Malaviya National Institute of Technology Jaipur

Mechanical Engineering Department

Assignment cum Tutorial Sheet- 7
Dr. Harlal S. Mali
EDM based Processes
1. A through hole(diam.=10mm) in a plate(5mm thick) is to be drilled using EDM. Estimate
the time required for the process. Assume R= 50Ω, C=10mF, Vs=200V, Vb=150V,
K1=0.18 to obtain MRR in mm3/min.
(Ans: t = 0.224 min, MRR = 1752.87 mm3/min.)
2. A 10mm diameter hole is to be drilled in a 5mm HSS plate by EDM using RC circuit.
The required surface finish is 20µm. Determine specifications of a capacitor to be used
when supply and discharge voltages are 220V and 150V, respectively. Use resistance as
50Ω and value of the constant as 0.4. Also estimate time required to complete the job.
(Ans: C = 2.286µF, MRR = 60.74 mm3/sec, t = 6.465 sec)
3. For RC circuit, adjusted for maximum power delivery condition, the following data are
available:
R=250Ω, C=25mF and supply voltage = 75V. Calculate charging current and frequency
of discharge when the circuit is closed. (Consider td=0.1*tc)
(Ans: ic = 0.0852 Amp, tc = 7.867 sec, f = 1.27 Hz)
4. Explain the following terms :
(a)duty factor,(b)ignition delay (c)flash point (d)relative electrode wear or wear ratio
(e)heat affected zone (f)dielectric strength (g)time constant (h)critical resistance in RC
circuit
5. What are the functions of the “adaptive control system” in EDM.
6. With the help of the neat sketch ,explain the mechanism of the material removal in EDM.
7. During EDM operation at steel sheet, calculate the surface finish if the capacitance used
is 18 µf and Discharging voltage is 130 V. K2 = 4.0. (Use the relation, HCLA =
K.V0.5.C0.33)
(Ans: 1.24 µm)
8. A through hole at 10*10 mm2 is to be drilled by EDM in 5 mm thickness plate. Estimate
the time required for the process. Assume Rc= 50Ω, Capacitance = 10 µf, Vsp= 200 V,
Vd= 180 V and K1=0.18 to obtain volumetric removal rate. Calculate surface roughness if
K2 = 3.
(Ans: t = 19.74 sec, Ra = 0.00188 µm)
9. EDM is used to machine a metallic sheet. Calculate surface finish, if C = 18 µf, Vb = 130
V, K = 4. Use the equation based on experimental results.
(Ans: HCLA = 1.239 µm)
10. A 10 mm diameter hole is to be drilled in a 5 mm HSS plate by EDM using RC circuit.
The required surface finish is 20 µm. Determine specification at a capacitor to be used
 when supply and discharge voltage are 220 V and 180 V respectfully. Use resistance as
50Ω and value of constant as 0.4 also estimate time required to complete the job.
(Ans: C = 1.878 µF, MRR = 76.023 mm3/sec, t = 5.16 sec)
11. During the calculation of VRR in EDM a supply voltage of 60 V is used instead of 40 V.
What is the ratio of the actual to the calculated VRR? Assume the maximum pass
condition.
(Ans: 0.44)
12. Find the condition for maximum power delivery to the discharging circuit in EDM.
13. Explain the working principal of wire EDM . Also explain how the stratified wire works?
14. Sketch different feasible dielectric flushing technique applicable in case of EDM.
15. Derive the relationship of surface roughness in EDM with its input parameters.
16. Write short noted on the following:
(a) re-solidification of molten metal in EDM,
(b) minimization of bowing of wire in wire EDM.
17. When using water as dielectric during machining of high speed steel (HSS) by EDM
process which specific problem do you expect?
18. Sketch the effects of following parameter on MRR during EDM: (a)resistance, (b) current
density, (c) pulse energy, (d)capacitance.
19. Illustrate the effect of (a) magnitude of current, and (b) frequency, on the shape and size
of the craters formed during EDM.
20. Draw the cause effect diagram of EDM parameters.
21. Show on a single graph the changes in discharge current and frequency of discharge to be
made to improve surface finish in Wire Electro Discharge Machining(WEDM) process.
A WEDM operation is to be performed on a slab of 18.75 mm thick aluminum using a
brass wire electrode whose diameter is 0.125 mm. It is anticipated that overcut will be
0.025mm. Using the current of 7 amps, what is the expected feed rate that can be used in
the operation? The melting temperature of aluminum may be taken as 660○C. Assume
Weller constant as 664 in SI unit.
(Ans: Feed Rate = 0.482 mm/sec)
2
22. A 40 mm through cavity is to be created in a 5 mm HSS plate by EDM using RC circuit.
The required surface finish is 20µm. Determine specifications of a capacitor to be used
when supply and discharge voltages are 220V and 140V, respectively. Use resistance as
40Ω and value of the constant(K) as 0.4. Also estimate time required to complete the job.
(Ans: Capacitance = 3.724 µF, Time = 2.02 sec)
23. With the help of labeled sketches only, show the mechanism of the material removal in
EDDG & Micro-WEDM machines available in AM&M Lab.
24. Explain the scientific principles involved in EDM process with the help of a neat
sketch(s) and suitable equations.
.........................................…………………………..xxxx………………………………………..