SREE VIDYANIKETHAN ENGINEERING
COLLEGE
(Autonomous)
A.Rangampet, Tirupati-517102
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the Internship report titled “WIRE EDM TECHNIQUES”
submitted by the student in the Department of Mechanical Engineering, Sree Vidyanikethan
Engineering College (Autonomous), A.Rangampet, Tirupati and is submitted in partial
fulfillment for the award of B.Tech. in Mechanical Engineering to the Jawaharlal Nehru
Technological University Anantapur, Anantapuramu is a record of bonafide work carried out
by the student under our guidance and supervision.
The results embodied in this report have not been submitted to any other University or
Institute for the award of any degree or diploma.
LIKKOLA BALARAJU
20121A0374
INTERNSHIP GUIDE
HEAD OF THE DEPARTMENT
INTERNAL EXAMINER
EXTERNAL EXAMINER
i
INTERNSHIP CERTIFICATE COPY
ii
ACKNOWLEDGEMENT
I express my deep sense of gratitude, appreciation and indebtedness to our internship provider
Micromachining Research Center (MMRC), Department of Mechanical Engineering,
Sree Vidyanikethan Engineering College in association with M/s. RV Machine Tools
(Industry Partner) for their valuable guidance and support and constant encouragement
during the internship work have helped me in completing the report.
I wish to express my deepest gratitude and thanks to Dr. R. Satya Meher Professor & Head,
Department of Mechanical Engineering, SVEC.
I express my profound gratitude to the Principal and Management of SVEC for permitting
me to do my internship work.
I also express my thanks for help rendered by Dr. S. Ragu Nathan Professor, Department of
Mechanical Engineering, SVEC.
Last but not least, thanks to my parents for their numerous supports in many different ways
throughout the study.
I also thank all who have helped directly or indirectly in completing the internship.
LIKKOLA BALARAJU
iii
SREE VIDYANIKETHAN ENGINEERING COLLEGE
VISION
To be one of the Nation’s premier Engineering Colleges by achieving the highest order of
excellence in Teaching and Research.
MISSION
➢ To foster intellectual curiosity, pursuit and dissemination of knowledge.
➢ To explore students’ potential through academic freedom and integrity.
➢ To promote technical mastery and nurture skilled professionals to face competition in
ever increasing complex world.
iv
DEPARTMENT OF MECHANICAL ENGINEERING
VISION
To become and be recognized as a nationwide center of excellence in Mechanical
Engineering and allied areas for acquiring self-reliance through education, engagement and
research.
MISSION
➢ Department of Mechanical Engineering is established to provide students with a sound
Mechanical Engineering education, advance the understanding and application of
Mechanical Engineering principles to work in multicultural and multidisciplinary
environment.
➢ Engage and impart knowledge to the students for innovative, high-impact and leading
edge research and development of modern Mechanical Engineering science through
contemporary curriculum.
➢ Maintain a collegial, supportive, and diverse environment that encourages students,
faculty, and staff to achieve to the best of their abilities.
➢ Serve our students by teaching them problem solving, leadership and teamwork skills,
and the value of a commitment, quality and ethical behavior for their employability.
➢ Serve the community and industry through proactive knowledge exchange.
v
PROGRAM EDUCATIONAL OBJECTIVES
After few years of graduation, the graduates of B. Tech. (ME) Program will be:
1. Pursuing further education in Mechanical Engineering, business administration, or
other disciplines.
2. In program related industry, allied industry, software industry, and able to start
entrepreneurial ventures related to Mechanical Engineering.
3. Able to recognize the developing technology through life-long learning for solving
problems related to Mechanical Engineering.
PROGRAM OUTCOMES
On successful completion of the Program, the graduates of B. Tech. (ME) Program will be able
to:
1. Apply the knowledge of mathematics, science, engineering fundamentals, and an
engineering specialization to the solution of complex engineering problems.
(Engineering knowledge)
2. Identify, formulate, review research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences. (Problem analysis)
3. Design solutions for complex engineering problems and design system components or
processes that meet the specified needs with appropriate consideration for the public
health and safety, and the cultural, societal, and environmental considerations.
(Design/development of solutions)
4. Use research-based knowledge and research methods including design of experiments,
analysis and interpretation of data, and synthesis of the (Conduct investigations of
complex problems) information to provide valid conclusions.
vi
5. Create, select, and apply appropriate techniques, resources, and modern engineering
and IT tools including prediction and modeling to complex engineering activities with
an understanding of the limitations. (Modern tool usage)
6. Apply reasoning informed by the contextual knowledge to assess societal, health,
safety, legal and cultural issues and the consequent responsibilities relevant to the
professional engineering practice. (The engineer and society)
7. Understand the impact of the professional engineering solutions in societal and
environmental contexts, and demonstrate the knowledge of, and need for sustainable
development. (Environment and sustainability)
8. Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice. (Ethics)
9. Function effectively as an individual, and as a member or leader in diverse teams, and
in multidisciplinary settings. (Individual and team work)
10. Communicate effectively on complex engineering activities with the engineering
community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and
receive clear instructions. (Communication)
11. Demonstrate knowledge and understanding of the engineering and management
principles and apply these to one's own work, as a member and leader in a team, to
manage projects and in multidisciplinary environments. (Project management and
finance)
12. Recognize the need for, and have the preparation and ability to engage in independent
and life-long learning in the broadest context of technological change. (Life-long
learning)
vii
PROGRAM SPECIFIC OUTCOMES
On successful completion of B. Tech. (ME) Program, graduates will be able to:
1. Design, develop, analyze and maintain of mechanical systems and processes by
applying the concepts of material science, Manufacturing, Design and Computer aided
Design & Manufacturing technologies.
2. Apply the principles of thermodynamics, Fluid mechanics and Heat Transfer in the
thermal design of various components of thermal energy systems and assess the
performance of various thermal energy systems.
3. Identify, define, analyze, formulate, and solve problems related to manufacturing and
service systems for optimized conditions by applying tools of Industrial Engineering
for effective decision making and support purposes.
viii
ABSTRACT
This report provides a comprehensive overview of Wire Electrical Discharge Machining (Wire
EDM) techniques, based on an internship experience. It delves into the principles of Wire
EDM, a non-traditional machining process known for its ability to manufacture complex and
precise parts. The report further explores various techniques and parameters that influence the
process, such as pulse duration, discharge current, and wire tension, among others. Real-world
applications and case studies from the internship are used to illustrate these concepts. The
report also discusses the advantages and limitations of Wire EDM, providing a balanced view
of the technique. This document serves as a valuable resource for those interested in the
practical and theoretical aspects of Wire EDM techniques.
In addition to the fundamental principles and techniques of Wire EDM, this report provides an
in-depth analysis of the impact of various parameters on the machining process. It includes a
detailed examination of the effects of pulse duration, discharge current, and wire tension on the
machining performance and the quality of the final product.
ix
LIST OF FIGURES
Fig. No.
DESCRIPTION
Page
No
1.2.1
straight cutting WEDM
2
1.2.2
Taper Cutting WEDM
2
1.4.1
PULSE ON and OFF GRAPH
4
1.4.2
Overview of wire Movement
5
2.1
Submerged WIRE EDM
6
2.2
Flushing type Wire EDM
6
3.1
Spark generation between WIRE and Workpiece
7
3.2
Spark Between wire and workpiece
8
3.3
spark Between wire and workpiece
9
4.1
Ignition and Plasma channel formation
10
4.2
Melting, evaporation and Ejection of metal
12
5.2.1
Wire EDM Machine with AC servo System
15
6.1.1
Topography and cross-section ZrO2–TiN
18
6.1.2
Topography and cross-section of Al2O3–SiCw–TiC
18
6.1.3
The spalling effect from a debris analysis
20
6.1.4
Material removed by spalling
20
6.1.5
Topography
22
6.1.6
Roughing mode EDM parameters
22
6.1.7
Roughing mode EDM parameters 2
23
x
LIST OF SYMBOLS AND ABBREVIATIONS
V
Voltage
I
Current
Mw
mass of water, kg
Cp
specific heat capacity, J kg-1 K-1
Q
heat stored, kJ
µ
dynamic Viscosity
v
volume m3
ρ
density kg m-3
To
pulse on time
Toff
pulse off time
SV
servo voltage
MRR
Material Removal Rate
SR
Surface Roughness
WWR
Wire Wear Rate
EDM
Electrical Discharge Machining
WEDM
Wire cut Electrical Discharge Machining
xi
CONTENTS
DESCRIPTION
PAGE NO.
Certificate
i
Copy of the Internship Certificate
ii
Acknowledgement
iii
College Vision & Mission
iv
Department Vision & Mission
v
Program Educational Objectives
vi
Program Outcomes
1
2
3
vi-vii
Program Specific Outcomes
viii
Abstract
ix
List of figures
x
List of symbols and abbreviations
xi
INTRODUCTION
1
1.1
Wire EDM introduction
1
1.2
Wire EDM Techniques
1
1.3
History of Wire EDM
3
1.4
Working principle of EDM
3
1.4.1
Step-by-step explanation of how Wire EDM works
4
TYPES OF Wire EDM Processes
6
2.1
Submerged Type WEDM
6
2.2
Non-Submerged (Co-Axial Flushing) Type WEDM
6
2.3
Dry and Near Dry WEDM
6
Material Removing technique in Wire EDM
xii
7
3.1
4
5
6
Important parameters implicated in the EDM
8
Four successive steps for Spark
10
4.1
The Ignition phase
10
4.2
Formation of the plasma channel
11
4.3
Melting and evaporation
11
4.4
Ejection of the liquid molten material
12
Equipment of EDM
13
5.1
Generators
13
5.2
Servo System
14
5.3
Dielectric System
15
CASE STUDY
16
6.1
Processes to mitigate the challenges
16
6.1.1
Adaptive Control systems
17
6.1.2
Precision power supply technology
19
6.1.3
Improved Dielectric fluids
21
7
CONCLUSION
24
8
REFERENCES
25
xiii