MAHARISHI MARKANDESHWAR ENGGINEERIING

COLLEGE MULLANA (AMBALA)

MAHARISHI MARKANDESHWAR UNIVERSITY
BY

SUSHIL KUMAR 11082416

SANDEEP KUMAR 11082421
JITENDER KUMAR 11082454
SUBHASH CHANDER 11082473

UNDER THE SUPERVISION OF

PROF. M.P.GARG
&
MR. ANISH KUMAR

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 MAHARISHI MARKANDESHWAR ENGGINEERIING COLLEGE MULLANA
(AMBALA)

DEPARTMENT OF MECHANICAL ENGINEERING

M.M COLEGE OF ENGG., MULLANA

CERTIFICATE

This is to certify that the project work titled development of table top model of “EDM”carried out by the
students SUSHIL KUMAR (11082416),SANDEEP KUMAR
(11082421),JITENDER(11082454),SUBHASH CHANDER (11082473) academic year
2012 is a genuine and eligible work for the award of credits for the partial fulfillment of degree in B. tech
mechanical engg. of MMU
The work has been submitted by these students for award of any other degree or diploma
of any other university/board.

PROF. M.P. GARG MR. ANISH KUMAR

Project supervisor Project coordinator

1. Prof. N.K. BATRA

Head of the department
Mechanical Engineering

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 DEVELOPMENT OF TABLE TOP MODEL OF
ELECTRIC DISCHARGE MACHINE

submitted in the partial fulfillment of the award of degree in mechanical

engineering

MAHARISHI MARKANDESHWAR UNIVERSITY,MULLANA,AMBALA

BY

NAME OF STUDENT ROLL NO.

SHUSHIL KUMAR 11082416

SANDEEP KUMAR 11082421
JITENDER 11082454
SUBHASH CHANDER 11082473

UNDER THE SUPERVISION OF

PROF.M.P GARG AND MR. ANISH KUMAR

2
MAHARISHI MARKANDESHWAR ENGGINEERIING COLLEGE MULLANA
(AMBALA)

3
 Development Of Table Top Model Of
Electric Discharge Machine

TABLE OFCONTENTS
S. NO. TOPIC PAGE NO.

I. DECLARATION 5
II. ACKNOWLEDGEMENT 6
III. ABSTRACT 7
1 INTRODUCTION 8

2 HISTORY 10

3 11
METHODOLOGY

3.1 METAL REMOVAL PROCESS 12

3.2 CHARACTERISTICS OF SPARK ERODED SURFACE 14
3.3 DIELECTRIC FLUID 16
3.4 ELECTRODE 17
3.5 TYPE OF EDM 19
3.6 APPLICATION OF EDM 21
3.7 ADVANTAGES &DISADVANTAGES 23
4 FABRICATION 24

4.1 PART WITH SPECIFICATION 25

4.2 MATERIAL REMOVAL RATE(MRR) 39
4.3 ASSEMBLY 40
5 PROCESS CHART 43

5.1 PROCESS SHEET OF TABLE 44

6 COST ESTIMATION 45

6.1 COST OF STAND 46

Development Of Table Top Model Of

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 Electric Discharge Machine

6.9 MISCELLANEOUS COST 47

7 FUTURE TREND OF EDM 48

8 RESULT AND DISCUSSIONS 49

9 REFERENCES 50

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 Development Of Table Top Model Of
Electric Discharge Machine

DECLARATION

Project Title- DEVELOPMENT OF TABLE TOP MODEL OF

ELECTRIC DISHCHARGE MACHINE
(EDM)

THE PROJECT DISSERTATION IS SUBMITTED/FULFILLMENT

OF ACEDEMIC REQUIREMENT OF 8TH SEMESTER OF B.TECH
IN MECHANICAL DEPARTMENT(ENGINEERING COLLEGE OF
MMU). THIS DISSERTATION IS A RESULT OF OUR OWN
INVESTIGATION. ALL SECTION OF THIS TEXT AND RESULT
WHICH HAVE BEEN OBTAINED FROM THE OTHER SOURCES
ARE FULLY.

TEAM MEMBERS:

SHUSHIL KUMAR 11082416

SANDEEP KUMAR 11082421
JITENDER KUMAR 11082454
SUBHASH CHANDER 11082473

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 Development Of Table Top Model Of
Electric Discharge Machine

ACKNOWLEDGEMENT

It is very difficult for anyone to complete this project without the active co-
operation and the benefit of advice from people who are expert in their field
of specialization. I would like express our gratitude to those who are
concerned with the processing of this report. I am very thankful to them
although this is hardly an adequate compression for the time they have
provided.
Our thanksare due to Prof. M.P Garg and Mr. Anish kumar Mechanical
Deppt.who guided us to take up the work in this area of edm. We would like
to thank the faculty of mechanical department for providing us this
apportunity.

NAME OF STUDENT ROLL NO.

SHUSHIL KUMAR 11082416

SANDEEP KUMAR 11082421
JITENDER KUMAR 11082454
SUBHASH CHANDER 11082473

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 Development Of Table Top Model Of
Electric Discharge Machine

ABSTRACT

Development Of Table Top Model Of Electric Discharge Machine(EDM)

have been taken for the reason that this process is fast developing
machining process. This process started with the itration on specification
and availibility of equipment in local market and drawing of the
specification was the main task.

The edm process can be compared with the conventional

cutting process, except that in this case, a suitable shaped tool electrode,
with a precision controlled feed movement is employed in the place of
cutting tool, and the cutting energy is provided by means of short duration
electrical impulses. EDM has found ready application in machining of
hard metals or alloys which can not be machine easily by conventionnal
methods. this phenomenon is same as the breakdawn of a capacitor or
breakdawn voltage. As a result material is removed from both the
electrode.

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 HISTORY
In 1920, the english scientist, priestley, first detected
the erosive effect of electrical discharge on metals.
more recently, during research, to eleminate erosive
effect on electrical contacts, the soviet scientist,
lazarenko decided to exploit the distractive effect of
electrical discharge and developed a controlled
method of metal machining. in 1943, they announced
the constraction of first spark erosion machine. The
spark generator used in 1943, known as the lizarenko
circuit, has been employed over many year in power
supplies for EDM machine and an improve form is
being used in many current application. Agie
launches in 1969 the world’s first numerically
controlled wire cut eedm machine. Seibu developed
the world first cnc wire edm machine 1972 and the
first system is manufactured in Japan.

DEVELOPMENT OF TABLE TOP MODEL OF

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 Fabrication
Parts with specification
1.1 Basin
1.2 Storage Tank
1.3 Table
1.4 Circuit
1.5 Electromagnet
1.6 Electrode and Work Piece
1.7 Guide way
1.8 X-Y Slide
1.9 Z-Slide
1.10 Guide way and work piece assembly
1.11 Dielectric material
1.12 Other Material

Assembly
Sub assemblies
1.Guide way assembly
2.Basin assembly
Full assembly

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Electrode:

Transformer

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 X-Y Slide:

Z Slide:

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BASIN:-

Material used : G.I Sheet

Dimensions : 300*200*200

DESIGN OF BASIN:
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TABLE:-
Material Used :

Dimension : 800*400*400

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DESIGN OF TABLE

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ELECTROMAGNET:-

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ELECTRODE AND WORKPIECE:-
a)Electrode
Copper electrode is brazed to the electromagnet for
proper functioning

Material Used : Copper

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Dimension : 3 Mmdia.,25mm Length
b) Work piece
Work piece on which the copper electrode will work.

Material used: shaving blade on stainless steel

GUIDE WAY
Guide Way is use for the proper sliding of work piece on into the
basin

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DESIGN OF GUIDEWAY

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WORK PIECE HOLDER
Work piece holder is used for holding the work piece
against the tool. In this, work piece holder is fixed in
between the guide way for sliding the work piece forth
& back.

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GUIDE WAY AND WORK PIECE ASSEMBLY

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ASSEMBLY:
SUBASSEMBLIES:-
1. Guide way assembly
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BASIN ASSEMBLY

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FULL ASSEMBLY

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25
 Circuit:

Applications:
Prototype production
The EDM process is most widely used by the mold-making, tool, and die industries, but is
becoming a common method of making prototype and production parts, especially in the
aerospace, automobile and electronics industries in which production quantities are relatively
low. In sinker EDM, a graphite, copper tungsten, or pure copper electrode is machined into the
desired (negative) shape and fed into the workpiece on the end of a vertical ram.

Coinage die making

For the creation of dies for producing jewelry and badges, or blanking and piercing (through use
of a pancake die) by the coinage (stamping) process, the positive master may be made from
sterling silver, since (with appropriate machine settings) the master is significantly eroded and is
used only once. The resultant negative die is then hardened and used in a drop hammer to
produce stamped flats from cutout sheet blanks of bronze, silver, or low proof gold alloy. For
badges these flats may be further shaped to a curved surface by another die. This type of EDM
is usually performed submerged in an oil-based dielectric. The finished object may be further
refined by hard (glass) or soft (paint) enameling and/or electroplated with pure gold or nickel.
Softer materials such as silver may be hand engraved as a refinement.

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Small hole drilling.
Small hole drilling EDM is used in a variety of applications.
On wire-cut EDM machines, small hole drilling EDM is used to make a through hole in a
workpiece in through which to thread the wire for the wire-cut EDM operation. A separate EDM
head specifically for small hole drilling is mounted on a wire-cut machine and allows large
hardened plates to have finished parts eroded from them as needed and without pre-drilling.

Metal disintegration machining

Several manufacturers produce MDM machines for the specific purpose of removing broken
tools (drill bits, taps, bolts and studs) from work pieces. In this application, the process is termed
"metal disintegration machining" or MDM. The metal disintegration process removes only the
center of the tap, bolt or stud leaving the hole intact and allowing a part to be reclaimed.
The EDM process is most widely used by the mould-making tool and die industries, but is
becoming a common method of making prototype and production parts, especially in the
aerospace, automobile and electronics industries in which production quantities are relatively
low.

Advantages
Some of the advantages of EDM include machining of:

(a) Complex shapes that would otherwise be difficult to produce with conventional cutting tools.

(b) Extremely hard material to very close tolerances.

(c) Very small work pieces where conventional cutting tools may damage the part from excess
cutting tool pressure.

(d) There is no direct contact between tool and work piece. Therefore delicate sections and weak
materials can be machined without any distortion.

(e) A good surface finish can be obtained.

(f) Very fine holes can be easily drilled.

(g) Electrically non-conductive materials can be machined only with specific set-up of the
process.

Disadvantages
Some of the disadvantages of EDM include:

(a) The slow rate of material removal.

(b) The additional time and cost used for creating electrodes for ram/sinker EDM.

(c) Reproducing sharp corners on the work piece is difficult due to electrode wear.

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(d) Specific power consumption is very high.

(e) Power consumption is high.

(f) "Over cut" is formed.

(g) Excessive tool wear occurs during machining.

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