim of this is to understand material removal mechanism in EDM. To identify the process parameters & purpose of dielectric fluid in EDM & to study the effect of process variables on Material Removal Rate (MRR).

Description: The discharge process during EDM can be separated into three main phases. They are: Preparation phase- On switching on the power supply, electric field is set-up in the gap between the electrodes. The electric field reaches maximum value at the point where the gap between the electrodes is smallest. Discharge phase- During the discharge phase a high current flows through the plasma channel and produces high temperature on the electrode surfaces. Interval phase- The gas bubble collapses and material is ejected out from the surface of the electrodes in the form of vapors and liquid globules. The evaporated electrode material

solidifies quickly when it comes in contact with the cold dielectric medium and forms solid debris particles which are flushed away from the discharge gap. The various process parameters of EDM are mainly related to waveform characteristics. Some of them are: Open circuit voltage -Vo Working voltage- Vw Maximum current - Io The pulse on time the duration for which the voltage pulse is applied - Ton The pulse off time - Toff The gap between the work piece and the tool spark gap - The polarity straight polarity tool (-ve) The dielectric medium External flushing through the spark gap.

Subsystems and Materials used EDM machine has the following major subsystems: Dielectric reservoir, pump and circulation system Power generator and control unit Working tank with work holding device X-y table accommodating the working table The tool holder The servo system to feed the tool Dielectric used: Paraffin Oil Work piece Material used: Mild Steel Procedure I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. First mount of work piece on work table. Check alignment of electrode & workpiece. Before switching mains on checking of all the subsystems of EDM is working properly or not. Once all subsystems are working properly, press mains on. Manually move the quill down and keep some distance between electrode & work piece. Manual movement is obtained with the help of switch provided on quill. When electrode touches job, buzzer starts & electrode goes up by sense pot. Press pump switch on, indicator on. Pump motor starts, dielectric fluid flows in tank. Control its flow & hence level in dielectric tank with the help of flow control valves. Press erosion on switch, if erosion indication on voltage is shown. Electrode comes down, sparking takes place.

Experimental Data: Following are the parameters were kept constant during the experiment, Ton = 6 s Toff = 6 s Voltage, V = 75 V (between job and tool)

Density of work piece = 7.85 gm/cc Time = 20 min Where, Ton: The pulse on time the duration for which the voltage pulse is applied Toff: The pulse off time Sample No Current (I, Ampere) Mass (Before experiment, in gm) 141.3071 144.9856 128.3420 Mass (After experiment in gm) 140.4728 143.8705 126.2201 Mass of removed material (in gm) 0.8343 1.1151 2.1219

1 2 3

6 8 10

Actual Material Removal Rate (MRR) Calculation Actual MRR = (= )

For sample 1: Actual MRR =0.8343 *10-6 /7.85*20 m3/min = 5.314 * 10-9 m3/min For sample 2: Actual MRR =1.1151 *10-6 /7.85*20 = 7.103 * 10-9 m3/min For sample 3: Actual MRR =2.1219 *10-6 /7.85*20 = 13.515 * 10-9 m3/min m3/min m3/min

Results: Sample No 1 2 3 Current (I, Ampere) 6 8 10 Actual MRR (m3/min) 5.314 * 10-9 7.103 * 10-9 13.515 * 10-9

MMR vs Current
16 14 12 10 8 6 4 2 0 0 2 4 6 Current (A) 8 10 12 MMR (m3/min)

Conclusion: 1. MMR also increases with applied voltage. 2. MMR is directly proportional to the current supplied. Sources of Error / Precaution: 1. Dielectric may not be clean. 2. Allow continuous circulation of dielectric through tank so that any impurity (in the form of removed material) can be easily washed out. 3. Keep the dielectric level constant. Suggestion; Two different materials in spite of using 1 material (three samples) can be tested hence will have better understanding of the experiment and its effect on different materials.