Maulana Azad National Institute of Technology Bhopal462051

Dept. of Mechanical Engineering

Assignment On
Electrical Discharge Machining (EDM)
Subject- Advanced Production Engineering
By

Mohit Chetwani and Palash Sahu

Scholar No 111116044, 45
VIIth Semester, 4th Year

Introduction
Purpose of the project is to perform certain modifications
in our previously undertaken project that was to make a
simulation of the system and develop controls for the Self
Balancing Robot. In this project we will be actually
constructing one such model of our robot using an extra
wheel in place of costly gyroscopes for the purpose of
balancing our robot which will save the cost and will
increase the stability of the robot.

Project-Aim
With the constantly increasing need for mobility,
particularly in urban areas, various problems arise
including the urban space and energy consumption. In
addition, exhaust and noise emissions have to be
mentioned. In order to be able to satisfy the mobility needs
in the future, new solutions are required. The project aims
at improving urban transport, whilst minimizing the
negative environmental impacts caused by increased
mobility. Therefore, it is necessary to develop new
concepts for individual urban transport to close the gap
between conventional individual transport and public
transport.

ABSTRACT
Electrical discharge machining (EDM) is one of the earliest nontraditional machining processes. EDM process is based on
thermoelectric energy between the work piece and an electrode.
Material removal rate (MRR) is an important performance
measure in EDM process. Since long, EDM researchers have
explored a number of ways to improve and optimize the MRR
including some unique experimental concepts that depart from
the traditional EDM sparking phenomenon. Despite a range of
different approaches, all the research work in this area shares the
same objectives of achieving more efficient material removal
coupled with a reduction in tool wear and improved surface
quality. In the end of the assignment scope for future research
work has been outlined.

INTRODUCTION
Electrical discharge machining is basically a non-conventional
material removal process which is widely used to produce dies,
punches and moulds, finishing parts for aerospace and
automotive industry, and surgical components [1]. This process
can be successfully employed to machine electrically conductive
parts irrespective of their hardness, shape and toughness [2-4].

INTRODUCTION

INTRODUCTION
Electrical discharge machining is basically a non-conventional
material removal process which is widely used to produce dies,
punches and moulds, finishing parts for aerospace and
automotive industry, and surgical components [1]. This process
can be successfully employed to machine electrically conductive
parts irrespective of their hardness, shape and toughness [2-4].

Working Principle of EDM

The working principle of EDM process is based on the
thermoelectric energy. This energy is created between a workpiece
and an electrode submerged in a dielectric fluid with the passage of
electric current. The workpiece and the electrode are separated by
a specific small gap called spark gap. Pulsed arc discharges occur in
this gap filled with an insulating medium, preferably a dielectric
liquid like hydrocarbon oil or de-ionized (de-mineralized) water [58]. Schumacher [9] described the technique of material erosion
employed in EDM as still arguable. This is because ignition of
electrical discharges in a dirty, liquid filled gap, when applying EDM,
is mostly interpreted as ion action identical as found by physical
research of discharges in air or in vacuum as well as with
investigations on the breakthrough strength of insulating
hydrocarbon liquids.

Inverted pendulum & Two Wheeled Robots

Inverted pendulum is commonly described as a pendulum or a rigid rod with bob
on one end mounted by a hinge to a cart which can be translated along a track by
an input force. The pendulum itself however is not actuated it is free to swing
about its point of marginal stability in vertical position only by properly actuating
the cart and using the reaction force of pendulum against the cart can the
pendulum be positioned.
In this feature lies the significance of inverted pendulum. It is an indirectly
actuated system that is the object of interest the pendulum can be controlled only
by exerting a force on the secondary object the cart. The nobility and challenges of
such a controller in real world has attracted attention from many parties
perhaps because of fame of segway two wheeled balancing robot has became a
prominent project for students it is certainly a topic of interest to anyone involved
in the study of control system and there application to robotic.

Literature review
Despite of the many studies on self balancing human transporter,
only few studies addressed the modelling of human transporter,
but the interest is on the rise. Mi-Ching Tsai, Jia-Sheng Hu, FengRung Hub employs a PI observer to detect abnormal information
in an auto-balancing two-wheeled cart caused by actuator faults
and steering load torques. Analysis and design of the PI observer
are then discussed in detail. They Verified that It has been verified
that the proposed control system has benefits such as detecting
possible failures of the ABTWC. The experimental results have
substantiated that the proposed fault diagnosis strategy has the
ability, in practice, to improve the ABTWCs safety.
Ronald Ping Man Chan , Karl A. Stol, C. Roger Halkyard found that

there has been much more research in two-wheeled robots

which actively stabilize themselves. Various models and
controllers have been applied both to explain and control the
dynamics of two-wheeled robots. We explore the methods which
have been investigated and the controllers which have been used,
first for balancing and movement of two-wheeled robots on flat
terrain, then for two wheeled robots in other situations, where
terrain may not be flat.
They got the result that A number of controllers have also been
applied to the two wheeled robot, showing varying performance.
However, it is quite clear that simple linear controllers can
effectively control the two wheeled robot, even for a largely unmodelled system.

Methodology
1. Derived the governing equation of motion of inverted pendulum by
using elementary mechanics
2. By using an appropriate control technique, like PD(proportional
derivative) control, we have determined the control input (Force on
the cart) as a function of control output (angle of tilt).
3. Applying the above technique to a Segway using Autodesk motion
analysis. Proper assumptions have to be taken while doing this.
4. Choosing appropriate sensors to measure control output (angle of
tilt) of the system. (accelerometer & gyroscope)
5. Determining the control strategy for turning.

Principle of Self balancing inverted Pendulum

Equations of Motion & Control Techniques

Parts & Components of a Three Wheeled Robot: Handlebar/Controls/User Interface

Chassis
Permanent-magnet brushed DC motor
Microcontroller (CPU)
Power source (Multiple rechargeable Lithium-Ion batteries)
Wheels etc.

Drive/Electrical System
The system consists of dual motor controllers and motors, one for
each rear wheel. The drive system and electrical system are
activated by a "power key," similar to an automobile's "ignition"
key.

Motors
Each rear wheel is independently driven by a high-speed
brushless electric
Motor that is quiet, efficient, and does not require periodic
maintenance to replace consumable parts. Each Motor is
microprocessor controlled to precisely regulate drive motion.

3-D Model of the Human Transporter

Created using Autodesk 3ds Max 2013

Introduction to PID Control

This introduction will show you the characteristics of the each of
proportional (P), the integral (I), and the derivative (D) controls, and how
to use them to obtain a desired response. In this, we will consider the
following unity feedback system:

Plant: A system to be controlled

Controller: Provides the excitation for the plant; Designed to control the
overall system behavior

PID controller generates the following responses

to change

Inverted Pendulum Technique

This human transporter is built to stay balanced in one place (balancing of IP)
Changes from the balanced state are first detected (in terms of tilt angle)

Signals are then passed to a PID controller

The PID controller then directs the motors to regain the balance
the feedback is sent to controller again to detect any further changes from the balanced state

Graphical results obtained using MATLAB

ExplanationThe above graph is the initial condition of the pendulum when we are not
using PID controller. Graph shows that as the time increases the angle with
vertical also increases continuously and after some time pendulum will lay
down or on the floor thin means the angle with the vertical become 90
degree.
This is the case of pendulum alone in the cart without control unit. Now our
aim is to control the movement of cart by balancing the pendulum. For these
we uses PID controller and for that the basic equation has been derived and
then converted to the Laplse form and then with the help of MATLAB
software we plotted the graph between angle of twist and variation in velocity
for balancing it with respect to time.
The variation is shown in below graph and important conclusion taken from
the graph.

Graphical results obtained using MATLAB

ExplanationThe Above graph shows the variation in pitch angle with the use
of PID control. It is clear from the graph that pendulum will
come in balance position after some time (for this 0.5 sec) as it
is tilted slightly. And at the same time when we look into the
graph of variation of velocity with time.
It shows that for balancing the pendulum cart initially moves
forward with fast rate and as the angle decreases velocity also
decreases and comes to constant position. Now from these two
graph it is understood that as we tilt the pendulum for certain
angle, the cart will move in the same direction for balancing the
pendulum.

Graphical results obtained using MATLAB

Conclusion
The variation in pitch angle with the use of PID control. It is clear
from the graph that pendulum will come in balance position after
some time (for this 0.5 sec) as it is tilted slightly. And at the same
time when we look into the graph of variation of velocity with
time.
It shows that for balancing the pendulum cart initially moves
forward with fast rate and as the angle decreases velocity also
decreases and comes to constant position. Now from these two
graph it is understood that as we tilt the pendulum for certain
angle, the cart will move in the same direction for balancing the
pendulum.
Since control of Segway was successfully achieved using
Autodesk, a small scale prototype of the same could be
manufactured as per the above CAD model.