instruction manual of edm machine

7/25/2019 Instruction Manual of EDM Machine

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WARRANTY CERTIFICATE

M/C Model: Electrical Discharge Machine Model M-25-6040 (25 Amps)

!"#$:-00%/&4

#AME: - 'MA A$C'AE Date:-22/&2/20&4

Warranty is for 15 months from date of dispatch or &2months from date ofinstallation whichever ends early. *arrant+ is not co,ered or machines .oring inollo.ing condition :-

1. faulty power source

2. Supply voltage variation more than 415 V. AC !hase " 1#$% 5#&' fre(uency "#.5 with independent neutral from main incoming supply.

. Voltage )etween earth * neutral more than 2 Volts.

4. +achine run on C,-V/0 !,W/ rom 1 phase to !hase.

5. +achine placed in unventilated Area.

3. nternational A)usive se of machine to malign machine performance.

6. Caused )y any terrorist or any person motive.

7. amages due to natural calamities. 8i9e earth (ua9e% fire% riot% flood% etc.

:. 0he warranty will automatically gat invalid% if the machine is opened% repaired%

modified )y any unauthori;ed person.

A0&,/' S


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EDM Principles and Technology

0he + !rocess 0a9es !lace n 0he Wor9 0an9 illed With ielectric luid. 0he,)>ect 0o ?e Cut ,r +achine s Called 0he Wor9 !iece@ Where as the Cutting 0ool s An

lectrode. ?oth Are Su)merged n the ielectric luid and separated ?y a Very Small


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ELECTRODE MATERIAL

0heoretically% all conducting materials can )e used. +aterial with the highest melting

point and the lowest electrical resistively are% in theory% the )est. Cost analysis show that%n +% electrode material@ the (uantity and the method of manufacturing are important

actor and deserve careful consideration.

lectrode +aterials Can )e divided as ollowsE Silver tungsten

Copper tungsten

Copper graphiteBs com)ination of metallic and non metallic material D

Chromium Copper

lectrolytic copper


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" PROD#CTION METOD ELCTRODE

0raditional machining methods such as turning% milling% shaping%

grinding% engraving etcJ

Stamping coining.

trusion or drawing.


5/18

CAPTER $% EDM APPLICATION

+ application depend on a s9illed operator. t is necessary to analy;e all + factor

to produce high (uality wor9..

lectrodes +aterial. Wor9 piece +aterial.

Surface roughness.

Spar9 gap.

lectrode Wears.

/emoval /ate.

uring spar9ing discharge D the gap area must )e flushed continuously to gat rid of

particles and residue.

f lushing and raining of the cavity is not good enough% increase the servo to a higher

setting. 0o get fine finish the vertical movement must )e vary fast.

0o achieve low or no electrode wear% start with a low discharge amperage% and as soon as

the whole area of the electrode contacts the wor9 piece% increase the amperage. 0his will

!rotect Sharp Corners or Angels.0o Set servo sensitivity )ear in mind that sensitivity depends on the current@ when the

current is low% servo is of small amplitude )ut high sensitivity.

Know * understand the discharge process.

" D'C1!E $3E!A'$# 3!$CE

0/- L,-M +A- SW0C&.

S0N! 8C0/,% A8


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CAPTER NO%&% POWER !#PPLY OPERATION IN!TR#CTION!

!#RFACE ' C#RRENT TA(LE%

!ACEE A!EA ggested crrent (A)

C7 ( Electrodes )C.7

r7( Electrodes )

r-

# mmQI 1# mmQ A I 3A A I 3A

1# mmQ I 25 mmQ 3A I 12A 3A I 12A

25 mmQ I 1## mmQ 12A I 21A 12A I 21A

1## mmQ I 4## mmQ 12A I 45A 21A I 45A

4## mmQ I13## mmQ 21A I 3#A 45A I 3#A

13##mmQ I 34##mmQ 21A I 3#A 3#A I 12#A

34##mmQ 21A I 3#A 12#A

1. Set the Appropriate duration * amperage to produce the desired finish. /ma

R#.5I .7 m can )e reached at LatM R 2 s% Where as LatM R5##s can !roduce/ma R :#I12#m.

2. With 0he duration longer than 5#us% duration * amperage can )e +atched in

direct ratio to permit machining with no electrode wear.When duration is short% and current high% electrode wear increases.

. Since different material have different characteristics% itBs -ecessary to useifferent duration setting according to the ta)les in the application note.

3


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4-&" 3A!8 $ E'#"

1. uty cycle is the off time )etween two pulses when no impact ioni;ation occurs

and dielectric condition are reN esta)lished. sually when the discharge is sta)le

And interval is short% efficiency is high and a protective coating will form on the

electrode. f the flushing is poor% particles are not removed and machiningefficiency decreases. So% itBs necessary to set the servo to raise the electrode

periodically to permit flushing.

2. -o matter whether the interval is short and the amperage high or the interval islong and the amperage low% the voltage must not change.

. 0he length of the interval must )e set according to the material characteristics to

get the highest efficiency.4. 0N, duty cycle D unctionE

1. 0N, duty cycle D in 1 for high speed machining.

2. f machining is unsta)le% ad>ust 0 T,ff duty CycleD manually to increase

off time.. when amperage is too high for corresponding electrode frontal area ad>ust

0N,ff duty CycleD to increase off time% use the chart no. N.

4-2 E!9$ E#''9' E'#"

1. ServoBs ad>ustment affects the velocity of electrode movement and must )e

synchroni;ed with discharge duration. When the voltmeter pointer is steady

synchroni;ed is Achieved.2" 0he servo monitors the discharge gap during discharge. +aintaining the proper

gap is one of the most important factors in +. So% we have vary carefully

designed this system to ena)le the most difficult wor9.

4-" D'C1A!E A3 E'#"

1.


8/18

CART NO% )* PEA+ C#RRENT AND REAL MACININ,

A.low spar9ing% current% slow machining speed . &igh spar9ing current%faster machining speed.

?. sing copper as electrode% the wear will increase according to machiningspeed. ?ut if using graphite as electrode% the wear is not eactly same as

copper depends on grade of graphite material D. At a same current out put

field% the wear is nearly same.

C. 0he surface finishing and spar9ing gap depends on the spar9ing

parameters.

rno"

$n time 3osition Crrentma


9/18

CART - . * ELECTRODE MATERIAL CARACTERI!TIC!

:

Electrode material Melting point =C !sisti,it+

>mm2/m

Densit+ / mm

Silver tungsten #.#47 #.#13

Copper tungsten #.#55 #.#15

Copper graphite #.#4 #.#26

Chromium Copper #.#23 #.##71

lectrolytic Copper 1#7 #.#136 #.##7:


10/18

CART NO% /* POWER !#PPLY #NIT%

1#

3E M - 20 M - 5 M - 50

Supply Voltage. 415V% !hase% 5# &'

+ains Voltage tolerance. " 5 $

,pen gap output VoltageVD.

35 " 5$

!ower actor. Appro. #.7

Connected 8oad KVAD. 2 KVA. KVA. 4 KVA.

+achining Current +a

Amps D.

2# Amps 5 Amps 5# Amps

Current /ange Selection. manual manual manual

!ulse ,n uration

2 to 5###s

Weight. 6# 9g Appro. 7# 9g Appro. :#9g Appro.


11/18

Mar0i Machine Tools

2adodara

EDM Controller Instruction Manual

11


12/18

F#NCTION +EY!

&"3M3 : sed 0o +a9e !ump ,nH ,ff.

2"3A!8 : sed 0o +a9e Spar9 unction ,nH,ff.

"A3 : sed 0o ,n +anual Auto !osition unction ,nH,ff"

4"3 : sed 0o ,n +anual ! +otion.

5"D$*# : sed 0o ,n +anual ,W- +otion"

6" ?@@ : sed 0o +a9e ?u;;er unction ,n H,ff.

%" AM3 : sed 0o Select Current .

" A/ : sed 0o Select Auto lush +ode.

B"!EE : sed 0o /eset All unction.

12


13/18

3E!AMEE! 3$

&" ap E Shows 0he Set


14/18

" $ E -on machining 0ime ,f Spar9 Cycle. !lease /efer 0echnology Chart or +ore etail

-0/8,CKS

1. ;; ;$* ;E9E; E 8 or 8ow 8evel ,f ielectric in Wor9ing

0an9. t lights when dielectric 8evel s 8ow in

Wor9ing 0an9 than set 8evel. Spar9ing

unction s disa)led f t 8ights.

2. 3 ;'M' E 0his 8 8ights When Uuill ,r A /am s At

8imit position

" D# ;'M' E 0his 8 8ight When Uuill or a /am is at -

8imit !osition.

4. A!8 A!C'# E 0his 8 8ights ,nly s Spar9ing unction %

When 0he +achining process is unsta)le.

When this 8 light it reduces 0he spar9ing

current and try to protect the electrode * wor9

!iece from damages due to arcing.

14


15/18

0/,?8 S&,,0-


16/18

0C&-,8,


17/18

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16


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instruction manual of edm machine

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