MECHANICAL ENGINEERING DEPARTMENT

DJJ40142- MECHANICAL WORKSHOP PRACTICE 4

EDM Wirecut Machine

SESSION : Sesi 2 2023/2024

PROGRAM : DKM (DIPLOMA MECHANICAL ENGINEERING)

LECTURER’S NAME : 1. TS. DR. JASON WILLIAM VITALES

2. RAFIDAH LAILI BINTI JASWADI

STUDENT’S NAME : WAI AN

MATRIC NUMBER : 07DKM22F1001
CLASS & SECTION : DKM 4B ((GROUP A)

COURSE LEARNING OUTCOMES (CLO):

CLO2 : Construct programs for EDM and CNC machining process using ISO codes or any related
machining software. (P5, PLO3)

CLO3 : 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 during practical work sessions. (A3,
PLO7)

Assetment Item Marks

Report Title & Objective /5

Introduction / Theory /5
Safety Precautions /5
Materials & Tools /5
Procedure /5
Result /5
Discussion /5
Conclusion /5
References /5
Writing and format style /5
Total / 50
TITLE: EDM WIRECUT MACHINE

1.0 OBJECTIVES
i. To understand how Electric Discharge Machining works and its applications in engineering field.
ii. To practice correct techniques in Electric Discharge Machining.
iii. To finishing a component using the Electric Discharge Machining.
iv. To apply code G and M in programming.

2.0 INTRODUCTION WITH THEORY EXPLANATION:

Wire electrical discharge machining (WEDM) uses a metallic wire to cut or shape a workpiece, often
a conductive material, with a thin electrode wire that follows a precisely programmed path.
Typically, the electrode diameters range from .004”- .012” (.10mm -.30mm), although smaller and
larger diameters are available.
During the wire cutting process, there is no direct contact between the wire and the workpiece
which allows for machining without causing any distortion in the path of the wire, or the shape of
the material. To accomplish this, the wire is very rapidly charged to a desired voltage. The wire is
also surrounded by deionized water. When the voltage reaches the correct level, a spark jumps the
gap and melts a small portion of the work piece. The deionized water cools and flushes away the
small particles from the gap.
The hardness of the work piece material has no detrimental effect on the cutting speed. Extrusion
dies and blanking punches are very often machined by wire cutting.
3.0 EQUIPMENT

No. ITEM DIAGRAM/PICTURE

1. CNC CONTROLLER MACHINE
- It is a control unit for the entire
operation of the EDM Wire-cut
machining process.
- It appears in 2 modes: Automatic which
means wire path will be detected; Manual
that bring outs inserting the operation code
manually.

2. LAPTOP
- For practicing and simulate our work-piece
or shape that we chose.

3. ELECTRIC DISCHARGE MACHINE

- Where the wire-cutting process occurs,
the material is cut using electrical
discharges.
- A thin wire is used as the electrode or
cutting tool.

4. WIRE ELECTRODE
- Usually made of brass or tungsten, it serves
as a cutting tool inside the EDM machine.
- By conducting electricity continuously, it
could produce a discharge that strong
enough to cut the workpiece.
4.0 SAFETY PRECAUTION:
i. Personnel safety, health, and welfare.
1) Wear industrial safety glasses with the side shields to protect eyesight.
2) Wear short/long sleeves with fitted cuffs that cannot get caught and drawn into
the Electric Discharge Machine.
3) Wear long pants and sturdy work shoes to protect the legs and feet from
any dangers.
4) Remove any jewelry or wrist watches and pull back long hair that could
get caught on the machine.
5) Do not touch the cutting tool with your hands as they may cut.

ii. Equipment safety and maintenance.

1) Always read and follow the safety information in the operator’s manual.
2) Make sure do not touch the wire while the EDM machines operate.
3) Make sure the environment is safe from danger while the machine is operating.
4) Don’t make any horse play during machining time.

iii. Workplace safety, health, and welfare.

1) Lighting conditions are adequate for the work undertaken.
2) Housekeeping is extremely important to avoid slips, trips, and falls.
3) Sweep up any metal pieces from the floor or work area with a brush or broom.
4) Provided with adequate fire-fighting equipment.

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5.0 PROCEDURES
Details with explanation below item including diagram and picture;

NO PROCEDURE DIAGRAM

1 Step 1: Prepare a CAD Model/Drawing

- A 2D model design of the product is created.
- Although some product designs might be
simple, preparing some CAD models might
require advanced knowledge, especially
complex product designs.
- The model or drawing should be properly
designed and some critical features such as
tolerance, construction lines, threads must be
shown for an effective and easier machining
operation.
2 Step 2: Construct NC Code
- CNC machines won’t understand the CAD
model or drawing.
- Therefore, the 2D model drawing must be
convert into coordinate form according to
each intersection point.
- Right before each coordinate, a specific code
must be entered.

3 Step 3: Setup Execution

- The right type of EDM machine is chose and
certain operations are configured right before
the machining operation begins.
- The right machine is selected depends on the
workpiece, the complexity of the design, and
the cost.
- Afterward, the workpiece is mounted on the
machine.

4 Step 4: Machine the Part

- The necessary and needed cutting tools was
attached by the operator and the process was
kickstarted.
- The process is automated and will run until
deemed complete by the computer program.
- During and after the machining process,
machinists will do several levels of inspection
to occur for quality assurance.

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6.0 RESULT
6.1 DRAWING PATTERN & EDM CODING
i. Drawing Pattern on graph paper

ii. NC code for the pattern

iii. Machine simulation diagram

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6.2 DETAILS SIMULATION

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7.0 DISCUSSION
i. What is the difference between CNC and EDM?
EDM is sometimes preferable to CNC machining when mold making, partly because of its ability to ac
Many injection molding companies use a combination of CNC machining and EDM, choosing between

ii. What makes resin important in the EDM machining process?

The use of ion exchange resins in EDM has several benefits, including improved surface finish, increas
Additionally, the use of purified dielectric fluid can increase the machining speed and
reduce tool wear, leading to a more efficient and cost-effective machining process.

iii. Discuss the advantages of machining thin materials using EDM Process.
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.

8.0 CONCLUSION
In the nutshell, this practical task enables to machine or cut a metal piece in a very rigid situation,
which means it help us to finish our workpiece in a slicker surface. For those who looks for a
perfect finishing for their work-piece, I highly recommend this skill for them. Lastly, the most
important things that need to beware is the water, maintenance for the water holder is highly
needed to prevent leakage.

9.0 REFERENCES
1. https://www.linkedin.com/pulse/enhancing-edm-performance-role-ion-exchange-resins-
purifying-ivey- guo#:~:text=The%20use%20of%20ion%20exchange%20resins%20in%20EDM
%20has%20several,fi nish%20of%20the%20machined%20part.
2. https://www.3erp.com/blog/7-situations-where-edm-is-better-than-conventional-
machining/#:~:text=EDM%20is%20a%20manufacturing%20and,of%20a%20sharp%20cutting%20t
ool.
3. https://fathommfg.com/advantages-of-edm

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