Wire electric discharge machine

EDM PROCESS

EDM is also known as spark machining or spark eroding machining process where the desired
shape of the material is obtained by using electric discharges i.e., sparks. Material is removed
from the work piece by a series of rapidly reoccurring sparks between two electrodes separated
by a discharge liquid and subject to an electric voltage. . The process depends upon the tool and
work piece not making physical contact. This type of technique is mainly used for hard metals.
Used in Drilling for micro holes in the nozzle, thread cutting, Rotary form cutting, Helical profile
milling, Curved hole drilling, Engraving operation on harder materials, Cutting off operation

WIRE EDM PROCESS

WEDM is a non traditional machining process that uses electricity to cut any conductive material
precisely and accurately with a thin electrically charged wire as an electrode.

Wire EDM machining works by creating an electrical discharge between the wire or the
electrode and the work piece. As the spark jumps across the gap, material is then removed from
the work piece and the electrode. Due to the inherent properties of the process, Wire EDM can
easily machine complex parts and precision components out of hard conductive materials.
To stop the sparking process from shorting out, a non-conductive fluid or dielectric is also used
in the process. The waste material is removed by the dielectric, and the process continues. 
What is taguchi
Taguchi method of quality control is an approach to engineering that emphasizes the
roles of research and development (R&D), and product design and development in
reducing the occurrence of defects and failures in manufactured goods.
Taguchi method is used :
Taguchi Method is a process/product optimization method that is based on 8-steps of
planning, conducting and evaluating results of matrix experiments to determine the best
levels of control factors. The primary goal is to keep the variance in the output very low
even in the presence of noise inputs.
Taguchi basic philosophy has three concepts: 
Design quality into the product. Achieve quality by minimizing deviation from the
target. Measure the cost of quality as a function of deviation from the standard (Taguchi
loss function).
INPUT PARAMETRS
Pulse-on time or pulse duration:

 The time interval during which the spark (electron discharge) occurs between electrode (wire)
and the work piece once the break down voltage of the dielectric is reached causing its
ionization.

Pulse-off time or pulse interval: 

The time duration between consecutive sparks during which there is no current supply to the
electrodes and deionization of dielectric takes place.

Gap voltage

Gap voltage is the voltage in the gap between two electrodes. The total energy of the spark is
determined by the applied voltage. , the voltage supplied is approximately 50 to 300 volts
because higher voltage is not suitable for high precision machining. Therefore, EDM discharge
gap is about 0.005 - 1.0mm.

Wire speed

The electrode wire (usually molybdenum wire) is used for high-speed reciprocating movement,
and the wire speed is 8-10m/s. The electrode wire can be reused, which saves molybdenum wire,
but the accuracy is low. it is generally used by domestic wire cutting machines.

OUTPUT PARAMETERS

Material removal rate

Material removal rate (MRR) is the amount of material removed per time unit, directly aiming at
the process productivity.

The material removal rate in a work process can be calculated as the depth of the cut, times the
width of the cut, times the feed rate. The material removal rate is typically measured in cubic
centimeters per minute (cm3/min).

Surface roughness

Surface roughness is the measure of the finely spaced micro-irregularities on the surface
texture which is composed of three components, namely roughness, waviness, and form. A
roughness tester is used to quickly and accurately determine the surface texture or surface
roughness of a material. A roughness tester shows the measured roughness depth (Rz) as well as
the mean roughness value (Ra) in micrometers or microns (µm) Average roughness is typically
measured in either microns (µm) or micro-inches (µ-in, µ”). One micron equals roughly 40
micro-inches (µ”).
Kerf width:The kerf is calculated by summing up the 'wire diameter to 2 3 wire–workpiece
gap dis- tance'. The wire–workpiece gap usually ranges from 0.025 to 0.075 mm and is
constantly maintained by a computer-controlled positioning system.

Dimension deviation

Wire wear rate

Overcut

Cutting speed.

Machining time

Accuracy

Length of cut

MATERIAL INCONAL 825

Inconal 825 is a nickel-iron-chromium alloy with additions of molybdenum, copper and
titanium. It is an alloy that provides high levels of corrosion resistance to both moderately
oxidizing and moderately reducing environments. Alloy 825 is similar to alloy 800 but has
improved resistance to aqueous corrosion.

Work piece material Composition

Iron 66.74 - 71.24% (Balance)

Chromium 17.5 - 19.5%

Nickel 8 - 10.5%

Manganese 2%

Silicon 1%

Nitrogen 0.11%

Carbon 0.07%

Sulphur 0.03%
 Properties

 High Specific heat capacity

 High Density
 Elastic modules
 Hardness
 Tensile strength
 Yield strength
 Elongation
 Coefficient of thermal expansion
 Thermal conductivity
 Melting point high
 Specific heat capacity

Optimization Techniques

optimization methods are used in many areas of study to find solutions that

maximize or minimize some study parameters, such as minimize costs in the
production of a good or service, maximize profits, minimize raw material in the
development of a good, or maximize production.

Genetic algorithm
The genetic algorithm is a method for solving both constrained and unconstrained
optimization problems that is based on natural selection, the process that drives
biological evolution. The genetic algorithm repeatedly modifies a population of individual
solutions.

Advantages

 Thin walls are possible.

 Cut internal corners with very small radii.
 Cut thin slots in extrusion dies with wire EDM.
 Produce blind and high aspect ratio pockets with sinking EDM.
 Produce non-round openings and cavities.
 An alternative to broaching for 2D shapes like gears.
 Disadvantages

 Machining time is too long.

 Excessive tool wear.
 High specific power consumption.
 Profile machining of complex contours is not possible.
 Only able to machine conductive materials.
 The metal removal rate is slow.
 Reproduction of sharp corners is the limitation of the process.
Applications

 Prototype production.
 Automotive parts.
 Aerospace parts.
 Medical devices for implantations.
 Prototypes.
 Small hole drilling.
 Blanking punches.
 Extrusion dies.
