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JM201

MECHATRONIC WORKSHOP
PRACTISE 2

EDM WIRE CUT

NAME MATRIX NO.


DANABALAN A/L PURUSOITHMAN 15DEM17F1021

NAGENTHIREN A/L MUNISVARAN 15DEM17F1023

BAWEN A/L MURALITHARAN 15DEM17F1026

PRATHAB A/L SARAVANAN 15DEM17F1030

LECTURER PN. AFIFAH


CLASS DEM2B

OBJECTIVES

1. Starting a CNC EDM wire cut machines.

2. Write a CNC program.

3. Prepare and display graphics using applications Autocad and


Mycam cuts.

4. Coordinate offset coordinate position of the wire cutting and die


on the workpiece.

5. Programming and cutting operations on the machine.

6. Stop the machine CNC wire cut EDM.


INTRODUCTION

Wire electrical discharge machining (WEDM), also known as


wire-cut EDM is a process of using a thin single-strand of metal
wire fed through a workpiece. The wire is constantly fed from a
spool is held between the upper and lower guides. The guides
move in the x-y plane and control the movement of the wire through
the workpiece during the cutting process. Most machines in use
today are CNC controlled. Wire EDM machines are very Precise
and can be programmed to cut very intricate and delicate shapes.
The wire-cut process uses water as its dielectric with the water's
resistivity and other electrical properties carefully controlled by
filters and deionizer units. The water also serves the very critical
purpose of flushing the cut debris away from the cutting zone.
Flushing is an important determining factor in the maximum feed
rate of material available in a given thickness, and poor flushing
situations necessitate the reduction of the feed rate.

Advantages
 The machine capability is cutting regarding to its hardness.
 It can cut intricate shapes, narrow slots, small products and
others
 No burrs generated during the process
 The wire electrodes ae cheap
 Very fine holes can be attained.
 Tapered holes may be produced.

Disadvantages
 Machine is very expensive
 Uses high amount of current
 High skills required to operate this machine
 It has slow material removal rate (MRR) and less flexible
compared to other machine
 "Overcut" is formed.

TOOLS & EQUIPMENT

EDM Wire Cut Machine

EDM Wire Cutting Head


JS EDM Controller

Brass wire electrode diameter 0.25mm

Steel plate
SAFETY PRECAUTIONS

 Make sure there are no leaks in the tank dielectric liquid tank
hose and pipe connections.

 Make sure a fire extinguisher near the machine for use in


emergencies.

 Make sure the materials are installed in areas where the right
job.

 Make sure the electrodes are not touching the thing work.

 Make sure the cutting wire is not touching things work.

 Make sure each cable there is no leakage.

 Clear oily liquid that is in place the working substance during the
installation process.

 Clean all dirt in the tank desk and storage tanks.

 Wear appropriate clothing while using machines.


PROCEDURES

Step to EDM WireCut

1. 415V main switchboard is open.

2. Switch on the cooler (chiller) is open.

3. EDM controller switch is opened and the safety button is


released the use of machines.
Steps for entering data:

1. By using autocad software, 2D shape is drawn and a point is


plotted

2. 2D autocad drawings saved in DXF format.

3. By using Mycam software, each line is attached drawings to


ensure examined.
4. Using Mycam software, autocad drawing format converted to a
format to be construed in NC programming of codes that will be
produced.

5. Drawing information is Stored and transferred into the wire cut


EDM machines.
Measures to cut programming:

1. On the machine control panel, programming information


transmitted is stored in the machine file.

2. Re-opened the file to be modifications and simulated. If there are


corrections to the cutting angle, the angle changed to suit the cut.

3. Auto Switch is pressed to check the position of the cuts will be


done.

4. After programming certain to be broken, Jog is used to adjust the


upper head and lower head plate cutting approaches.

5. In the control panel, switch memory, water, power EDM pressed


for the inclusion of water and related processes.

6. Cycle start switch is pressed and disconnect the start.

Codes to type:-

M CODES

M CODES FUNCTION

M00 PROGRAM STOPS

M01 SELECTIVE PROGRAM STOPS

M02 PROGRAM ENDS


M21 SINGLE BLOCK HOLD ON

M22 SINGLE BLOCK HOLD OFF

M30 PROGRAM ENDS & REVERSES

M41 MACHINING POWER OFF

M42 WIRE FEED OFF

M43 MACHINING LIQUID SUPPLY OFF

M70 REVERSE TRAVEL STARTS

M81 MACHINING POWER ON

M82 WIRE FEED ON

M83 MACHINING LIQUID SUPPLY ON

M98 CALL SUB-PROGRAM

M99 SUB-PROGRAM ENDS


G CODES

G CODES FUNCTION FORMAT

G04 HOLD G04 P_ OR G04X

G92 PROGRAM ORIGIN G92 X Y Z


SETUP

G00 FAST POSITIONING G00 X Y U V

G01 LINEAR CUTTING G01 X_ Y_ U_ V_

G02 CLOCKWISE ARC G02 X_ Y_ I_ J_ U_


V_
CUTTING

G03 ANTI-CLOCKWISE ARC G03 X_ Y_ I_ J_ U_


CUTTING V_

G17 XY PLANE SETUP G17

G90 ABSOLUTE G90

COORDINATE

INSTRUCTION
G91 INCREMENT G91

COORDINATE

INSTRUCTION

G22 SOFTWARE LIMIT ON G22 X_ Y_ I_ J_

G23 SOFTWARE TRAVEL G23

LIMIT OFF

G94 MANUAL SPEED FEED G94 F_

G95 SERVO SPEED FEED G95

G20 IMPERIAL SYSTEM INPUT G20

G21 METRIC SYSTEM INPUT G21

G40 WIRE DIAMETER G40

COMPENSATION

CANCELED

G41 WIRE DIAMETER LEFT G41 D_

COMPENSATION

G42 WIRE DIAMETER RIGHT G42 D_


COMPENSATION

G50 WIRE INCLINATION G50

CLEARED
G51 WIRE INCLINATION TO G51 T_

LEFT

G52 WIRE INCLINATION TO G52 T_

RIGHT

G60 WORKPIECE TOP & G60

BOTTOM CIRCULAR

ANGLE ARE EQUAL

G61 WORKPIECE TOP & G61 R_

BOTTOM CIRCULAR

ANGLE ARE UNEQUAL

G48 AUTOMATIC CIRCULAR G48

ANGLE ON

G49 AUTOMATIC CIRCULAR G49

ANGLE OFF

CONCLUSION

The desired objectives have been successfully implemented. Any


guidance given by lecturers is very useful and effective. We have
been successfully using CNC EDM wire cut machine with skill and
know how to enter the program and run machine for the design of
the products made. In addition, we also know how to apply the
program to form the G-code to get the result as above. All that was
taught to us was really helpful to our advantage as we go into the
working world later.