In the hardware project work Powder Mixed Electric Discharge Machining (PMEDM) tank has been fabricated to conduct experiments on PMEDM to improve surface finish and to increase material removal rate. New fixtures have been fabricated such a way that it can hold the work pieces perfectly. The flow of the dielectric is made continuous and constant and stirrer is installed for better mixing of powder particles. Different material are used for the fabrication. Different designs have been discussed. Future concern of the project is mentioned.

1. Submitted by
K.Santosh kumar(08bme109)
M.Vikash(08bme247)
Hari Krishna(08bme085)

2. Introduction
 EDM-non-conventional process
 It is the one of the major component of EDM
machine.
 defects -low MRR and poor surface finish
 EDM converted to PMEDM

3. Experimental setup
 machining tank of 7ltr capacity
 T-table
 Fixture assembly
 Stirrer to avoid particle settling
 A small tank to avoid any
sedimentation if occur
 Pump for the circulation of the
fluid
 Magnets to remove debris if any
 Dielectric –kerosene or water
 Additives- Si and Al powders
Cad
model

4. Methodology
 Tank fixed to T-table
 Holding fixtures are fixed inside
 Stirrer at one of the corner
 Small tank and pump are fixed to
tank
 Work piece attached
 Dielectric and additives
introduced
 Stirring
 EDM process
 Circulation of fluid

5. Q.Y.Ming,L.Y.He/Journal of
materials processing
technology (1995)
H.K.Kansal et al., (2008)
Courtesy: journal for machining processes(2007)
Some of the designs referred:
I II

6. III
IV
Journal of
machining
process (2007) Form 2LC CNC (1992)

7. Fabrication process
• Acrylic sheets are used
• Sheets of dimensions 200×200×200mm are cut
• Attached with the help of anabond
• Grinding at corners is done
• Tested for leakage
Cad
model
Machining tank

8.  Made of mild steel
 Dimensions -188×50×6mm
 Edges grinded for good surface finish
 Slot of 160×10mm is removed at center with milling machine
Cad
model
Fabricated
model
Holder

9. Work holding
Made of mild steel
Billet of dimensions- 40×50×30mm
Profile drawn on one of the surface(refer above fig) with accurate
dimensions
Hole of 10mm made at the center
A slot of 3mm made at corner
Nut and bolt of 10mm dia used to fit to the holder
Cad
model Fabricated
model

10. Stirrer
•Shaft is connected to the motor by means of coupler
•The shaft is connected to a wheel which acts as impeller by means of
super m-seal
•Attached at one of the corner with the help of a l-board
It is gear motor of 12v
capacity and 300 rpm
Shaft with couple
and plastic wheel

11. Clamps
•Made of mild steel
•Thickness of 6mm,length of 300mm,width of 3mm
•U shape is made with bench vice
•Hole is made at bottom
•Fits to t-slotted nut
•These are two in number
Cad
model
Fabricated
model

12. Pump
Voltage-240v
Frequency-50Hz
Flow rate-400L/hr

13. Exploded view
Cad
model

14. Fabricated model
Front view of
fabricated model
Top view of
fabricated model

15. Draft sheet
Drawing sheet of fabricated model

16. Cost estimation
S.NO PARTICULARS COST
1.
Acrylic tank 1200/-
2.
Small tank 120/-
3.
Pump 200/-
4.
Electric motor 200/-
5.
Stirrer and impeller 60/-
6.
Gate valve 40/-
7.
Miscellaneous 100/-
Total - 1920

17. Future scope
Installed in PMEDM
machine
Installed
here

18. Problems faced
Acrylic tank-holes
Small tank-hole
Pump
Leakage

19. References
[1]Kobayshi, K., 1995, “The Present and Future Developments of EDM and ECM”,
Proceed. of the ISEM-11.
[2] Mohri, N., Saito, N., Narumiya, H., Kawatsu, Y., Ozaki, K. T. and Kobayashi, K.,
“FinishMachining by EDM Using Powder Suspended Working Fluids”, Journal of
JSEME, vol. 49.1992
[3]O.A. Abu Zed, On the effect of electro-discharge machining parameters on the fatigue
life of AISI D6 tool steel, Journal of Materials Processing Technology 68 (1) (1997) 27–
32.
[4] P. Cushy, V.K. Jain, G.K. All, Experimental Investigations into electrical discharge
machining with a rotating disc electrode, Precision Engineering 15 (1) (1993) 6–15.