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