DJJ40142 MECHANICAL WORKSHOP

PRACTICE 4

REPORT PRACTICAL TASK EDM

NAMA PENSYARAH: ENCIK MUHAMMAD AZAM BIN NGAH

NAMA PELAJAR NO. MATRIK KELAS

ROSDIANA ISMAIL 20DKM19F2014 DKM5A
ROVINDA PETRUS 20DKM19F2018 DKM5A

SESI 1 2021/2022
1.0 LEARNING OUTCOMES

At the end of this experiment, students should be able to:

1. Construct programs for EDM and CNC machining process using ISO codes

2. Demonstrate safety procedures in the workshop according to the workshop

safety regulation correctly to create a secured environment in an organization
while doing practical work and ability to work in team to complete assigned
tasks

2.0 INTRODUCTION
Electrical-discharge machining (EDM) or also known as; electrodischarge or
spark-erosion machining. It is basic operation based on the erosion of metals by spark
discharges. When two current-conducting wires is touch each other, an arc produced. It
focused closely at the point of contact between two wires, note that a small portion of the
metal has been eroded away, leaving a small crater. This phenomenon has been known
since the discovery of electricity, but on 1940s a machining process based on this
principle was developed.

The EDM Die Sinker systems consists of a shaped tool (electrode) and the
workpiece connected to a DC power supply and placed in a dielectric (electrically
nonconducting) fluid. The cutting process occurs when the potential difference between
the tool and the workpiece is sufficiently high, the dielectric breaks down and a transient
spark discharges through the fluid, removing a very small amount of metal from the
workpiece surface.

The Wire Electrical Discharge Machining (EDM) is one of the greatest innovations
affecting the tooling and machining industry. This process has brought to industry
dramatic improvements in accuracy, quality, productivity and earnings.

The Wire EDM machining is an electro thermal production process in which a thin
single-strand metal wire in conjunction with de-ionized water (used to conduct
electricity) allows the wire to cut through metal by the use of heat from electrical sparks.
Due to the inherent properties of the process, wire EDM can easily machine
complex parts and precision components out of hard conductive materials.
3.0 THEORY
The EDM Die Sinker process can be used on any material that is an electrical
conductor. The melting point and the latent heat of melting are important physical
properties that determine the volume of metal removed per discharge. As shown in Figure
4.1.

Figure 4.1: EDM Die Sinker working principle.

While, the wire EDM machining (also known as "spark EDM") works by creating
an electrical discharge between the wire or electrode, and the workpiece. As the spark
jumps across the gap, material is removed from both the workpiece and the electrode
(Figure 4.2).

Figure 4.2 : Wire spark

To stop the sparking process from shorting out, a non-conductive fluid or dielectric
is also applied. The waste material is removed by the dielectric, and the process
continues.
MACHINE

Figure 4.3 Wire cut EDM machines.

Figure 4.4: Die sinker EDM machines.

Wire EDM‟s are manufactured in various sizes and styles of flush or submerged
type machines to fit the needs of the consumer. Large scale EDM‟s can handle
workpieces weighing over ten thousand pounds and can cut over twenty inches thick.
 Automatic Wire Threaders (AWT) are usually standard equipment on most models. In
addition to the X-Y table travels, wire EDM‟s have U / V travels for providing the
movement to cut tapers (Figure 4.5). Most machines can cut tapers of 20-30 degrees
depending on workpiece thickness.

Figure 4.5 : Table travel

Computer Numerical Control (CNC)

Numerical control is produced with the needs of the operator in mind.

Programs, machine coordinates, cutting speeds, graphics and relevant information is
displayed on a color monitor, with easy to use menu‟s. The control unit displays
menu‟s that are designed to give top priority to operability. Characters and commands
are input using the keyboard (Figure 4.6). The system is very easy to use, allowing the
operator to quickly become familiar with it, resulting in his/her learning curve being
drastically reduced. Besides executing NC data for positioning movement of the axes,
the control amends these movements when using offsets, tapering, scaling, rotation,
mirror images, or axis exchange. The control also compensates for any pitch error
compensation or backlash error in the axes drives, to ensure high accuracy positioning.
The machine has multiple coordinate systems, and jobs can be programmed in absolute
or incremental modes saving valuable programming time. For example, multiple jobs can
be set-up on the worktable, while storing the separate reference points or locations of
these jobs in specific coordinate registers.
 The numerical control offers the capabilities of scaling, mirror imaging, rotation,
axis exchange and assist programs. This enables an operator to produce an entire family
of parts from a single program without the need to edit the program. Mirror imaging is
great for left and right handed parts. Scaling is useful when working with "shrink factors"
for plastic cavities or extrusion dies. Assist programs find the edge of parts, vertically
align the wire, and perform centering routines that are very useful to the operator when
setting up jobs. Other features include technology to aid in the prevention of wire breaks,
background editing and graphic display (Figure 4.7) of programs while the machine is
running.

Figure 4.6: Programs are input through the USB port

Figure 4.7: Graphic display

Complete G Codes M Codes lists for Sodick Wire EDM with Mark 25 Mark 21 CNC controls

List of G Codes
G Code Description
G00 Rapid Motion (appears as a dotted line in graphics)
G01 Straight Line Cutting Motion
G02 Circular Cutting Motion – Clockwise (CW)
G03 Circular Cutting Motion – Counterclockwise (CCW)
G04 Dwell (ex: G04 x5.0 to dwell for 5 seconds at sharp corner only)
G05 X Axis Mirror image (turns CRT readout red when on)
G06 Y Axis Mirror Image (turns CRT readout red when on)
G08 X-Y Exchange (turns x,y,u,v, to lower case letters when on)
G09 Cancel G05, G06, G08
G11 Block Skip On (activates slash code, /, in NC program)
G12 Block Skip Off
G13 AWT REF=1 Wire break recovery with C888 discharge
G14 AWT REF=0 Wire break recovery turned off
G15 AWT REF=2 Wire break recovery without C888 discharge
G20 Inch Mode
G21 Metric Mode
G22 Soft Limit On
G23 Soft Limit Off
G26 Pattern Rotation On (ex: G26 RA45.0)
G27 Pattern Rotation Off
G28 Return To G29 Reference Point
G29 Reference Point Memory (for auto wire threader)
G30 Return To The Last G92 Location
G40 Wire Radius Compensation Cancel
G41 Wire Radius Compensation Left
G42 Wire Radius Compensation Right
G50 Taper Cancel
G51 Taper Left
G52 Taper Right
G54 Work Coordinate System Number 0
G55 Work Coordinate System Number 1
G56 Work Coordinate System Number 2
G57 Work Coordinate System Number 3
G58 Work Coordinate System Number 4
G59 Work Coordinate System Number 5
G74 4 Axis On
G75 4 Axis Off
G80 Sensor touch
G81 Move To Limits
G82 Move To Half Of Axis Display
G83 Read Current Position and Store To An H Register
G90 Set Absolute Mode
G91 Set Incremental Mode
G92 Assign Values to Axis Displays In Current Work Coordinate
G97 Assign Values to Axis Displays In ALL Work Coordinates
G104 Dwell At All Sharp Corners (ex: G104 X5.0)
G105 Cancel G104 code
G140 4Axis Offset Off
G141 4Axis Offset Left
G142 4Axis Offset Right
G154 TO G159 Work Coordinate Screen 10 to 15
G254 TO G259 Work Coordinate Screen 20 to 25
G354 TO G359 Work Coordinate Screen 30 to 35
G454 TO G459 Work Coordinate Screen 40 to 45
G554 TO G559 Work Coordinate Screen 50 to 55
G654 TO G659 Work Coordinate Screen 60 to 65
G754 TO G759 Work Coordinate Screen 70 to 75
G854 TO G859 Work Coordinate Screen 80 to 85
G954 TO G959 Work Coordinate Screen 90 to 95
FLAG2D0 M01 code off
FLAG2D1 M01 code on
FLAG3D scale factor input

List of M Codes
M Code Description
M00 Program Stop
M01 Optional Stop
M02 End Of Program
M03 AWT Jump
M05 Sensor Touch Off
M06 Disable EDM Power During Movement.
M33 Rotate Wire Tip Disposal Arm Forward. Use to remove the wire tip container.
M43 Rotate Wire Tip Disposal Arm Back.
M98 Jump to a Sub-Routine from the main program.
M99 Return from a Sub-Routine to the main program.

List of T Codes
T Code Description
T80 Wire Drive On
T81 Wire Drive Off
T82 Worktank Drain Closed
T83 Worktank Drain Open
T84 High Pressure Flushing Mode On (high flush)
T85 High Pressure Flushing Mode Off (low flush)
T86 Flushing Pump On
T87 Flushing Pump Off
T89 Switch To Non-Submersed Machining
T90 Cut Wire By Auto Wire Threader Sequence One
T91 Thread Wire By Auto Wire Threader Sequence Two
T94 Switch To Submersed Machining
T96 Worktank Fill Pump On
T97 Worktank Fill Pump Off
4.0 SAFETY AND HEALTH
1. Make sure the student follow the laboratory or workshop safety regulators.
2. Workshop must be conduct by lecturers or experience technician.
3. Always know the hazards associated with the materials that are
being utilized in the workshop.
4. Always wear appropriate protective clothing.
5. Never perform unauthorized work, preparations or experiments.
6. Be familiar with the location of emergency equipment - fire
alarm, fire extinguisher, emergency eye wash and safety shower.
Know the appropriate emergency response procedures.

5.0 DISCUSSION
1. Explain the history of the EDM machine.
The first EDM machine that used a wire as an electrode became commercially available in 1967. It
was developed in the Soviet Union. After that, wire EDM machines that were capable of following
lines from drawings were developed by Andrew Engineering. Electro Discharge Machining (EDM)
is an electro-thermal nontraditional machining process, where electrical energy is used to generate an
electrical spark and material removal mainly occurs due to the thermal energy of the spark.

2. Give 3 examples of material that can be cut using EDM m a c hi ne .

i ) T i t an i u m
i i ) M e t al
iii) S teel

3. Give 3 examples of material that cannot be cut using EDM machine.

i) Rubber
ii) Plastic
iii) Wood
4 . Explain the following CNC program example for Sodick Wire Cutting EDM CNC machines with Mark
21 / Mark 25 CNC controls.

CNC Program
Code Condition / Action
N005 G54 (SELECT COORDINATE SYSTEM A00)
N010 G92 X.250 Y-.300 ASSIGN VALUES TO AXIS DISPLAYS IN
CURRENT WORK COORDINATE
N015 G90 (SELECT ABSOLUTE MODE)
N020 C411 (SELECT CUTTING CONDITION)
N025 G42 H061 (SELECT RIGHT OFFSET AND VALUE)
N030 T94 (SUBMERGE MODE)
N031 T91 (AUTO WIRE THREAD)
N035 T84 (HIGH PRESSURE FLUSHING)
N040 G01 Y0 (MOVE IN Y-AXIS from X.25 Y-.30 to P2)
N045 X.5 (MOVE TO THE RIGHT IN X-AXIS, linear motion,
X.5 to P3)
N050 Y.500 (MOVE UP IN Y-AXIS, linear motion, Y.5 to P4)
N055 X0 (MOVE IN X-AXIS, linear motion, X0 to P5)
N60 Y0 (MOVE IN Y-AXIS, linear motion, Y0 to P6)
N065 X.150 (MOVE IN X-AXIS, linear motion, X.15 to P7)
N070 G40 Y-.02 (MOVE TO POINT 8 AND CANCEL OFFSET)

N075 M00 (PROGRAM STOP TO SUPPORT PART)

N080 G01 X.250 (MOVE TO ENTRY LINE)
N90 G01 Y-.300 (MOVE BACK TO START POINT)
N095 M02 END OF PROGRAM
5. Generate the wire EDM programming for following drawing, cutting direction is follow the position
given.

Code Condition / Action

N010 G00 X0 Y0 (SET PROGRAM ZERO)
N015 G90 (SELECT ABSOLUTE MODE)
N020 C411 (SELECT CUTTING CONDITION)
N025 G42 H061 (SELECT RIGHT OFFSET AND VALUE)
N030 T94 (SUBMERGE MODE)
N031 T91 (AUTO WIRE THREAD)
N035 T84 (HIGH PRESSURE FLUSHING)
N040 G01 Y1.25 (MOVE IN Y-AXIS from X0 Y0 to P1)
N045 G02 X.5 I.25 J0 (MOVE IN X-AXIS, circular motion clockwise, I for
radius .25, J for relative coordinates from start point
to P2)
N050 G01 Y.75 (MOVE IN Y-AXIS, linear motion, Y.75 to P3)
N055 G03 X1 I.25 J0 (MOVE in X-AXIS, circular motion
counterclockwise, I for radius .25, J for relative
coordinates from start point to P4)
N060 G01 Y1.25 (MOVE UP IN Y-AXIS, linear motion, Y1.25 to P5)

N065 G02 X1.5 I.25 J0 (MOVE IN X-AXIS, circular motion clockwise, I for
radius .25, J for relative coordinates from start point
to P6)
N070 G01 Y0 (MOVE IN Y-AXIS, linear motion, Y0 to P7)

N075 X0 (MOVE IN X-AXIS, linear motion, X0 to P8)

N095 M02 (END OF PROGRAM)

6.0 CONCLUSION

In the conclusion of this report, we can learn about EDM systems, the electrode (cutting tool), and the workpiece
held by the machine tool. The power supply controls the electrical discharges and movement of the electrode in
relation to the workpiece. During operation, the workpiece is submerged in a bath of dielectric fluid (electrically
nonconducting).

7.0 REFERENCES

>prototype-shortrun
• https://prototype-shortrun.com/american-wire-edm/history-of-edm-
machining/#:~:text=The%20first%20EDM%20machine%20that,were%20developed%20by%20Andrew%2
0Engineering.

> dokumen.tips
• https://dokumen.tips/documents/88467736-report-edm-die-sinker.html?page=21