Design and Fabrication of Wire Cut Electrochemical Discharge Machining system Nikhil Kumar Chouhan(632/MP/07)

Vikas Sharma(658/MP/07) Vikas Suryavanshi(659/MP/07) Project Guide Dr.Sanjay Kumar Chak

Division Of Manufacturing Process And Automation Engineering

Netaji Subhas Institute of Technology ,New Delhi-110078

CONTENTSIntroductionLiteraeture surveyMotivationObjectiveProposed methodologyProject update Refrences

INTRODUCTIONElectrochemical discharge machining is recentnon-convention

hybrid technology used to machine the non-conducting material.

Basically electrochemical discharge machining (ECDM) is an extension of the electrochemical machining (ECM) process.

Electrochemical discharge can be effectively and economically used for machining of a wide range of conducting and non-conducting materials, ceramics, and composites

INTRO………Advancements in today’s materials technology need

appropriate processes for machining of low machinability materials with the desired dimensional and geometric accuracy at a high rate of production and low cost.

In order to meet with the requirements of present day part manufacturing with any kind of non-conducting work materials for achieving enhancedproductivity, dimensional quality features and cost reduction criteria the travelling wire electrochemicaldischarge machining technique has great potential.

It is a complex combination of ECM and WireEDM process.

INTRO………The Travelling Wire Electrochemical Discharge Machining

(TW-ECDM) process can be applied for cutting of non-conductive engineering materials with the scope of generating intricate shapes and profiles.

It is expected to have tremendous application for generating intricate shapes and profiles of advanced non-conducting ceramic materials like zirconia(ZrO2), silicon nitride (Si3N4), alumina (Al2O3),diamond, glass, ruby and composites like FRP etc.

LITEREATURE SURVEY Indrajit Basak et al, has been analyzed the ECD phenomenon as a switching

process between the tool (one of the electrodes) and the electrolyte and it has been found that an extra control parameter can be obtained by introducing an additional inductance in the circuit.

Anjali V. Kulkarni and V. K. Jain,Wire-cut EDM (WEDM) is one of the most favorable variants owing to its ability to machine conductive, exotic and high strength and temperature resistive (HSTR) materials with the scope of generating intricate shapes and profiles

Crichton and McGeough ,have reported, from observations made using high-speed photography, that both spark and arc discharges are possible in an electrolyte.

B. Bhattacharyya et al, conducted experiments with ECDM on non-conductive ceramic materials and discussed the influence of electrolyte concentration, voltage and tool tip geometry on material removal rate (MRR) and condition of machined surface.

LITEREATURE SURVEY………W.Y. Peng et al , conducted study of electrochemical discharge machining

technology for slicing non-conductive brittle materials, glass and quartz. They investigated the electrolyte supply for more stable and stronger spark release. The lower ambient pressure could evoke more drastic reaction. The power source is modulated to find the suitable parameters for different material properties being sliced under different energy intensity.

Peng and Liao tested other nonconductive brittle materials Tsuchiya et al, that TW-ECDM can slice thin optical glass and engineering

ceramics with a vertical lineset-up. The various influences due to electrolyte type,concentrations, and power source parameters were demonstrated.used travelling wire electrochemical discharge for machining of glass and ceramics

The slicingof composite material with horizontal wire set-up has beenconducted by Jain et al.

MOTIVATIONFrom the literature survey it is understood that emphasis is

made on wire cut ecdm for slicing hard non-conductive materials

A limited research work has been carried out in the travelling wire electrochemical discharge machining (ECDM).

Hence the present research work considers the investigation and study of slicing the hard non-conducting materials.

OBJECTIVE 1

• A prototype model of an Electrochemical Discharge Machine integrated with wire feed mechanisam is to be developed

2• The investigation is to be carried

out on various engineering materials like quartz,ceramics,sic,glass etc.

3• The effects of process parameter

are to be evaluated –voltage, electrolyte concentration, tool geometry.

Proposed methodologyThe present research work will be focused on the machining of

nonconducting materials by using the wire cut mechanism of ecdm. The effective wire cut mechanism to be developed to achieve the required objective.

Studied the different litereature ,several research paper,white paper,thesis and their attributes towards the objective.

PROJECT UPDATESuccessfully completed the design and drawing work related to

projectImplementing the design into practical platformAlready setup the base arrangement,wire mechanism flask

setup material procurement different types of chemicals brass edm wire etc.

Only 20-25% work is left in fabrication of setupDEVELOPMENT OF THE EXPERIMENTAL SETUPKeeping in view the influences of various process parameters

of Travelling Wire Electrochemical Discharge Machining, the experimental setup is to be indigenously developed for performing experimental studies

For Successful Completion Of

Project

WAY

FORWAR

D

REFRENCES Improving machining performance of wire electrochemical discharge machining by adding

SiC abrasive to electrolyte By C.T. Yang, S.L. Song, B.H. Yan, F.Y. Huang  Jain V.K, Rao P.S., Chaudhury S.K. and Rajurkar K.P., ” Experimental Investigations Into

TWECDM of Composites”, Trans ASME , Journal of Engineering for Industries 113(1) (1991) pp 75-84.

R. Wuthrich, V. Fascio, H. Langen, Investigations of spark assisted chemical engraving, J. Electrochem. Commun. 5 (2003) 203–207.H. Tsuchiya, T. Inoue, M. Miyazaki, Wire electro-chemical discharge machining of glass and ceramics, in: Proceedings of the Fifth International Conference on Production Engineering, Tokyo, 1984,pp. 413–417.

W.Y. Peng et al, ‘Study of electrochemical discharge machining technology for slicing non-conductive brittle materials’, Journal of Materials Processing Technology Volume149, 2004, pp.363–369.

Bhattacharyya B., Doloi B., Mitra S., Sorkhel S.K.,“Experimental Analysis On The Electrochemicaldischarge Machining (ECDM) System Foradvanced Ceramics”, Proceedings Of International Conference On Precision Engineering (ICPE '97),taipei,taiwan, Pp 715-720.