CHAPTER 1

INTRODUCTION
1.1. What is Electric Discharge Machining?
Electric discharge machining (EDM) is a manufacturing process whereby a desired shape is
obtained by using electrical discharges. Material is removed from the work piece by a series of
rapidly repeating current discharges between two electrodes separated by a dielectric fluid.
The EDM process removes material from the work piece by thermal energy. The space between
the electrode and the work piece is filled with a dielectric fluid. When there is a sufficient
voltage and small gap between the tool and the work piece the electric force overcomes the
dielectric force, the dielectric fluid ionizes and changes from an electrical insulator into an
electrical conductor. At this stage sparking occurs and the distance between the tool and the work
piece is called spark gap. In a small ionize column the energy density becomes strong enough to
vaporized the work piece material. Thermal energy is provided by current flowing between the
electrode and the work piece. By increasing the current material removal of the work piece also
increases. When no current flows between the electrode and the work piece, the voltage is said to
be “the open circuit voltage”.

Figure 1-1: EDM process

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1.2. Specifications of EDM
Figure 1-1 shows the following specifications of EDM

• It has 1-axis of motion

• Tool acts as a cathode and work piece acts as an anode

• Usually copper is used as a tool whereas any conductive material can be used as a work
piece

• There is a specific wear ratio between the tool and the work piece

• This is a non-conventional process whereby machining process takes place without physical
contact of tool and work piece

• A specific voltage gap is maintained between the tool and work piece throughout the
process

• Since EDM is a nonlinear process, a very strong power supply is required to maintain
specific voltage and current throughout the process

• In industrial scale 5-100 Ampere are used for EDM process

• “Turn on time” is the time when the machining process takes place

• “Turn off time” is the time when the machining process is stopped

• During turn on time the material vaporized and carbon is formed

• Kerosene oil is continuously flow through pump for the entire process

• During turn off time carbon is removed from the work piece due to oil flow

• During turn on time tool moves vertically downward

• During turn off time tool moves vertically upward

• Typically no sensors are used to monitor the process

• Electric force dominates the dielectric force

• During machining process temperature increases

• Material vaporized after the machining process

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1.3. Applications of EDM
Now a days EDM is used at a large scale for different applications in industry.
EDM is used:
• To make dies of shoes, guns, bots, guns, glass and different artificial coins
• To make drills in different conductive materials
• Cutting of different conductive materials
• It is used for grinding purpose
• It is used to make edges of a surface

Figure 1-2: EDM Applications

1.4. Limitations of EDM

As far as EDM operation has many applications, there are some limitations:
• Since EDM process takes place in kerosene oil, so there is always a danger of fire as shown
in figure 1-3
• EDM is a nonlinear process, so it may extract infinite current from the power supply, so we
need some special type of power supply with strong switching capabilities
• There is always a wear ratio between the tool and the work piece, so after some time we
need to replace the tool of EDM
• EDM is a slow machining process and it consumes energy

Figure 1-3: EDM Spark

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1.5. Advantages of EDM
There are many advantages of using EDM in industry:
• Products are made by using different dies. It means die accuracy is important. EDM can
give accuracy on microscopic level
• This is very difficult to drill hard material like cast iron by a simple drill machine. EDM
performs this operation easily and accurately.
• Fixed automation is involved in process
• It can make hole in carbide materials
• There is low initial cost

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 CHAPTER 2
LITERATURE REVIEW
2.1. History of EDM
2.1.1. Development of EDM in USSR:
In 1941 the USSR was involved in World War II in critical materials were needed to be
conserved. Tungsten was widely used as electrically contact material for automotive engine
distributor breaker point. As pitting occurred, the engine required maintenance. It was probably
that military vehicles would not be in service when needed. Event replacement of the breaker
points caused valuable tungsten to be discarded.to address this issue, the government assigned
Mascow University to investigate whether the life of components could be extended by
suppressing sparking between the breaker points.

As part of their experimentation, the Lazarenkos emerged the breaker points in oil. They
observed that while the oil did not eliminate the sparking, it did create more uniform and
predictable sparking and pitting, as compared to operating points in air.

The Lazarankos experiment was not successful because it did not develop a means for extending
the life of the automotive breaker points due to sparking. But the Lazarankos, being very
observant engineer, decided to investigate the possibility of controlled metal removal through the
use of sparks.

2.1.2. Development of EDM in USA:

A company in the USA discovered a need for a machine to remove broken traps and drills.

Harding an electrical engineer came up with an idea of using sparks to erode the taps and drills
from the valve bodies. Originally, an electric-etching tool was used to produce the sparks. The
etching-tool electrode was placed on the broken tap or drill and then withdrawn. As the electrode
was lifted from the tap or drill, a spark occurred. The spark melted a small portion of metal.

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2.2. Types of EDM
There are many types of EDM. Some of them are mentioned below
1. Electrical Discharge Grinding
2. Multiple Electrode Machining
3. Multi Lead Machining
4. Wire Cut Multiple Work piece Machining
5. Wire Cut Multiple Electrode Machining
6. Micro EDM Drilling
7. Electrical Discharge Texturing

2.2.1. Electrical Discharge Grinding Machine

As electrical discharge grinder machine (EDGM) is a type of die sinker EDM machine that is
referred to as a grinder, due to its appearance. This machine differs from a normal die sinker
machine because the electrode remains stationary while the work piece traverses under the
rotating electrode.

The EDGM machine’s installation is very similar to that of the die sinker. The EDM power
supply is interchangeable between EDGM and die sinker machines when the same machine
manufacturer provides both.

Figure 2-1: Electrical Discharge Grinding

2.2.2. Multiple Electrode Machining

Multiple- electrode machining uses a standard die sinker machine and EDM power supply. But
this machining makes use of multiple electrodes, instead of a single electrode. It is very
important to understand that when using the multiple electrode technique, only one spark occurs
at any instant.

Although only one spark occurs at a time, the use of multiple electrodes increases the spark off
time and allows additional time for the EDM chip to exit the sparking gap

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2.2.3. Multi Lead Machining
Multi lead machining differs from multi electrode machining because a spark may occur because
a spark may occur at each sparking gap spark on time.

Multi lead machining requires a specially designed EDM power supply that provides an
individual sparking output to each sparking gap. Insulation is required to electrically isolate each
electrode from to others. Only one electric power supply panel is required for all of the power
supply outputs.

Figure 2-2: Multi Lead Machining

2.2.4. Wire Cut Multiple Work piece Machining

Wire cut machines do not have the same concerns as die sinker machines when considering
multiple machining operations with wire cut-machines, the work-piece is arc stacked and then
the stack is machined as an assembly however, there must be a positive electrical contact from
one work piece to the next, or wire breakage will result

Figure 2-3: Wire Cut EDM

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2.2.5. Wire Cut Multiple Electrode Machining
Some wire cut machines provide multiple electrode wires for machining multiple work pieces.
Others are designed with a single electrode wire to transverse through the first sparking gap, then
to the second, and possibly to some sequence sparking gaps. In most instances, these are
specially designs, proprietary machines, intended to produce parts in production quantities.

Figure 2-3: Wire Cut Multiple Electrode Machining

2.2.6. Micro EDM Drilling

Micro drilling machines are specially designed to repeatedly produce high precision, tiny holes,
usually in the range of 0.076-0.304mm in diameter.

These machines are comparable to die sinker machines in that a servo has advanced that
electrode and as it advances, sparking occurs between the electrode and work piece they are also
comparable to wire cut machines in that a wire is used for the electrode and that normally
deionized water is used as electric fluid.

Figure 2-3: Micro EDM Drilling

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2.2.7. Electrical Discharge Texturing
Electrical discharge texturing is an example of using EDM process to perform a machining
operation on a very large work piece in order to create a uniform, no directional surface finish
without a pattern. This machining operation produces a specified surface on steel holes of
different diameters and lengths.

Figure 2-3: Electrical Discharge Texturing

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2.3. EDM Die Sinking Machine
There are three major assemblies in die sinking machine.

Power Supply

Dielectric Unit

Machine Tool

2.1.1. Power Supply

The power supply provides sparking gap to each individual gap for material removal. Power
supply also monitors the electrical requirements at the sparking gap and directs the machine
servo in advancing, retracting, or maintaining the position of the electrode, in reference to the
work piece.

2.1.2. Dielectric Unit

The dielectric unit provides the dielectric fluid to the machine to dip the work piece. Moreover,
the dielectric unit provides fluid at sparking gap for cooling purpose and to remove the EDM
chip. This unit also includes the filtering of the fluid.

2.1.3. Machine Tool

The machine tool is the main point for EDM machining system. Since, the machining takes at the
machine, subassemblies are included on the machine to protect the machinist, monitor the
dialectic fluid and control the progress of the machining operation. They also used to control the
stability of the servo feed.

2.4. EDM Die Sinking Machine Components

Work tank

Servo head

Depth spot limit switch

Dielectric Fluid

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2.4.1. Work Tank
A work tank is attached to the base of the machine. During machining, it is required to fill
sparking gap between the tool and the work piece with kerosene oil for control dielectric
conditions. So, the work tank has the dielectric fluid where the work piece is submerged.

Often work tank are made from sheet metal with the removable, or hinged, front door for easy in
setting up the work piece in other designs work tank retract into the machine base to create an
open area around the work piece and electrode during setup inspection

Mounted to the work tank is dielectric fluid-manifold. This manifold is connected to dielectric
fluid flushing system. It provides attachment point for connecting the electrode or work piece to
the dielectric system. The fluid flushes the EDM chips from the sparking gap. The manifold
usually has a valve for setting and a gage for monitoring dielectric fluid flushing pressure.

When we use a dielectric fluid assembly that uses a pump for filling the work tank, then an
overflow standpipe is part of work tank assembly. This allows dielectric fluid, used for chip
removal, to return to the dielectric reservoir. This maintains the dielectric fluid level in the work
tank. When air is used to fill the work tank, normally the overflow stand pipe is not required.

Many EDM has a monitor to make confirm that the dielectric fluid level in the work tank is not
lowered during the EDM cycle. Often, this monitor’s a float switch. Dielectric fluid should leak
from the work tank in order to cause the fluid to lower enough that the sparking is exposed;
ignition of the pressurized automated kerosene oil is possible. This is imperative that safety
instructions, provided by the machined manufacturer, be observed in the use of fluid level
monitoring devices.

Dielectric fluid level should be monitor carefully. In many cases, the monitor will be a
mechanically actuated, dielectric switch. The dielectric fluid level should drop below a preset
height; the float switch electrical contacts will open and cause the machining cycle to stop. The
float switch may be mounted to rod and manually adjusted for fluid height. There should be no
front to back or side to side looseness between movable slide and the stationary portion of the
servo head. Any such looseness will result in erratic servo operation and impossible deformation
of EDM surfaces. In addition to maintain efficient sparking conditions the movable slides must
have very little friction, response instantaneously in very small increments. The way system must
be able to support the electrode weight and push against hydraulic force that is produced by
dielectric fluid flowing through sparking gap.

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2.4.2. Servo Head
The servo head is part of machine that automatically positions the electrode to the work surface
so that sparking will occur. The most common types of servo drives are electric motor and
hydraulic.

The EDM machine servo head operates under very difficult conditions, as compare to many
other machine way systems. The servo head may dwell for long period of time for one place, or
it may move only a very small distance over a long period of time. During this time the way
system is continuously oscillating back and forth in response to commands from electronic
control servo controller, thus maintaining efficient sparking conditions. Proper lubrication is
necessary to prevent the way surface materials from galling under these conditions because of
this some manufacturers prefer ant friction ball or roller way system.

2.4.3. Depth Stop Limit Switch

The basic EDM machine includes the switch with an actuating plunger for controlling the depth
of EDM operation. Actuation of this switch stops the EDM sparking cycle and in many
instances, causes the servo movable slide to retract to its most upper position. A micrometer,
mounted on the servo head movable slide, actuate the limit switch plunger. In some instances,
the micrometer is held in place by a magnetic base. This magnetic base attachment allows the
micrometer to be positioned anywhere along the travel line of the movable slide. For depth stop
setting, the electrode is advanced toward the work piece top surface. Until very low energy level
sparking is observed, the servo system then automatically holds the electrode in position above
the work piece surface through the distance of sparking gap. Sparking surfaces must be
previously wetted with dielectric fluid for controlled sparking to take place. During the time
sparking is observed, the micrometer is advanced until the switch plunger is activated. The point
when limit switch actuation is zero, in reference to work piece .The micrometer is then back off
by the amount required for the depth of cut.

2.4.4. Dielectric Fluid

The dielectric acts as a medium through which controlled electrical discharges takes place. The
dielectric acts as a quenching medium which cools and solidify the gaseous EDM debris which
may cause by discharge. The dielectric oil acts as an agent to carry away the solidified EDM
debris. The dielectric acts as an agent to caught the heat and let it to drive away from the system.
Dielectric fluid performs as role of insulator between the electrode and the wok piece. There are
many dielectrics to choose from based on the insulation properties of the fluid. Air in one of
common Insulator but it is not a very good insulator. Water is one of the best choices but water
has a few drawbacks. Firstly it causes the problem of rust.

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 CHAPTER 3
DESIGN OF ELECTRIC DISCHARGE MACHINE
Our EDM is capable of making dies and molds of different metallic materials precisely. We have
used a copper tool that can work on the work piece with the maximum range of 10 in area
and 5cm in depth. The maximum material removal rate is 0.24496 /min. In other words
50 of machining would be completed in 2hrs. The level of fluid would be detected by using
fuel sensing unit. Motion of tool is controlled by using feedback system.
3.1. Objective
3.1.1. Requirements
We made an EDM through the process of calculations, modeling, dimensions, CAD
design, analysis and simulation. We assumed that maximum volume of the work piece
will not exceed to 50 the material of the work piece will be aluminum and the
maximum current should be 16 ampere.

3.1.2. Fabrication
After completing the design we fabricated EDM through the process of manufacturing to
apply all the calculations and design to implement a project. We used:

 Mild steel
 Galvanized iron
 Metal sheet
3.1.3. Autonomous Control
Usually in industry EDM machines operate manually. So to make a fully controlled machine
we used different type of sensors. For example we used a fire sensor for the safety
purpose, a level sensor that will stop the working if the fluid amount is not according to
the requirement and we used servo system for a controlled vertical motion of the tool.

3.1.4. Inexpensive
Cost is an important factor for any product. So our mission was to make a competitively
low cost EDM machine.

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3.2. EDM Specifications
It has 1-axis of motion.

Aluminum is the work piece.

Copper is used as a tool.

Maximum machining area of the work piece is .

Maximum height of the work piece is .

Maximum current limit is 16 Amperes.

Figure 3-1: Work piece Specifications

3.3. Material Removal Rate of the Work Piece

The material removal rate of work piece in EDM is basically a function of the current and
melting point of the work piece material

Mrr= Material Removal Rate of work piece ( /min)

K= constant of proportionality= /min Ampere

Tm= melting temperature of work piece

We have selected the material removal rate of ⁄ according to our machining

features.

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3.4. Wear Rate of the Tool
The material removal rate of the tool in EDM is basically a function of the current and melting
point of the work piece material

Wear rate of the tool (m /min)

I=Current in Amperes

Tt=Melting point of the tool Material

For copper with melting point 1083˚C

3.5. Wear Ratio of the tool and work piece

The wear ratio between the tool and the work piece is given by

R= Wear Ratio of the tool and work piece

Tr=Ratio of work piece to electrode melting point

When the work piece is aluminum and tool is copper

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3.6. Process of EDM

Flame
Control Sensor
Drive Pump
Drive
Circuit
Circuit
Actuator Power Sensor
Supply
Tool Senso Tool Senso
r r
Figure 3-2: EDM Process

Figure 3-2 shows the complete working of our EDM. There is a central control unit in EDM.
When the user gives a start instruction, it checks all sensors status. If all sensors show normal
status, it means the conditions are suitable for working and machining starts.

Before the EDM starts working, user needs to specify the current value from the power supply.
At higher current value, the machining process becomes faster but it is compromise of neatness.
An ideal process requires as low current as possible.

Pump continuously circulates the fluid during the entire process.

Actuator moves vertically down and up for machining and removal of waste material.

Graphical user interface shows the current position of the tool.

In case of emergency the process should auto stop.

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3.7. EDM Branches
The figure 3-3 shows the branches of EDM. It has three major portions.

• Sensors
Control
• Arduino

• Structure
Mechanical • Fluid
• Heat

• Drives
Electrical • Power Supplies
• Actuator

Figure 3-3: EDM Branches

An EDM machine needs to interface and communicate with all above mentioned categories.

Sensors are required to give the feedback of the process. We used many sensors for EDM to
make it autonomous and for safety purpose.

We used kerosene oil to remove the carbon from the work piece during erosion process and to
make the process linear.

We used a drive circuit for the vertical up and down motion of the tool.

There are two power supplies in this project.

To run all digital circuits in the project including oscillator, drive circuit and drive circuit.

Second power supply is used for machining process. Its range is from 1-16ampers.

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3.8. Controller

3.8.1. Sensors
The following sensors are used in EDM.
• Flame Sensor
• Encoder
• Limit Switch

Flame Sensor
Fire in EDM machine is often results from a drop in kerosene oil level and some other reasons.
When fire occurs, the kerosene oil and oil vapors can easily catch fire in a short time. An
unattended EDM machine may be consumed by fire and there is a need to make safety circuit.

There are three basic categories of for fire detecting purpose and we choose flame detector out of
these three categories as these types of flame detectors detects presence of light as compare to
others two, which detects smoke and heat. Moreover flame sensor cannot work for slow fires
however it give faster response for rapidly developing fire like combustible gas and liquid so it is
best choice for our project.

Figure 3-4: Fire Sensor

Flame detector usually works at specific range, which works with the help of optical sensors to
record the incoming radiation of a particular wavelength. The energy which is radiated from the
flame is normally electromagnetic radiation and it can be distinguished at various spectral ranges
like ultra violet (UV) and infrared (IR). Depending upon the sensor used, there are number of
flame detectors available including infra-red flame detectors, UV flame detector, UV/IR, IR and
tripe IR spectral band detector

This sensor price is $97.This sensor can work against pressures as high as 5 psi (34.5kPa) when
properly installed. It detects ultra violet in flames. It can afford 0.5 G maximum vibrations and
bear ambient Temperature Range (C) from -18 C to 102 C.

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Incremental Encoder
We used incremental encoder to find the position of the tool or to determine that how much in
depth the machining has been take place.

Incremental encoder is shown in figure below. It has a receiver and a transmitter. Transmitter is a
LED and receiver is photo sensor. There lies a disc in between the LED and photo sensor. This
disc has small holes, typically they are approximately 500. When the disc attached to a shaft
rotates, though LED continuously emit light the receiver accepts a series of square wave. This
square waves are counted through a controller and show the position of the tool.

Figure 3-5a: Encoder Figure 3-5b: Square wave

Limit Switch:
This is a type of contact sensor. When the vertical axis exceeds to a defined range it makes
contact to the vertical axis and the polarity of the motor is reversed.

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3.9. Mechanical

Figure 3-8: Work Tank

Figure 3-6: 3D Model of EDM

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3.9.1. Analysis of Mechanical Structure
Figure 3-7 a. is showing the stress analysis; we can see the maximum stress is shown in green
color, which indicates the stability of the structure.

Figure 3-7a: Stress Analysis

Figure 3-7b: Displacement Analysias

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 Figure 3-9: Servo Head

3.9.2. Heat Produced:

During erosion process heat is produced and the temperature rises

3.9.3. Conduction:
• The Flow of heat through work piece

3.9.4. Convection:
• The Flow of heat through fluid

3.9.5. Radiation:
• The Flow of heat through radiation

Watt/

3.9.6. Fluid:
Fluid is require due to the following reasons

• To increase the heat removal rate

• To remove the chip from the work piece

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Due to the following reasons Kerosene oil is the best option:

• To make the process linear

• Comparatively high flash point as compare to other hydrocarbons

3.4.5. Pump Requirement:

Pump is required for lifting the fluid to the work piece. Its necessary calculations are
given here

OR

=Density of kerosene oil=800

̇ Flow rate of kerosene oil=

h=1050mm

P=4.2watt

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3.10. Electrical
3.10.1. Current calculations:
For aluminum 6063, the melting point is 600 ˚C.

3.10.2. Actuator

EDM tool needs a continuous up and down motion for feeding to get an accurate material
removal. Moreover we need proper feedback system to know the current position of the tool. By
knowing the position we can calculate the require time for machining, voltage and current
ratting. So we are using servo motor.

Servo Motor:
Servo motor has the following features:

• It provides feedback
• Feedback is the actual position of motor
• Feedback is provided by sensor
• The feedback sensor is mostly optical

3.10.3. Power Supply:

The power requires operating the motor is given by:

The power loses by the motor is given by:

The mechanical power obtained by motor is given by:

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 • Maximum current limit is 16 Amperes

• We will used two small power supplies

• The relation between the secondary voltage to the output voltage of a power supply is
given by:

For maximum 16 Amperes and maximum rated voltage 40 volts

Maximum Rated Power= =16×40

Maximum Rated Power= =640watt

Transformer:
• The relation between primary and secondary current, voltage and turn ratio for a
transformer is given by:

Where
is primary voltage of transformer
is the secondary voltage of transformer
is the number of turns of primary coil
is the number of turns of secondary coil
is the current induced in secondary coil
is the current in primary coil

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3.11. Graphical User Interface
We used matlab GUI for making the project distinguish from other EDM.

We interfaced position sensor, fire sensor and a temperature with matlab GUI, through arduiono
controller. GUI shows all sensors outputs.

When we open GUI, it asked the user to start the machining. If user press start button as shown
in figure, The GUI checks the status of all the sensors, if they give green signal, the erosion
starts.

Figure 3-10: GUI Start

26
If once user pressed start button, GUI starts to show the user information of the position,
temperature and fire sensor.

Figure 3-11: GUI during Process

During working of EDM, if any sensor gives a dangerous signal, an alarm rise up and quickly the
process stops. As shown in figure

Figure 3-12: GUI during emergency

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 CHAPTER 4
FABRICATION OF EDM MACHINE
First of design of all parts of EDM is done on PRO E software and then after doing complete
satisfaction we come to our component making work and then assemble them accordingly.

Our EDM machine consists of these components:

1- Work piece
2- Tool
3- Work tank
4- Column
5- Oil tank reservoir
6- Servo head

4.1. Work Piece

As we mentioned EDM is a machine of making dies and molds so, there should be a work piece
which will be converted into die or mound. So, for our project we decided to use aluminum as
our work piece.

4.2. Tool
Tool is the piece which is used in EDM process to make any die or mold. We can use different
materials for the tool e.g. copper, steel etc. But we are using copper because it has low material
removal rate.

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4.3. Work Tank
Work tank is the very important part of the EDM. It is the part of EDM in which electric
discharge machining is done. Work piece is put in the work tank for machining purpose and it is
also filled with kerosene oil. So, it is very important to design and fabricate it very carefully.

Figure 4-1: Work Tank

We used the metal steel for the fabrication of work tank. In the process of the fabrication
of work tank we have to do different manufacturing techniques. The wall of the work
tank is made by bending the sheet of the steel to form the corners. Finally, the welding
process is done on one side of the wall to close it firmly. This closed wall then put on to
the oil tank reservoir to make its base. The roof of the oil reservoir is working as the base
of the oil tank. The wall is attached to the base by welding process and it is made sure
that there is no deficiency in the welding of any side of the work tank where it is
necessary. Because we put kerosene oil in the tank and there should be no leakage of the
fluid from the tank.
There are two holes in the geometry of the work tank e.g. one is circular and other one is
the rectangular hole. The circular hole is used for the fluid level purpose in the work tank
and there is a piece of mild steel on the rectangular hole which is tightened firmly with
the base of the tank. It is used whenever we want to approach the oil reservoir and to
avoid any harm to the base of the tank in machining process. Work piece is also put on
this piece for machining purpose.

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4.4. Column
It is the part of the EDM which is attached to the roof of the oil reservoir. It is a hollow square
pipe which is used to approach the pump to the reservoir and also to support the z-axis motion
controlling mechanism. The material used to fabricate it is metal steel. The different techniques
used for its fabrication are cutting, bending and welding. The height of the column is important
because the tool will reach to the work piece for the fabrication only if it has well calculated
height. So, this matter was in our mind while designing this column.

Figure 4-2: Column

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4.5. Oil Tank Reservoir
Oil tank reservoir is also important part of the EDM; it is used to store the
kerosene oil. As, we know the kerosene oil plays an important role in the machining process so,
it is made sure that there should be no shortage of the oil in the work tank during the machining.
So, reserved oil storage tank is very necessary for the EDM. The 3D design of the reservoir is
shown in the figure

Figure 4-3: Reservoir

We used the metal steel for the fabrication of the oil tank reservoir. In the process of fabrication
of the reservoir there are also different techniques are used e.g. cutting, bending and welding etc.
The oil reservoir is designed and fabricated as we can make a column for the c-frame on it.
Through this column; which is empty from the inside and is attached to the reservoir, we put the
pump in the reservoir to pump the kerosene oil in the work tank. The roof of the oil reservoir has
a rectangular hole in it, which is covered with a rectangular plate of mild steel. It is used
whenever we want to approach the oil reservoir from outside. The work piece is also placed on it
for the machining purpose.

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4.6. Servo Head
It is the Z-axis motion control part of the EDM. It is attached to the column of the c-frame with
the bolts. The main purpose of this part is the up and down motion of the work tool. It consisted
of a servo motor, a lead screw, gears, belt, tool clamper and two limit switches. The fabrication
of this part is the most important thing in the whole fabrication of EDM. The servo motor is
attached to a smaller gear and lead screw is attached to a bigger gear. There is a belt on these two
gears and tool clamper is attached to the lead screw. When the servo motor rotate in one
direction it rotates the gear attached to it and the gear attached to the lead screw will also rotate
because it is attached to the previous gear with a belt. So, the lead screw will do it’s up and down
motion and the tool attached to the tool clamps will also move up and down with the linear
motion of lead screw.

Figure 4-4: Servo Head

Figure 4-5: Servo Head

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4.7. Assembling Of All Parts
Then we assemble these all parts to make a complete EDM. First of all tank is connected
on the reservoir then column is attached. Then at the end servo head is assembled with
the column. As shown in figure

Figure 4-6: Assembly

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4.8. Different Side Views of EDM
Our EDM machine is looks as:

Figure 4-7: Complete Assembled EDM Machine

34
 Figure 4-8: Complete Assembled Parts

Figure 4-9: Complete Assembled EDM Machine

35
 Conclusion
Good EDM process requires not only the proper selection of EDM material, but it also
need of proper machine settings, such as peak current, on time, off time, gap size, and
tool polarity and most importantly the flushing conditions. Due to the many variations in
work piece geometry, the EDM machine setting conditions for new geometries are
mainly selected from experience and fine-tuned as the work progresses. In fact, the
geometry of the piece being produced will determine the right selection. There is not only
one proper combination of settings for copper, but in reality as many different setting
combinations as the number of pieces that can be manufactured by EDM.

36
 Future Recommendations
We interfaced GUI with machine, which gives only the information of sensors. In future we can
improve GUI by providing some extra features, for example we can make history of operations,
upon the user request GUI should show the require information.

EDM is operating with one axis and only one work piece is machined at a time. In future we
should make an EDM for multi operations at a time, with multi tools and multi work pieces.

We can switch towards Computer Numeric Control (CNC) EDM, where user need to give
coordinates and the tool physically reaches there accordingly.

By increasing the amperes the speed of machining can be increased.

37
 References
1. Serope Kalpakjian, Steven R. Schmid, ”Manufacturing Process” , 3rd edition

2. Bruce R. Munson,” Fluid Mechanics”, 5th edition

3. Elman C. Dason, ”Electric Discharge Machine”

4. Singal R.K, “Fundamentals of Machining and Machine Tools”

5. Grover, “Fundamentals of Manufacturing Engineering”

6. www.aliexpress.com

7. www.the-jeep-guy.com

8. www.compare.ebay.com

9. www.support.automation.siemens.com

10. www.aliexpress.com

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 Appendix

GUI Code
function varargout = Final_Tension(varargin)

gui_Singleton = 1;
gui_State = struct('gui_Name', mfilename, ...
'gui_Singleton', gui_Singleton, ...
'gui_OpeningFcn', @Final_Tension_OpeningFcn, ...
'gui_OutputFcn', @Final_Tension_OutputFcn, ...
'gui_LayoutFcn', [] , ...
'gui_Callback', []);
if nargin && ischar(varargin{1})
gui_State.gui_Callback = str2func(varargin{1});
end

if nargout
[varargout{1:nargout}] = gui_mainfcn(gui_State, varargin{:});
else
gui_mainfcn(gui_State, varargin{:});
end

function Final_Tension_OpeningFcn(hObject, eventdata, handles, varargin)

global a;
a = arduino('COM3');
a.pinMode(12,'output');
a.pinMode(13,'input');
a.pinMode(8,'input');
a.pinMode(2,'output');
a.pinMode(3,'output');
a.pinMode(4,'input');
a.pinMode(7,'output');
a.pinMode(6,'input');
a.pinMode(5,'output');
setappdata(gcf,'button',0);
handles.output = hObject;
guidata(hObject, handles);
function varargout = Final_Tension_OutputFcn(hObject, eventdata, handles)
varargout{1} = handles.output;

function pushbutton1_Callback(hObject, eventdata, handles)

for i=1:1
global a
global b
p=999;
count=0;
a.digitalWrite(2,1);
a.digitalWrite(3,0);
a.digitalWrite(7,1);
a.digitalWrite(5,0);
str1=get(handles.pushbutton1,'string')
str2='Start'

39
 fix=strcmp(str1,str2)
if fix==1
set(handles.pushbutton1,'string','OFF')
set(handles.pushbutton1,'BackgroundColor','red')
while 1
f=a.digitalRead(4);
c=a.analogRead(6);
T=-0.0810810810810*c+56.135;
edit2=num2str(T);
pause(0.0000000000000000000000000000000001);
set(handles.edit2,'string',num2str(edit2));
set(handles.text3,'string','°C')
if T>37
set(handles.text6,'string','High Temperature')
end
if f==0
l=a.digitalRead(2);
if l==1
set(handles.edit1,'string','Fire')
set(handles.edit1,'BackgroundColor','red')
set(handles.pushbutton2,'Visible','on')
end
end
c=a.digitalRead(8);
b=a.digitalRead(13);

if b~=p
if b==1
if c==1
count=count+1;
count
edit3=num2str(count);
set(handles.edit3,'string',num2str(edit3));

end
if c==0
count=count-1;
count
edit3=num2str(count);
set(handles.edit3,'string',num2str(edit3));
end
end
end
p=b;
fix
end

else
set(handles.pushbutton1,'string','Start')
set(handles.pushbutton1,'BackgroundColor','green')
a.digitalWrite(2,0);
a.digitalWrite(3,0);
a.digitalWrite(7,0);
a.digitalWrite(5,0);
break;
end

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end
function edit1_CreateFcn(hObject, eventdata, handles)
function edit2_CreateFcn(hObject, eventdata, handles)
function edit3_CreateFcn(hObject, eventdata, handles)
function pushbutton2_Callback(hObject, eventdata, handles)
a.digitalWrite(2,0);
a.digitalWrite(3,0);
a.digitalWrite(7,0);
a.digitalWrite(5,0);

41