Acknowledgment

The completion of this expansive report stands as a testament to the collaborative effort and
support received from various individuals. I extend my heartfelt gratitude to Surendra kumar
yadav for their unwavering guidance, insightful feedback, and encouragement throughout the
research process. The collaborative spirit of [Colleague/Institution's Name] significantly enriched
the discussions and perspectives presented in this report, for which I am sincerely thankful.
Special appreciation is reserved for [], whose contributions, whether big or small, have left an
indelible mark on this work. This report is the culmination of a collective endeavor, and I express
my deepest appreciation to everyone who played a role in its realization.

I
INDEX

Titel Page No.

CHAPTER-I: GENERAL INTRODUCTION 1-3

1.1. Introduction of EDM ` 1
1.2. Basic principle of EDM Process
1
1.2.1. Die-sinking 2
1.3. Some of the most important parameters implicated in the
EDM manufacturing processes are the following. 3
1.4. Application of EDM 3

CHAPTER-II: BRIEF INTRODUCTION OF THE PROJECT 4-6

2.1. Cause of residual stresses in EDM process 4
2.2. Different methods of measuring residual stresses 5
2.2.1. EDM-Hole Drilling Method 5
2.2.2. Fin diffraction method 5
2.2.3. X-RAY Diffraction method 5
2.2.4. Bending deflection method 5
2.2.5. The principle of layer removal method 6

CHAPTER-III: LITERATURE REVIEWS 7-9

3.1. Experimental studies on residual stresses 7
3.2. Cracks Causes 8
3.3. Objective of the present works 9

CHAPTER-IV: EXPERIMENTAL WORKS 10-11

4.1. Procedure 10

II
CHAPTER-V: RESULTS AND DISCUSSION 12-17
5.1. Phase transformation 12
5.2. Crater Shape 13
5.3. Conclusion 17

REFERENCES 19

III
 LIST OF FIGURES
FIGURE NO. TITEL PAGE NO.

Figure 1.1 Die-sinking 2

Figure 2.1 Close-up of the EDM machine region 4
Figure 3.1 EDM surface with surface cracks and sketch
of sub-surface region 9
Figure 5.1 Un EDM surface of En-19 14
Figure 5.2 SEM photograph of EDM surface of En-19 at
5 amp current 14
Figure 5.3 SEM photograph of EDM surface of En-19 at
25 amp current 15
Figure 5.4 SEM photograph of EDM surface of En-19 at
45 amp current 16

LIST OF TABLES

TABLE NO. TITEL PAGE NO.

Table 4.1 Sample no. 1 10

Table 4.2 Sample no. 2 10
Table 4.3 Sample no. 3 11

IV