3.

6
NCONVENTIONAL MACHINING PROCESSES JNTU-HYDERABAns
The
AD
principle of electric discharge grinding is
that of Electric
Discharge same as R
Machining (EDM). The Tool
method comprises a
dielectric medium, power machining
voltage 40 80 V), servo system, supply (or
a
Feed
The grinding wheel is ram, grinding wheel, etc. -
made of an
electrically Dielectric fluid
The wheel which acts conductive
material (usually
is
graphite). as cathode
Votage o
partially immersed whereas the --
-Component
completely immersed. The component
anode is which acts as source

connected to the power cathode and the anode are

that dielectric flows in supply. The wheel (tool) rotates such
Inter Electrate Charging Dischargng
tool and the Gap (IEG) between the
component. This eliminates the flushing of the gap.
The machining is
circut crci

accomplished without any

between the tool and physical contact
the Figure (1: R-C Circuit
component.
The mechanism of
material removal is same as that of Rotary-impulse Generator (RIG) Type Circuit
EDM. The metal is removed
desired MRR and surface by melting and vaporization. The
finish can be obtained by considering
optimum machining parameters.
Some of these parameters are, Tool
Current
0.5-200 A
Pulse frequency : 50
250 kHz Generator
Wheel speed : 180 m/min
Q14. What do you D -Conponent
understand by power circuits for
E.D.M?
Molor
Answer :
Power Circuits in EDM Process Figure (2): RIG Type Power Circuit
The different types of In this type of
power circuits involved in EDM power cireuit, the power is supplied from
process are as follows, a rotary
impulsed generator (RIG). The process is accomplished
in two half cycles. In
1. first half cycle, capacitor of capacitánce
Resistance-capacitanc
circuit
(R-C) or relaxation type Cis charged through diode, D°.
During the next half cycle,
the sum of voltage
provided by generator and voltage
2.
Rotary-impulse generator type capacitor is supplied to the discharging spark in of charged
tool and the component. A typical RIG pówer circuitbetween the
Controlled pulse (vacuum tube) is shown
type in figure (2).
4. Oscillator-controlled pulse (vacuum tube) type Q15. Explain the
working of an R-L-C circuit of
5. Vacuum tube and electric discharge machine.
transformer circuits
6. Vacuum tube (power supply) Model Paper-l, Q7(a) |Dec-14,
R09, Q5(a)
7.
OR
Transistor pulsed circuit. With the help of a
1. R-L-C circuit used forline diagram; explain the
Resistance-capacitance (R-C) Type Circuit controlling the pulses in
electric discharge machining
The principle circuit of electric
discharge machining May/June-13, R09, Q5
is based upon self- oscillation. In this
type, a capacitor of OR
capacitance, 'C' is charged through a resistor ofresistance 'R Draw line
from direct source of current potential, V A small gap is
a diagrams and explain the control of
pulses in electric discharge machining by using
.

maintained between the tool and the component. A dielectric R-L-C circuit.
fuid is filled in the gap such that the
component is immersed Answer
Nov/Dc-12, R09, 5
in it as shown in figure (1). The capacitor is
charged until the Electric Discharge Machining by
current potentiäl reaches the breakdown voltage, V, in this In EDM process, the metal
an
using R-L-C Circuit
gap. Immediately after the breakdown of dielectric, the spark depends upon the magnitude and duration removal rate is mainiy
of spark
discharge attains-the maximum value. As a result, it produces between the workpiece and discharg
tool. The spark is initiated
an oscillatory flow of current. controlled by relaxation circuit and
in figure (1). . (i.e., R-L-C týpe), as show
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LOGO on the TITLE COVER. before vou buv
UNIT-3 Thern Metal Removal Processe: 3.7

Inan. EDM process, the tool and workpiece are made as cathode and anode respectively, immersed
in a dielectric Tiud
variables
variableswith ther
with their range
range are toare are and anode resp
as

Thenrocess
pr tabulated below.
SLNo. Process Variable
Range
Electric current 0.5 A 400 A
2.
Voltage 40 V 300 V (D.C)
Pulse duration 2 4s-2000 us
4.
Temperature 10,000°C- 50,000°C
Rate of spark 2 10,000 per sec
and anode
As the voltage inereases; the dielectric fluid gets ionized and the intensity of
of current between
cathode (tool)
arkoiece)
(workpiece) reached
reached to a critical value.
a
value, thue
thus S1onized curten
spark breakdown takes place for removal or maca
Relaxation Circuit (R-L-C Type)
The relaxation circuit (R-L-C) can be divided into three parts, they are,
) Charging circuit
i) Discharging circuit
G) Sparking circuit.
AMWwW Tool
R L

Diekctric
medum
(+) wwww- Workpiece
Figure (1: R-LC Cireuit used for EDM Process
In this circuit, a bank of condensers are charged until the spark occurs. The magnitude of voltage gradient is governed by
the working gap between workpiece and tool in
dielectric medium.The voltage raises, if voltage is applied at 'C'. When voltage
supplied at U, the dielectric medium breakdown occurs due to formation of strong electrostatic field between electrodes
and
workpiece. Thus, the dielectric medium gets ionized and sparking occurs. At each spark, millions of electroris are developed and
the voltage
suddenly falls to zero. During sparking period, the variations in voltage is shown in figure (2).
E-
U---

Spark time

Charging time
Figure (2): Voltage Variation
his method is suitable to cut very hard materials, and for large amount of metal removal rate
016. Explain mechanics of metal removal in electric discharge machining.
Answer
Mechani of Metal Removal
in EDM
Model Paper-|l,Q7(a)

e The echanism ofmetal removal in EDM process involves an electric erosion

ofremoved by répeated and small electric sparks between the tool and theeffect
workby
the
spark discharge..Inthis process,
ies voltage
of
of molecules intc rkpiece. The spark is produced when a
pulses a
are
s applied a small gap between the tool and the
across
workpiece. This results in iónization (breakdown
nto ions and electrodes) ofdielectric fuid. The tool is fed accurately to
Sng a Sservo maintain the constant discharge gap by
system
PECTR M ALLAN-ONE JOURNAL FOR ENGINEERING STUDENTS
as shown in figure.

SIA GROUP
 uOIE spnning head of thickness 5 mm.
Q15. Differentiate between thermal and
non-thermal processes. Nov/Dec.-13, R09, Q6(a)
OR
Compare and contrast between thermal and non-thermal processes. Nov/Dec.-12, R09,.Q6
Answer :
Model Paper-1, Q8(a)
Differences between thermal and
non-thermal processes.
Thermal Process Non-Thermal Process
1. In thermal process, metal
removal takes place due to |1. In non-thermal process, material removal takes
bombardment of electrons with very high temperature. place due to chemical reaction of electron beam
2| High energy densities can be achieved. 2. High energy densities cannot be achieved
3. Thick laminar structures can be machined. Thin films or layer can be
It is highily recommended for construction of deep
machined.
It has limited range for construction of
cavities.
deep
cavities.
5. Low resolution is obtained. 5. High resolution is obtained.
6. Metal removal rate per unit area is less. Metal removal rate per unit area is more.
7. Operating temperature range is more. Operating temperature range is less.
8. It is suitable for drilling holes and making slots. 8. It is suitable for machining large surfaces.
9. Electron beam and laser machining processes 99. Ultrasonic machining is an
example of non-thermal
areexamples of thermal process. processS.
0 0f a r the SIA GROUP LOGO on the TITLE CoVER before vou buv
 this process is within 0.8 mm.
metallic and non-metallic materials. The cutting accuracy obtained by
Q23. Compare and contrast EBM and LBM processes.
Model Paper-ll, Q9(a)
Answer:
Comparison of EBM and LBM
Electron Beam Machining (EBM) Laser Beam Machining (LBM)
1.| A high velocity electron beam is used for machining8 1. An intense and unidirectional beam of light is
operation. used for machining.
Material Removal Rate (MRR) in this process is given 2. Material Removal Rate (MRR) in this process
P
by, (MRR M * is given by, (MRR),M K.x
60 EAt
3. The MRR is high. 3. The MRR is low.
4. Better surface finish. Surface finish is comparatively low.
5. Wear rate of material is more. 5. Wear rate of material is less.
6. Working medium is vacuum. 6. Working medium is air.
7. High power is consumed for machining in this process. 7. Power consumed by this process is comparatively
less.
8. The process can be used for microdrilling upto the
8. The process can
be applied for drilling upto the
size of 0.002 mm.
size of 0.005 mm.
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