This document discusses a micro project on a lathe machine completed by a student. It includes certificates confirming the student's completion of the project for their Mechanical Engineering diploma program. The main document discusses electric discharge machining (EDM) and focuses on tool electrode design and manufacturing for the EDM process. It covers different tool materials, fabrication methods, aspects of electrode design like material selection and wear compensation, and some innovative 3D electrode designs that can machine complex shapes faster and with less wear.

1. MAHARASHTRA STATE BOARD OF
TECHNICAL EDUCATION
SHIVAJIRAO S. JONDHALE POLYTECHNIC
MICRO PROJECT
Academic Year: 2021-22
TITLE OF PROJET
LATHE MACHINE
Program: MECHANICAL ENGINEERING
Program code: ME5I
Course: Advanced manufacturing processes
(AMP)
Course code: 22564

2. MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate
This is to certify that
SHASHANK SAI NALLA
Roll No. 607 of 2 Semester of Diploma in Mechanical engineering of Institute,
Shivajirao S. Jondhale POLYTECHNIC (Code: 0147) has completed the Micro
Project satisfactorily in Subject - MEM (22343) for the academic year 2021 -
2022 as prescribed in the curriculum.
Place: KALYAN Enrollment No: 2001470091
Date: ……………………… Exam Seat No: …………………………………….

4. Manufacturing procedure for tool electrode
Electric discharge machining (EDM) is a nontraditional machining
process based on the thermal erosion of the electrically conductive
workpiece and tool electrodes. The product cost manufactured by the
EDM process mainly depends on the tooling cost, which comprises the
cost of tool material, tool fabrication, and tool maintenance. The
properties of tool material affect the machining performance parameters
like material removal rate (MRR), tool wear rate (TWR), and surface
roughness. The performance parameters are also influenced by the tool
geometry, tool fabrication method, and the way by which both tools and
workpiece interact with each other. In the EDM process, tool wear is
difficult to avoid and high TWR decreases the accuracy of the machined
parts. Therefore, to obtain the desired accuracy it is necessary to calculate
TWR and provide wear compensation. The tool electrode fabrication
method also decides the TWR. Tool electrodes are generally
manufactured by metal forming techniques like forging and drawing,
other than that, powder metallurgy, additive manufacturing are also
being used. The process performance of the tool can be improved by
cryogenic treatment and coating of the tool electrodes. This review
provides the literature survey about the different types of tools used in the
EDM process, methods of fabrication, tool wear types; measurement and
compensation techniques.

5. Different Aspects of Electrode Design
The prime role of EDM tool is to convey the electrical
pulse to allow erosion of work piece with little or no tool
wear rate. A lot of effort has gone into the EDM tooling
problem regarding inexpensive tool materials, ease of
manufacture, rapid work piece erosion, coupled with
low. To improve machining efficiency, roughing, finishing
and semi-finishing electrodes are used in EDM process.
EDM is mostly employed in obtaining mould cavities,
cylindrical hole machining and
3-dimensional cavity machining. In cylindrical hole
machining, through holes and cavities are produced by
electrodes of constant cross section. However, in 3-
dimensional cavity machining any cavity is machined
with one or more electrodes with varying cross section.
The tool design procedure is approximately same for
both the cases . They have classified EDM tools depending
upon the value of area of projection of electrode on the
work piece plane. Two major factors governing the
tool design are material selection and electrode wear.
Material Selection
The selection of the most appropriate electrode material
is a key decision in the process plan for any sinking
EDM job. The important variables to be considered for
selection of electrode material are material removal rate,
tool wear rate, surface roughness, machinability and
material cost. Properties of different electrode materials
and their influence on EDM performance as well as on
fabrication of electrodes.

6. Electrode material should have the basic properties like
electrical and thermal conductivity, a high melting
temperature, low wear rate, and resistance to deformation
during machining. However, due to unpredictable nature
of EDM process, the basis of material selection is mainly
empirical based on experimental data.
3 Innovative Tool Electrode Designs
Generally 3-D form tools are employed in EDM process
which are found costly, take more time for their
manufacturing and associated with high wear rate
particularly when subjected to cutting of complex shapes.
Therefore researchers have investigated many
innovative electrode designs summarized in following
subsections.