final year project report BS tech mechanica

1. 1
Effect OF Pulse Off Time on TWR Through
EDM Die Sinker
Submitted By:
Adeel Ahmad 15S-BSMT-151149
Tariq Jamil 15S-BSMT-151154
M. Rehman 15F-BSMT-121058
Supervisor
Engr. Noman Asif
DEPARTMENT OF TECHNOLOGY
GLOBAL INSTITUTE LAHORE

2. 2
Effect OF Pulse Off Time on TWR Through
EDM Die Sinker
This project is submitted to Global Institute Lahore in partial fulfillment of the
requirement for awarding the degree of
Bachelor of Science
in
Mechanical Technology
________________ _________________
Internal Examiner External Examiner
(Engr. Noman Asif) ( )
DEPARTMENT OF TECHNOLOGY
GLOBAL INSTITUTE LAHORE

3. 3
Approval

4. 4
Declaration

5. 5
DEDICATION
First of all We would like to say a humble thanks of Our honorable Teacher Sir. Noman
Asif Saab. Because He give us the main ideas and guidelines to improve our work and
go away toward the success. He was especially come in the University in his off days just
for our guidance and He also cooperate with us to complete our project. In short we
would unable to complete the project without him because his motivational instruction
give us the power to doesn’t stop in the way just go toward the end point and achieve the
success.
Secondly we also thanks all over the management staff and university owners to give us
the opportunity to prove our self and improve our technical skills and also give us the
permeation to use the university resources just like Machinery, labs and library for
completing the project.
Third we also saying thanks to our parents to give us the full support with every resource
that they were provide us because from the last four years they give us the motivation in
every week situation.
Thanks All Of Them.

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Acknowledgement
First of all, we would like to thank God, for His provision of strength that helped us to
overcome any difficulties during the entire work. Without His help we couldn’t be able to
finish it.
Secondly, we would like to thank our head of the department & our Supervisor Sir Noman
Asif Sahib, whose give us continuous guidance helped us to complete this project in time.
We are also grateful to his motivation and his dynamic suggestions for solutions to any of the
challenges faced during the project.
Third we also thanks all over the management staff and university owners to cooperate
with us and give us the opportunity to groomed our technical communicative and
learning skills and also give us the permeation to use the university resources just like
Machinery, labs and library for completing the project. They were also stand with us in
every difficult situation and give us the motivation for completing our project in time.

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Table of Content:
 Front Page 1
 Title Page 2
 Approval 3
 Declaration 4
 Dedication 5
 Acknowledgement 6
 Table of Content 7
 List Of Figure 9
 List of Tables 10
 Abstract 11
 Chapter no 1 12
1.1: Introduction 12
1.2: Working Principle 12
1.3: Classification of EDM 13
1.3.1: Ram EDM 13
1.3.2: Wire EDM 14
1.3.3: Drilling EDM 16
1.4: Component of EDM 17
1.4.1: Work Piece 17
1.4.2: Electrode 17
1.4.3:Dielectric: 18
1.4.4:Circulation System 20
1.4.5: Machining Tank 20
1.4.6: Storage Tank 21
1.5: Parameters of EDM 21
1.5.1: Peak Current 21
1.5.2: Voltage 21
1.5.3: Pulse on Time 21
1.5.4: Pulse off Time 21
1.6: Application of EDM 21
1.7: Advantages of EDM 22
1.8: Dis-Advantages of EDM 22
 Chapter no 2 23
Literature Review 23
 Chapter no 3 25
3.1: Objectives 25
3.2: Design 25
3.3: Material 27
3.4: Components of New Circulation Tank 28
3.5: Stirrer 30
3.6: Parts of Stirrer 30
3.6.1: Motor 30
3.6.2: Rod 31

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 Chapter No 4 31
4.0 Conclusion ______ 31
4.1: Problem Statement_______________________________________31
4.2: Objectives of the research__________________________________31
4.3: Literature Survey_________________________________________31
4.4: Methodology____________________________________________32
4.4.1: Brief description of how project is completed .________________32
4.4.2: Experimentation.________________________________________33
4.4.3: Experimental set up._____________________________________33
4.4.4: Utilization of research results._____________________________34
4.5 Research Time Table_______________________________________34
 References 33

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List of Tables:
Table 1.1: Tool Material used in EDM & their Characteristics 18
Table 1.2: Tool Performance of Different dielectric fluids 20
Table 4.1 Experimentation parameters.__________________________________33
Table 4.2 Following response parameters________________________________33
Table 4.3 Research Time Table._______________________________________34

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List of Figures:
Figure 1.1.1: TWR Inspection with 0.001-Gram least count Weight Scale 11
Figure 1.1: Working Principle 12
Figure 1.2: Ram EDM 14
Figure 1.3: Wire EDM 15
Figure 1.4: Drilling EDM 16
Figure 1.5: Types of Electrodes 17
Figure 3.9 Function of Dielectric Fluid___________________________________19
Figure 1.6: Different method of flushing in EDM process 20
Figure 3.1: Pump 26
Figure 3.2: Storage tank 28
Figure 3.3: MS Pipe 28
Figure 3.4: PVC Pipe 28
Figure 3.5: Gauges 29
Figure 3.6: Clamp 29
Figure 3.7: Stirrer 30
Figure 3.8: Motor 30
Figure 4.1 Copper tool Measurement with Weight Scale____________________32

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Abstract
Electrical discharge machining is a non-traditional machining process that is used for cutting the
hard materials just like. Tool steel, Titanium and other hard materials that can’t be proceed or cut
easily. Spark is produced in EDM that melts the metal in the EDM cutting procedure. Dielectric
is used to flush away the debris of cutting wastage during EDM procedure. Original tank of
EDM machine has capacity of some 300 to 400 liters for Dielectric.
In order to perform EDM machining with additives of different kind cost is so high which limits
is application. So, a separate tank has been designed to reduce this consumption of Additive and
Dielectric. In order to ensure proper mixing of additives a stirrer has also been used. We use D2
(Tool Steel) material as a work piece it has good mechanical properties and harder material and
Copper or Brass material as a Tool or Electrode and Chemical Tween-60 is add in kerosene oil
as a dielectric fluid to Improve MRR and Reduce TWR.
Fig. 1.1.1: TWR Inspection with 0.001-Gram least count weight Scale

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Chapter 1
Introduction & Types of EDM
1.1: Introduction:
Electrical discharge machining is a non-conventional cutting process. Electrical discharge
machining is a machine that is complete its operations with removing the material by local
melting or vaporizing small areas at the surface of work piece. This process is also known as
thermal material removal process. We remove the material from the surface of work piece by
electric spark that is generated between work piece and tool submerged in a dielectric medium.
EDM is also used for machining of hard metals which cannot be machined easily by
conventional metal cutting processes. The products include dies, tools made of tungsten,
carbide,& brass etc.
1.2: Working Principle:
EDM works on the principle of removing the material by sparking that is generated
between the work piece and the tool with the voltage sparking in dielectric fluid. The working
system is shown in (Fig. 1.1). The work piece and tool are connected by D.C voltage generator.
Positive charge is on electrode and negative charge on work piece. When electrode & work piece
are connected with each other spark is generated and cutting process is performed according to
requirements. Electrode is designed according to shape that is required on the work piece.
Fig. 1.1Working principle

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1.3: Classification of EDM:
There are three main types of EDM;
1: Ram EDM
2: Wire-cut EDM
3: Drilling EDM
Each are used to produce very small and accurate parts as well as large items like automotive
stamping dies and aircraft body components. The largest single use of EDM is in die making.
1.3.1: RAM EDM:
In ram EDM, the electrode/tool is attached to the ram and the ram is connected with the
positive pole, of a pulsed power supply. The work piece is connected to the negative pole. When
the work piece is on its position so that there is a gap between it and the electrode. The gap is
required to flow the die electric fluid. Once the power supply is turned on, thousands of direct
currents, or DC, impulses per second cross the gap in the beginning of erosion process. The
temperature of generated spark range is from 14,000° to 21,000° Fahrenheit. As the erosion
continues, the electrode working efficiency increase into the work while maintaining a constant
gap dimension.
The finished EDM's work piece can produced several distinct layers. The surface layer will have
small globules of removed work piece metal and electrode particles are also attached with it,
which are easily removed with hands. The second layer is called the “white” or “recast” layer
where EDM effected the surface of this layer structure of the work piece. The third layer is the
heat-affected zone or “annealed” layer. This layer has been heated but not melted.
All of these surface conditions are affected by:
• The EDM cycles of on- and off-time
• The duty cycle, this is the ratio of on-time relative to total cycle time.
• The gap distance between the work piece and the electrode.
Ram EDM machines are also known as Diesinkers or vertical EDMs. They range in size from
tabletop models to large CNC units. Ram EDMs have four sub-systems:
• A DC power supply to provide the electrical discharges, with controls for voltage, current,
duration, duty cycle, frequency, and polarity

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• A dielectric system to introduce fluid into the voltage area/discharge zone and flush away work
and electrode debris, this fluid is usually a hydrocarbon or silicone based oil
• A consumable electrode, usually made of copper or graphite
• A servo system to control infeed of the electrode and provide gap maintenance CNC Ram
EDM machines have automatic tool change capability allowing long unattended running times,
use of multiple electrodes for rough and fine metal removal, orbiting controls for cavity
enlargement, and contouring capability.
Fig. 1.2 Ram EDM
1.3.2: Wire EDM:
The wire EDM process uses a consumable, electrically charged wire to get very effective
and fully furnished cuts. The process is usually used to cutting fine details in pre-hardened
stamping and blanking dies. The wire is continuously flow in the circle and a fresh wire is
produced for cutting every time. Typical wire diameters range from 0.002 - 0.013 of an inch, or

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0.05 - 0.33 of a millimeter. These wires will produce a kerf slightly larger than their own
diameter. A 0.012 inch/0.3-millimeter wire will create a 0.015 inch/0.4-millimeter kerf. Wire
EDM’s can run for long periods without operator attention.
Four basic wire EDM subsystems include:
• The DC power supply
• The dielectric system
• The wire feeding system
• The work positioning system
The wire system principle of operation is the same as the ram type, using a series of DC
discharges between the wire and work piece. As with ram EDMs, flushing with dielectric fluid is
critically important. In some cases, both wire and work are completely submerged. However, this
may cause electrolytic corrosion on some work piece materials. Since the wire electrode is very
thin, power used is limited and removal rates are slow. The actual removal rate is calculated in
square inches per hour.
A two-axis wire EDM can only make cuts at right-angles to the work table, while a CNC
positioning system with a two-axis table can perform a wide variety of angled cuts. Independent
multi-axis machines can cut tapered angles and make cuts that result in different top and bottom
profiles. This capability is needed in making items such as extrusion dies and flow valves. The
wire never touches the work during cuts. The wire control servo system is able to maintain a
wire-to-work distance of approximately .001 inch. The wire cuts along a programmed path
starting at either an edge or in a predrilled hole. Parts to be cut can be stacked for production
quantities.
Fig. 1.3 Wire EDM

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1.3.3: Drilling EDM:
A third type of EDM is designed for drilling small, but very deep holes. These holes may
have a depth-to diameter ratio up to 100 to 1. Tubular electrodes up to a foot long are rotated at
speeds of about 100 RPM while drilling. As the electrical discharges occur, this rotation aids in
flushing and provides for uniform electrode wear.
Some of the hazards in EDM machining include the chance of flash fire in the dielectric fluid if
the level falls too low. Smoke can be irritating to the eyes and lungs and but can be controlled
with exhaust and smoke eating devices. The dielectric fluid can be irritating to the skin as well.
Fig. 1.4 Drilling EDM

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1.4: Components of EDM:
There are some main components of EDM.
1.4.1: Work Piece:
Work piece must be conductive like polycrystalline, titanium, high temperature alloys.
1.4.2: Electrode:
Electrode selection is important factor in Ram EDM.
Figure 1.5 Types of Electrodes
1. Functions of electrode:
 The purpose of electrode is to transfer the electric charge and to erode the work piece to a
desire shape. Different electrode materials greatly effect on Machining. Some will
remove metal efficiently but have great removal, and some material of electrode slight
wear but remove metal slowly.
2. Electrode Selection:
There are some main factors that are evaluate during selecting an electrode for machining
process.
 Cost of electrode material
 Easy or difficult to making an electrode.
 Type of finish desired.
 Amount of electrode wear.
 No of electrode required during complete the job.
 Material of electrode that is suitable for work piece.

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3. Materials of Electrode:
There are some material that is used to making an electrode. All materials have its own
properties & Temperature to wear.
 Zinc
 Brass
 Cooper
 Graphite
 Tungsten
Material Material Removal Rate Wear ratio Fabrication Cost Application
Graphite High Low Easy High All metals
Copper High in roughing Low Easy High All metals
Brass High in finishing High Easy Low All metals
Tungsten Low Low Difficult High For small holes
Tungsten- Low Low Difficult High Accurate work
Copper alloys
Cast Iron Low Low Easy Low Restricted
Steel Low High Easy Low Finishing
Zinc Alloys High in roughing High Easy Low All metals
Table 1.1 Tool material used in EDM and their characteristics
4. Properties of Electrode:
 High material removal rate.
 Low wear rate of electrode.
 High degree of electric efficiency.
1.4.3: Dielectric:
The dielectric is usually allowing viscosity hydrocarbon oil. The work-piece and
electrode tool are separated by the dielectric. The dielectrics very important for working
of the EDM. When the tool and work gap is about 0.03 mm and at about 70 V, the
dielectric is ionized to form a column or path in the tool and work gap so that a surge of
current takes place as the spark is produced. The spark discharge will be in a micro small
area at around 10,000°C and thousands of atmospheric pressures and takes place in less

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than a micro second for each spark. A tiny part of work material is vaporized due to the
arcing The tiny metal particles are cooled into small spheres and are swept from the area
by the flow of dielectric fluid
1. Functions of Dielectric fluid:
There are some main functions of dielectric fluid used in EDM process are:
 Dielectric must be electrically non-conductive.
 When the breakdown voltage is reached it should breakdown electrically instantly.
 Remove all metal parts(carbon) from the arc gap.
 Good cooling media.
Fig: 3.9 Function of Dielectric Fluid.
2. Properties of dielectric:
According to requirement of EDM process dielectric has following properties.
 High electric strength for proper insulation.
 High flash & fire point to prevent fire hazards.
 Low viscosity.
 Low decomposition rate for long life.
 Low cost.
 Good quenching properties.
3. Common Dielectric Fluids:
The different fluids used are:
 Kerosene
 Paraffin oil
 Transformer oil
 Lubricating oil, etc

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SR # Dielectric fluid
Material removal
rate cm / amp
Wear ratio-work material
/ tool material
1. Kerosene 40.0 2.8
2. Distilled water 54.5 2.7
3. Glycol 103.0 6.8
Table 1.2 Performance of different dielectric fluids in machining steel
using brass tool
4. Dielectric flushing in EDM:
The different methods of circulation of dielectric fluid for flushing in EDM are:
 Pressure dielectric flow
 Reverse dielectric flow
 Vacuum dielectric flow
 Vibration flush cut
1.4.4: Circulation system:
Circulation system of EDM is used to circulate dielectric medium with the help ofPipes,
Pump & strainer. Circulation system plays an important role in EDM.
1.4.5: Machining Tank:
Machining tank is also known as the upper tank of EDM. Work piece is hold on Die in
machining tank. The size of work piece is decided according to the capacity of machining
tank.
Fig 1.6

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1.4.6: Storage tank:
Storage tank is commonly used for storage of the dielectric fluid. Pump throws fluid from
storage tank to machining tank for machining process. After machining process dielectric
fluid goes back to storage tank with piping system.
1.5: Parameters of EDM:
There are some main Parameters of EDM.
1.5.1: Peak current:
The peak current is the maximum amount of current which an output is capable of
sourcing for brief periods of time. The difference between the steady state value & the
peak current is what is referred to as the inrush current. The peak current should be
within limits and only last for a short duration to avoid stressing the components or
causing excessive heating or damage.
1.5.2: Voltage:
The lighting spark occurs at very long distance from the cloud to the ground, & the
voltage reaches millions volts. In EDM, the voltage supplied is approximately 50 to 300
volts because higher is not suitable for high precision machining. Therefore, EDM
discharge gap is about 0.005 – 1.0 mm.
1.5.3: Pulse on time:
Pulse on time mean that time when an EDM’s electrode performs cutting operation with
the dielectric medium.
1.5.4: Pulse off time:
Pulse off time means time when an EMD’s electrode cannot perform cutting process.
This time also called non-cutting time.
1.6: Applications of EDM:
There are some main applications of Electric discharge machine.
1. Dies, fixtures, gauges
2. Cutting tools
3. Press tools, extrusion dies
4. Die molds for plastics
5. Die-casting dies, mold inserts
6. Re-machining, repairing of worn dies for hot and cold forging.

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7. Making forging dies like connecting rod forging dies, etc.
8. Sintering dies
9. Calibrating tools
10. Shaping carbide tools, templates.
1.7: Advantages of EDM:
There are some advantages of EDM.
1. It can make complex shapes that would otherwise be difficult to produce with
conventional cutting tools.
2. Hard materials can also be machined.
3. Vary small work piece can also be machined.
4. The fact that the process takes place in a fluid improves the removal of metal chips from
the cutting area and enhance cooling characteristics of the tool and workpiece.
5. The process allows for “Heavy” duty operation in higher frequency & current (A) values
which result in increased process efficiency.
6. Easy to increase productivity.
7. It can help to improve quality.
1.8: Dis-advantages of EDM:
There are some dis-advantages of EDM.
1. Applying the EDM method for turning & grinding is not easy.
2. More expensive process than conventional milling & turning.
3. Only able to machined conductive materials.

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Chapter 2
Literature Review
1. Many researchers have worked on EDM, according to Ankit K.R Singh, who is research
on effects of Di-electrical on Electrical discharge machine, Dielectric is an important
parameter in EDM & plays an important role to achieve high MRR and surface finishing
during operation. Di-electrical fluid behave as a medium which control the electrical
discharge and bear heat during process. Dielectric also help remove the debris particle
and control the temperature of work piece.
2. Many researchers have work on EDM some added nono particles, micro size particles or
liquid additive. Sometimes we add powder such as Ti, Si, Graphite, Cu, Al2O3, etc. in
dielectric fluid that can help us to increase the conductivity of dielectric fluid.
3. Kun-Ling Wu & Being Hwa Yun research on characteristic of electrical discharge
machining characteristic of electrical discharge machining using Dielectric with
surfactant, They use different types of surfactant (like Tween 60 or Span 80) in Kerosene
oil These surfactant can change the characteristic of Dielectric. Experiment result show
that after the addition of Surfactant in Dielectric, conductivity is increased. The
machining efficiency is also increased& material removal rate is affected.
4. According to M.Schward who is search on Material Removal rate & Electrode wear in
Die Sinking during using of Graphite electrode. He says Graphite is a handsome
electrode that is used in EDM & more profitable than Cooper electrode.
5. Electrode is an important component of EDM. Electrodes design with different materials
that are suitable according to work piece. The purpose of electrode is to transmit the
electric charge and make the work piece desired to a shape.

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Chapter no 3
Design of separate circulation tank
3.1: Objectives:
• To design Machining tank with reduced dielectric capacity.
• To design separate storage tank with pump for circulation of dielectric.
• To Use stirrer for mixing of powder or liquid additives.
3.2: Design / Calculation:
• Machining tank (Length = 1ft, Width = 1 ft, height = 1ft)
 4 sheets are used with following dimension:
Length = 1ft Height = 1ft & Thickness = 2mm
• Storage tank (Length = 2 ft, Width = 1 ft, Height = 2.5 ft)
 Sheets are used with following dimension:
Length = 2 ft Height = 2.5 ft , & Thickness = 3mm (QTY = 2)
Length = 1 ft , Height = 2.5 ft , & Thickness = 3mm (QTY = 2)
Length = 2 ft , Width = 1 ft , & Thickness = 3mm (QTY = 2)
Storage tank is commonly used for storage of Dielectric material. Dielectric
is transferred to machining tank through piping system & after machining
process Dielectric material transfer to storage tank through exit pipe.
• MS Pipe (Dia = 1.5 inch , Length = 1.5ft)
MS pipe used to control the pressure & flow of dielectric material.

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• Plastic Pipe (Dia =0.75 inch , Length = 5ft)
&Plastic Pipes (Dia = 0.5 inch Length = 5 ft) (Qty = 3)
Pipes are used for circulation of Dielectric material. These pipes are used to
throw the Dielectric material on work piece withpressure that helps to
remove the Carbon dregs from the surface of work piece.
• 3 Gauges (0 ~ 35PSI & 0 ~2.5 bar)
Gauges are used to measure the pressure of Dielectric material.
• 4 Wheels (Capacity = 150kg weight):
• Pump
 Model= VSS-3500
 Dimension = (L=126, W=95 & H=124)
 Power Consumption = 99watt
 Flow Rate = 4000 Lit/H
 Delivery Head = 4.0 meter
 Operating Voltage = 220~240 volt
Fig 3.1 Pump

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3.3: Material:
 Material of Machining Tank = SS sheets.
 Material of Storage Tank = MS sheets.
 Material of Pressure control pipe = MS
 Material of Circulation pipes = PVC
 Material of Stirrer’s road = MS
 Material of Stirrer’s Fan = Plastic
3.4: Components of New Circulation Tank:
There are some components that are used in Designing of new
circulation tank.
1: MS Sheet (Storage Tank) 2: SS Sheet (Machining Tank)
3: PVC Pipe 4: MS Pipe
5: Valve 6: Gauges
7: T joint 8: Clamps
9: Stirrer 10: Silicon
11: Pump
1. Machining Tank:
Machining tank is used to cover the work piece with Kerosene oil.
2. Storage Tank:
Storage tank is used to store the Kerosene oil and throw the oil on Work
piece with the help of piping system.

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Fig. 3.2 Storage Tank
3. MS Pipe:
MS pipe is used to control the pressure of Kerosene oil.
Fig. 3.3 MS Pipe with values
4. PVC Pipe:
PVC Pipe is used to travelling the oil from MS pipe to Blue pipe.
Fig. 3.4 PVC Pipe

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5. Valves:
Valves are used to control the pressure of Kerosene oil during operation.
6. Gauges:
Gauges are used to measure the pressure of oil.
Fig. 3.5 Pressure Gauges
7. Clamp:
Clamps are used to control the leakage of oil from joints.
Fig. 3.6 Clamp
8. Stirrer:
Stirrer is used for Homogeneous mixing.
9. Pump:
Transfer of Liquid from Storage tank to Machining tank.

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3.5: Stirrer:
Stirrer is commonly used for mixing and dispersing solid and liquid
material, mixing of two difference liquids who have different viscosities.
Mixers are available with different speed and digital display or without
display.In our project stirrer is used to mixing surfactant in Kerosene oil to
increase the MRR and decrease the rear and tear of electrode.
3.6: Parts of Stirrer:
There are some main parts of stirrer.
3.6.1: Motor:
Motor is used to rotate the rod & fan. It provide the power to rotate the
fan that can cause of dielectric’s mixing. The maximum rotation of
motor are 400RPM.
Fig. 3.8 Motor

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3.6.2: Rod:
Rod is attached with Motor. It is used to transfer the rotatory motion frommotor to fan.
1. Fan:
Fan is used to mixing of Dielectric material. The rotation of fan can be change with
the help of motor.

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Chapter no 4
Conclusion
4.1: Problem Statement
Tool wear problem is very important issue in EDM machining operations’ because due to this
problem we face different type of losses that given blow,
i. This issue direct impact the final shape of die cavity.
ii. Increase the tool cost of manufacturing operations.
iii. Increase the machining time.
4.2: Objectives of the research
The main objective of the research is given blow:
In this sturdy we gain variations in tool wear
characteristics that we present them namely, Tool wear rate surface roughness after all for
solution of these problems we investigate them with varying machining parameters because,
whenever we use the Electric Discharge Machine for our working purpose we need maximum
material removal rate and minimum Tool wear rate with high definition accuracy to archive this
goal we just want to take some experiments on EDM to enhance the MRR and decrease TWR.
4.3: Literature Survey
Electric Discharge Machining (EDM) is a nontraditional machining
method that we used to produce die cavities with high accuracy via erosive effect of electrical
discharge. First of all we use electrically conductive tool means electrode that is the male shape
of die cavity, this tool is prepared to machine the die cavity. This method is especially used to
machining hard die steels, complex cavities and small work pieces. Die casting, forging,
injection molding, upset forging, extrusion, and powder compaction dies manufacturers are used
the EDM Technology.

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4.4: Methodology
Methodology is the method that completely explain the our EDM project therefore
it consists of four points,
4.4.1: Brief description of how project is completed.
4.4.2: Experimentation.
4.4.3: Experimental set up.
4.4.4: Utilization of research results.
4.4.1: Brief description of how project is completed.
First of all it declared that the
material is purchased from the market just like,
1) copper tool material with dimensions of (50 X 15 Ø)mm
2) D2 Material work piece with dimensions of (50 X 50 X 7)mm
3) Kerosene oil
4) Tween 60
5) 0.001 Gram least count Weight Scale etc.
After collection of required material we are getting ready for experiments on our specific
parameters.
Fig: 4.1 Copper tool Measurement with Weight Scale

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4.4.2: Experimentation
 Experimentation parameters.
Sr. No Input Parameter (Variables) Level 1 Level 2 Level 3
1 Dielectric type K K+T60 K+T60
2 Work piece Material D2 D2 D2
3 Pulse Off Time (Poff) 12 25 50
4 Electrode Material Copper Copper Copper
5 Polarity Positive Negative -
Table: 4.1 Experimentation parameters.
 Following response parameters (Table) are selected.
Sr. No Response parameters
1. TWR (Tool Wear Rate)
Table: 4.2 following response parameters
Machining will be performed for one set of parameters and then work piece and tool electrode
will be weighted again to calculate MRR and TWR respectively. After this surface roughness
will be measured and recorded
4.4.3: Experimental set up
Specially designed Separate circulation system with storage tank will be used for
dielectric circulation in EDM Die Sinker. Chapter No: 03 will explain construction of this
circulation system. Small size machining tank will also be fabricated. This will reduce the
dielectric quantity for machining resulting in reduced machining cost. Another thing that is
important to discus is the material of tool and work piece of our experiment, now we used the D2
material as a work piece. It has good mechanical properties and maintains its hardness at high
temperature and good physical properties like thermal conductivity, melting point and electric
resistivity. Electrode material usually steel copper and brass. But we use copper material for our
experiments to get someone special results of our experiments. Now we setup the process
parameters that show performance parameters mainly surface roughness. The EDM machining

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parameters are divided into two groups Non Electrical parameters and Electrical parameters.
These parameters are normal and stable machining are set throughout the experiments. We setup
the EDM machine parameters with respect to (Table # 01). Then we will be move on next setup
to utilization of our research results.
4.4.4: Utilization of research results.
Electric Discharge Machine is a slow process. Various
combination of parameters are checked to decrease the Tool Wear Rate. Brass & Copper Tool
and positive polarity have decrease the Tool Wear Rate in presence of Dielectric Kerosene oil
and mixed additive like chemical Tween-60. These parameters give us the amazing Tool Wear
Rate decrease results on lowest rate of pulls off time.
4.5 Research Time Table.
Table: 4.3 Research Time Table.
Sr. No Month Activity
01 September & October
2018
Meeting with our supervisor with respect to final year
project discussion.
02 November & December
2018
Calculate the research papers and all over the
objectives on EDM project.
03 January & February
2019
Sturdy the calculated data and get the mind blowing
knowledge about EDM.
04 March
2019
Make a proposal on EDM with respect to our
supervisor instructions
05 April & May
2019
Working on project with respect to proposal under
supervision of Mr. Numan Asif
06 June
2019
After complete the project we will be submit it to the
university management on time.

35. 35
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