ASSIGNMENT / LABORATORY /

CASE STUDY / PROJECT

KOLEJ KEMAHIRAN TINGGI MARA

KUANTAN PAHANG

PROJECT REPORT CNC

PROGRAMMING & MACHINING

SESSION: JAN – JUN 2023
GROUP GROUP 2
1. IRFAN AIMAN BIN ISMAIL SHAH
NAME 2. MUHAMMAD SYAZWAN FAHMI BIN ABDUL KHADIR
3. AIN NAJWA BINTI ROHAIZAT

1. 2215713
MATRIX NO 2. 2215708 SEMESTER 3
3. 2215711
CODE & COURSE DMV30203 CNC PROGRAMMING & MACHINING
LECTURER / VTO SIR AZHARI

SUBMISSION 23/5/2023
DATE
1. Safety

1. Never make contact with the electrode while the machine is running.
2. Ensure that the place where the operation is grounded.
3. A dry environment should surround the equipment.
4. Wearing conductive clothing or accessories like jewellery is not advised.
5. Never look directly at the spark; instead, wear the proper eye protection.
6. Put on closed-toe, rubber-soled shoes that are non-slip. Given that you might
spend a lot of time standing, your shoes should also be comfy.
7. Maintain your machine properly. The machine needs to be oiled and cleaned.
When maintenance is required, be sure a skilled expert completes the task.
8. Know the equipment. Avoiding actions which implications those are unsure of
is one of the best methods to avert mishaps. The unexpected will be reduced if
operator familiar with the machine's quirks.
9. Keep combustible things away from the area around the equipment.
10. Keep the wits about and concentrate solely on the machining. Avoid drinking
alcohol while working.

2. Machine ( component @ main part)

a) Working Table
The work table holds and supports the workpiece. Their motion is controlled by
two stepper motors. Wire EDM machining is finished by relative movement
between the working table and cathode wire. The working table of the
highspeed feed wire cut EDM machine is equipped with X and Y axis slides, a
priceless linear guideway, and a priceless ball screw. The mechanical rigidity
and controllability of the XY cross structure have been established and are
generally acknowledged due to its extensive application. Today, many machine
tools regularly use its highly developed production and design methods.

b) System for Running Wire

The electrode wire feed, the electrode wire's reciprocal feeding, and the
electrode wire coiling on the wire drum without overlapping are all controlled by
the wire running system.
c) CNC Control
CNC systems must have strong coupling high-precision stepper motors as well
as programming instructions. Additionally, the entire wire EDM machining
procedure is controlled by CNC tools. Being able to manage the cutting process
automatically and order the wire path are necessary for controlling the entire
operation.

d) Wire
To produce the electrical discharge, the wire acts as the electrode. As a result,
the thickness and shape of the workpiece directly affect the wire's diameter.
Brass is the most widely used material for EDM wires because of its excellent
conductivity. The wire cuts more swiftly the more zinc there is in the copper and
zinc alloy, which is a copper and zinc alloy. The corrosion rate of brass wire is
reduced when the zinc concentration exceeds 40%, thus there needs to be a
balance.

e) Dielectric Fluid
Dielectric fluid must be present in the tank used for the wire-cut EDM method.
This liquid prevents the workpiece's tiny particles from sticking to the wire
electrode. The most popular medium is deionized water, which cools the
process and results in a workpiece with a flat surface.

f) Power Supply
The wire electrode and the workpiece receive pulses from the power supply unit
that range in voltage from 100V to 300V. Additionally, the frequency and
strength of the electrical charges that pass through the wire electrode and
interact with the workpiece are adjusted. Therefore, delivering the proper kind
and quality charges during wire EDM machining requires a highly developed
power supply unit.

g) Recycling System
A pump draws the working solution (deionized water) from the tank, which is
then directed into separate up and down nozzles after passing through a filter
to remove pollutants. The working solution then returns via a filter next to the
tank. Changes must be made if the working solution and filter have an impact
on cutting quality.
3. Standard procedure

a) On machine

i. Turn on primary power source

ii. Switch on compressed air

b. Create file & Key in program

i. Select program

ii. Press edit

iii) Press auto in graphic settings

c. Simulation
d. Setting W/piece

e. Run/execute programming
f. Off machine
3. Programming & Project a. Drawing
b. Programming
 4. Discussion Explain any difficulties during the process and the
way to solve it.

The treatment plan requires overcoming a lot of obstacles. For instance, the components
have a poor finish. First off, we can be using a cutting tool that is either too abrasive or
ineffective for the task. If that occurs, we'll have to start again and replace the tool.
Additionally, there's a chance that dirt or other debris may clog the equipment. We need to
establish a regular maintenance programme to stop this. Another issue we have is with the
machine tool because it gets pretty hot. In the long term, overheating the tool might damage
our machinery and negatively impact our results. To fix this problem, we'll need to lubricate
this equipment. Because friction may generate a lot of heat.In addition, the programme isn't
operating as it should be, which is the problem we're experiencing. The most likely cause
of this issue is human error. Even though modern EDM Wire Cut machines are highly
dependable, only qualified professionals should use them. The machine will experience an
error if it receives incorrect data. To avoid this, we must make sure that our instructor is
monitoring our work. Finally, the machine begins to tremor or shake. If our EDM Wire Cut
machine vibrates more than usual or makes a "chattering" noise, something is amiss. If this
problem is not resolved straight away, the machine can suffer if our components are not
produced to the necessary standard. We must adjust the spindle speed and evaluate the
health of our drivers and spines in order to resolve this problem.

5. Conclusion

Wire EDM (WEDM) and bandsaws have some similarities. In both cases, a part form
is traced using a constantly moving, flexible strip of metal held taut between two guides.
The electrode in a WEDM process is a spool of consumable wire that travels through
a complicated system of wheels and rollers, over an electrical contact, through a
doughnut- or v-shaped guide, through the workpiece into another set of guides on the
opposite side, across an opposing contact point, and finally on to a waste bin or take-
up reel for disposal of the now-used electrode. Both create a little "kerf," or the tiny slit
that develops behind the blade when it cuts through a substance. Additionally, both may
create intricate forms using wire. EDM is the undisputed champion in this battle.It is
important to remember that the wire in the process is constantly moving, and not to be
reused. As a result, the copper, brass, or other metallic wire can be miles long, adding
cost to the process. And, while the process uses no force and thus does not cause
burrs and can be used on delicate items, the possibility of thermal stress is certainly
present.

Most machining operations using wire EDM begin with a rough pass with a fairly fast
feed rate and high dielectric flow. Successive skim passes take smaller cuts with a
reduced dielectric flow to bring finished surfaces into tolerance. The reduced dielectric
flow avoids distorting the wire during these skim passes.Cuts that do not begin along
an edge of a part (such as holes) require predrilling to allow the wire to thread through.
Many wire EDM machines are fitted with small hole drilling electrodes for this purpose,
permitting starting holes to be made in hardened steels without the use of conventional
drills. Small hole drills usually employ an EDM electrode mounted in a spinning mandrel
with dielectric pumped through the electrode to flush the hole. The process of making
small holes in hardened material using standalone EDM drills is sometimes referred to
as hole popping.