UNIT – 2

PART-A ANSWER KEY

1.List the applications of wire EDM.

Since Wire EDM is ideal for creating small delicate items, its application is widely spread. However, it
is mostly used in:
• Blanking punches and extrusion dies.
• Automotive and aerospace parts and components
• Implantable medical devices
• Prototypes proof of concept builds
• Small hole drilling on hard and soft materials

2.List the desirable properties of a good dielectric fluid.

A good fluid dielectric should have high dielectric strength, high thermal stability and inertness
against the construction materials used , non inflammability and non toxicity , good heat transfer
properties and low cost.

3.Give the roles of dielectric fluid in EDM.

-It acts as a spark conductor concentrating the energy to a very narrow region.

-It acts as a coolant for the workpiece and the tool.

-It acts as an insulating medium during the charging time of the sparking circuit in order to
discharge an effective spark for machining.

-It acts as a coolant in quenching the spark and helps arching to be prevented.

-It acts as a flushing medium for the disposal of the product of machining.

4.List the types of EDM flushing techniques.

There are four types of flushing: pressure, suction, external, and pulse flushing. Each job needs
to be evaluated to choose the best flushing method. Pressure flushing, also called injection flushing,
is the most common and preferred method for flushing.

5.Indicate the range of pulse duration and current in EDM.

6.Name the most commonly used spark generating circuits.

7.How to minimize tool wear in EDM.

8.What is an arc gap? How is the arc gap controlled in EDM.

Electrode gap (spark gap) is the distance between the electrode and the part during the process of
EDM. Electro-mechanical or hydraulic systems are used to respond to average gap voltage. To obtain
good performance and gap stability a suitable gap should be maintained.

The continuous EDM process with the gap control method is carried out by feeding the tool
electrode only in the z-direction. A copper pipe with 2.5mm internal diameter and 4.0mm external
diameter is used for the tool electrode and steel is used for the workpiece.
9.Quote the dielectric fluids used in EDM.

commonly used dielectric fluids in EDM are hydrocarbon oil, e.g., transformer oil, paraffin oil,
kerosene; lubricating oil, gas, air and also deionized water.

10.Distinguish wire cut EDM and EDM process.

Wire cut EDM EDM

Thin wire is used as a tool Shaped tool is used. (Mirror image of the
workpiece)

2. Very thin wire made of brass or Expensive alloy of silver and tungsten are
molybdenum is used as the electrode (tool). used as the electrode (tool) which are
traditionally made by cutting and grinding.

3. The whole workpiece is not submerged in The whole workpiece is submerged in

dielectric medium. Instead, the working dielectric medium
zone alone is supplied with a co-axial jet of
dielectric medium

4. It is easy to machine complex two It is difficult to cut complex two dimensional

dimensional profiles. Profiles.

11.Assess the influence of current in MRR in EDM process.

12.Assess the ways of gap-flushing used in EDM.

Various methods of flushing are,

Suction through electrode Suction through workpiece

Pressure through electrode Pressure through workpiece

Jet flushing Periodic cycling of electrode

13.List the factors affecting the metal removal rate.

14.Classify the tool materials in EDM.

- Metallic Materials

Electrolytic copper, Tellurium or Chromium Copper, Copper Tungsten, Brass,

tungsten, Steel, Zinc, Zinc Alloys, Tunsten Carbide and Aluminium.

- Non-Metallic Materials – Graphite

- Combination of metallic and non-metallic- Copper Graphite.

Copper and brass are the two commonly used tool materials since it satisfies all the
requirements but exhibits high wear rate.

Copper tungsten - Less wear ratio, able to produce good surface finish.

Tungsten carbide - Difficult to machine to the required shape or profile

Graphite and copper graphite - Easily machined and available in various grades.

15.Interpret the meaning of plasma.

an ionized gas consisting of positive ions and free electrons in proportions resulting in more or
less no overall electric charge, typically at low pressures (as in the upper atmosphere and in
fluorescent lamps) or at very high temperatures (as in stars and nuclear fusion reactors).

"the current passed through a column of plasma"

16.Summarize the advantage of EBM over LBM.

LBM EBM

A high intensity of beam of laser is used to A high intensity beam of focused electrons
supply heat for material removal. is use to supply heat for material removal.

It does not require any vacuum chamber It requires vacuum chamber

There is no restrictions on workpiece size EBM process is suitable for small

components

LBM is independent of electrically Electrically conductive material only can

conductive machined.

17.How plasma arc is used in the machining process.

In the plasma arc machining process, the material is removed by directing a high-velocity jet of
ionized gas at high temperatures (11000 ° C to 28,000 ° C) on the workpiece. This high-temperature
plasma jet melts the contents of the workpiece.

18.Define the principle of electron beam machining.

EBM process is used for machining of materials using high velocity beam of electrons.

The component to be machined (workpiece) is held in vacuum chamber and beam of

electrons is focused on to it magnetically.

When electrons strike the workpiece their kinetic energy is converted into heat energy

and raises the temperature of workpiece. Due to high temperature, a small amount of

workpiece material vaporises that means there is removal of metal from the workpiece.
19.Give the wear ratio for brass, copper, copper tungsten and non metallic electrode.

20.Summarize the advantages of plasma arc Machining.

In plasma arc machinings, hard and brittle metals can be made easily. It can be applied to almost
all types of metal. The best parts of this process are that we get a higher cutting rate. We obtain
better dimensional accuracy in the case of machining small cavities.

- Plasma arc machining can be used on difficult materials

- The use of plasma keeps cutting the workpiece free from contact of the gun

- Workers are more productive and have increased accuracy

21.Classify the various types of lasers.

Lasers are classified into 4 types based on the type of laser medium used:

• Solid-state laser

• Gas laser

• Liquid laser

• Semiconductor laser

22.Distinguish between the vaccum and non vaccum EBM.

Non-vacuum electron beam welding employs essentially the same equipment as in-vacuum
EBW but the beam is passed through a series of separately pumped pressure stages to allow the
beam to be projected into the atmosphere without causing excessive gas leakage into the beam
generator.

23.Describe the Acronym of LASER?

The acronym laser stands for "light amplification by stimulated emission of radiation." Lasers
work as a result of resonant effects. The output of a laser is a coherent electromagnetic field. In a
coherent beam of electromagnetic energy, all the waves have the same frequency and phase.

24.List the function of electron beam gun?

The electron gun is responsible for producing a fine beam of highly accelerated electrons that can
be focused on the screen. The main function of the electron gun is to produce and accelerate the
beam of an electron inside the vacuum tube of the CRT.

25.Summarize the commonly used gas mixture in PAM.

GAS OR GAS MIXTURES MAATERIAL TO BE MACHINED

Nitrogen – Hydrogen Stainless steel and non- ferrous metal
Argon - Hydrogen
Nitrogen – Hydrogen Carbon , alloy steels and cast irons
Compressed Air
Nitrogen – Hydrogen Aluminium and magnesium
Argon - Hydrogen