TITLECNC EDM (Electric Discharge Machining) Wire-Cut

THEORYWire electrical discharge machining (WEDM), also known as wire-cut EDM is a process of using a thin single-strand of metal wire fed through a workpiece. The wire is constantly fed from a spool is held between the upper and lower guides. The guides move in the x-y plane and control the movement of the wire through the workpiece during the cutting process. Most machines in use today are CNC controlled. Wire EDM machines are very Precise and can be programmed to cut very intricate and delicate shapes.

The wire-cut process uses water as its dielectric with the water's resistivity and other electrical properties carefully controlled by filters and deionizer units. The water also serves the very critical purpose of flushing the cut debris away from the cutting zone. Flushing is an important determining factor in the maximum feed rate of material available in a given thickness, and poor flushing situations necessitate the reduction of the feed rate.

OBJECTIVESThere were objectives that needed to be achieved in this CNC EDM Wire-Cut project. The objective was : to understand the function and feature provided by the CNC EDM Wire-Cut machine. to learn the tool and equipment needed while operating the machine. to understand the safety precaution when operate and handling of CNC EDM Wire-Cut machine.

EQUIPMENTThe equipment that used during this project were :1. EDM Machine used as the machine for this project.

2. Electrode Wire used to cut material.

3. Lab Sheet used as reference for this project.4. Computer with CAD/CAM software used to make simulation for this project.

SAFETY PRECAUTION1. The lever of the machine was spin.2. Choose command on the EDM Machine.3. Press JOG.4. All coordinates was checked to make sure the machine work in good condition.5. Make sure the machine returned to its original origin back.

PROCEDURE (i) Key In The Codes

1. F8 - F3 - F1 - F2 - X0 Y110 ENTER2. F8 F3 F2 X100 Y110 F7 155 J0 ENTER3. F8 F2 X110 Y0 CENTER 10 J 554. F8 F1 X0 Y05. ETC - END

(ii) Cutting Process

1. The conductive work piece is mounted to the machine and the work piece is secured to the table in such way that the electrode can make the desired cut path without interference either from the work piece, or the work holding device.2. The material needs to be removed and the part should be tightly fastened to table to ensure that it remains in place during the process.3. The work piece must be aligned relative to the machine axis that consists of X, Y, Z, U and V axes.4. The ball indicator is usually attached and the work piece is adjusted until it is vertical and parallel within the desired tolerance.5. The machine coordinate system has to be set to the appropriate position after the work piece is secured to the machine table and aligned to machine axes.6. The Wire electrode is positioned to work piece.7. The brass electrode while being spooled off and under tension is brought within a close proximity of the work piece edge.8. The edge position command and designate is executed to the appropriate axis.9. The process for the cutting had been program using G and M codes.

RESULT (EDM MACHINING)

Figure 1.EDM Machines animation result.

Figure 2.Wire-Cut Codding Result.

RESULT (WIRE-CUT SIMULATION)

(i) Practical Task 1

Figure 3.Practical Task 1 Simulation.

Figure 4.Practical Task 1 Code.

(ii) Practical Task 2

Figure 5.Practical Task 2 Simulation.

Figure 6.Practical Task 2 Code.

DISCUSSION1. Do you manage to use the Wire-Cut process on a material?No, because the EDM Machine had a problem with its Wire-Cut. Therefore, we just learned theoretically on how to insert Codes using the simulation on the EDM Machine from the Lecturer.

2. What do you learn in this task or project? We learn more about safety procedures when handling the EDM Machine such as to check if the machine table can move on coordinates X, Y, and Z. Furthermore, the Lecturer also show us about the basic codding that most commonly used for the EDM Machine and the function or feature of this machine.

3. What can you expect from this project?We expect that we can handle the EDM Machine more practical so we can improve our understanding on how the cutting process really work and look likes.

CONCLUSION As a conclusion, the objectives have been successfully implemented. Any guidance given by lecturers is very useful and effective. Even though, we have not successfully using CNC EDM Wire-Cut machine because of some minor problem. However, we managed to enter the program and run for the design of the products made by using the machine simulation. In addition, we also know how to apply the program to form the G-code to get the result as above. All that was taught to us was really helpful to our advantage as we go intothe working world later.

REFERRENCE1. CNC IS ABC. Deenesh Kumar A/L Nalathambhi. Mawardi Bin Mohamad. Mad Noh Bin Lajim. Politeknik Kuching Sarawak.2. CADCAM (JF504). Deenesh Kumar A/L Nalathambhi. Politeknik Kuching Sarawak.3. http://mienasukasuki.blogspot.com/2011/09/report-bengkel-cnc-edm-wire-cut.html4. www.edmmachining.com/wire_edm.htm5. www.wisegeek.org/what-is-edm.htm

TITLECNC (Computer Numerical Control) Turning Machining.

THEORYCNC Turning Machines and convertional turning machines each have the same basic components, such as the main motor, the spindle, the bed, the tool turret, the headstock, the cross-slide, the carriage and the way systems. However, CNC Turning Machine in addition are outfitted with a computerized control and servomotors to operate them. Manual CNC turning can be very versatile and productive machine tools, but when coupled with a CNC, they become the high tech production turning machine of the machine shop. Additionally, repetitive operations such as turning, facing and boring are ideal machining application for CNC turning machines CNC Turning Machines can also be designed to include a variety of optional components and features. These options are basically designed to reduce setup time part handling and cycle time for an instance, one option for minimizing part handling time is to add a part loading magazine or a robot arm. The maximum spindle speed (RPM) of a CNC turning machines can also very depending on the need or application.The factors that determine the spindle speed range selected can include the type of part material, the part sizes and the annual part production quantities to be machined. Another factor that influences the spindle speed things is the type of tool culter material that will be used, such as HSS, coated carbide, diamond and ceramic.High production turning machines can be designed with dual chucks that enable a part to be machined on the both ends. Also live tooling can be incorporated that allows milling and drilling at various angles. Other option may include a second or third turret, a bar feeder, a parts catcher, a steady rest follower and a tool setter.

OBJECTIVESThere were objectives that needed to be achieved in this CNC Turning Machine project. The objective was : to understand the function and feature provided by the CNC Turning Machine. to learn the tool and equipment needed while operating the machine. to understand the safety precaution when operate and handling of CNC Turning Machine.

EQUIPMENTThe equipment that used during this project were :1. CNC Turning Machine (Spinner TC46-MC) used as the machine for this project.

2. Computer software (Sinumerik 810D) used to make simulation for this project.3. Lab Sheet used as reference for this project.

SAFETY PRECAUTION1. Machine info at computer panel (Black Normal) (Red Critical).2. Emergency button was released.3. Hydraulic pump was turned ON to make sure its working.4. Automatic lock at the door was used to complete the circuit before the machine process started. (Make sure door always closed)5. The door can only be opened by using key.6. The jaws clamp was checked by using foot pedal.7. Pin hole (Center) can go IN or OUT by using foot pedal.8. Automatic tool changer (12 Tool Bit) working properly.9. Coolant Noozle (Liquid Semi-Organic) was working.10. Machine only use 2 axis. (X and Z).11. Close door for safety.12. Reference tool must press button JOG and REF. Point.13. To check rotation press (Multi Plus ON).14. Only JOG ON and REF OFF if want to check axis Z.15. Spindle can spin and press MO3 and MO4 must be carefully depend the machine and worker and lastly check the lamp.

PROCEDURES

(i) Lathe Machines

1. Main supply (415 Volt) was turned ON.2. CNC Machines was turned ON.3. Hydraulic Pump was turned ON.

(ii) Setting Reference Point

1. Set the Feed Rate of the machine.2. Mode selection switch at reference point.

(iii) Edit File

1. Select Edit.2. Chose File.3. Select File Input.4. Select Monitor.

(iv) G Codes Key InAbsolute Coordinates (G90)G90 G95 G96 F0.15 S180 T2 D2 M4 M41G0 X50 Z100G1 X0 Z80..Point AG1 X15 Z65.Section A-BZ55...Section B-CX40 Z30...Section C-DZ0.Section D-EG0 X50 Z100M02

RESULTXzZz

Figure 1.Simulation Result

DISCUSSION1. Do you manage to use the Turning process on a material?No, because the CNC Turning Machine had some minor problem with it. Therefore, we just learned theoretically on how to insert Codes using the simulation and how the CNC Turning Machine operated from the Lecturer.

2. What do you learn in this task or project? We learn more about safety procedures when handling the Machine such as to check if the machine parts can move without any error or problem. Furthermore, the Lecturer also show us about the basic codding that most commonly used for the CNC Turning Machine and the function or feature of this machine.

3. What can you expect from this project?We expect that we can handle the CNC Turning Machine more practical so we can improve our understanding on how the turning process really work and look likes.

CONCLUSION As a conclusion, the objectives have been successfully implemented. Any guidance given by lecturers is very useful and effective. Even though, we have not successfully using CNC Turning machine because of some minor problem that should be fix. However, we managed to enter the program and learn basic process of the machine. All that was taught to us was really helpful to our advantage as we go intothe working world later.

REFERRENCE1. CNC IS ABC. Deenesh Kumar A/L Nalathambhi. Mawardi Bin Mohamad. Mad Noh Bin Lajim. Politeknik Kuching Sarawak.2. CADCAM (JF504). Deenesh Kumar A/L Nalathambhi. Politeknik Kuching Sarawak.3. WWW.WIKIPEDIA CONTROL NUMERICAL CONTROL.COM4. S.K.KRAR,J.W.OSWALD.(1976) TEHCNOLOGY OF MACHINE TOOLS.MCGRAW-HILL5. www.buhlmann.be/worknews/fundamentals.pdf