Seminar Report on

MODIFIED EDM
Submitted in partial fulfilment of the requirements for the award of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
under

UNIVERSITY OF KERALA

Submitted by

AMAL D S
(Reg. No. : 14409027)

DEPARTMENT OF MECHANICAL ENGINEERING

MOHANDAS COLLEGE OF ENGINEERING AND TECHNOLOGY
ANAD, NEDUMANGAD, THIRUVANANTHAPURAM 695 544
MAY 2018
 MOHANDAS COLLEGE OF ENGINEERING & TECHNOLOGY
ANAD, THIRUVANANTHAPURAM

Department of Mechanical Engineering

Mind Set for Learning

CERTIFICATE

This is to certify that the report titled “MODIFIED EDM” is

an authentic report of seminar presented by,
AMAL D S (Reg No: 14409027)
of Eighth Semester Mechanical Engineering, in partial fulfilment of the
requirements for the award of the degree of Bachelor of Technology in
Mechanical Engineering by University of Kerala at Mohandas College
of Engineering and Technology, Thiruvananthapuram during the
academic year 2017-18.

Seminar Guide: Seminar Coordinator: Head of the Department:

Mr.DEEPAK G Mr.ADHIN D Dr.SIVASUBRAMONIAN B

Assistant Professor, Assistant Professor, Professor,

Dept. of ME Dept. of ME Dept. of ME

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 ACKNOWLEDGEMENTS

I wish to express my profound gratitude to Mr.Deepak G, Assistant Professor,

Department of Mechanical Engineering, Mohandas College Of Engineering And
Technology for his guidance and encouragement in this seminar.

I extend my thanks to Dr.Sivasubramonian B, Professor and Head, Department of

Mechanical Engineering, Mohandas College of Engineering And Technology for his
advice and help extend during course.

I am also wish to express my sincere gratitude to the seminar coordinator Mr.Adhin D,

Assistant Professor, Department of Mechanical Engineering, Mohandas College Of
Engineering And Technology.

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 ABSTRACT

Ti-6Al-4V is a well-known Ti alloy widely used in the aerospace industry and belongs to
the group of difficult-to-machine materials. It is less suitable for both conventional chip
removal (machining) techniques and electric discharge machining (EDM). The very low
material removal rate (MRR) of the Ti alloys during the EDM process causes
prohibitively long machining durations. The goal of this study was to improve the EDM
performance of the Ti-6Al-4V alloy by the addition of graphite powder into the kerosene
dielectric liquid. The EDM performance was quantified by MRR, tool electrode wear rate
(EWR), relative wear (RW), surface roughness and texture properties. The experiments
conducted have shown that the use of graphite powder mixed with the kerosene dielectric
(GPMKD) during machining considerably increases the MRR, improves the Ra and
Rz(DIN) surface roughness and decreases the RW. 3D topographic views of the
machined workpiece surfaces attained with GPMKD revealed uniformly distributed
surface valleys and peaks over the surface and peaks with short and round tops since the
discharge energy of a spark is distributed over a large area at the machining gap. The
experimental results strongly indicate the adaptability of the proposed technique to EDM
die sinking and EDM drilling applications of the Ti-6Al-4V alloy in the aerospace
industry. The EDM machining performance of Ti-6Al-4V alloy using GPMKD is also
compared to that of AISI 1040 steel, which is commonly used in EDM applications.

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 TABLE OF CONTENTS

Chapter Title Page No.

ACKNOWLEDGEMENT Iii
ABSTRACT Iv
LIST OF FIGURES Vi
LIST OF TABLE Vii
NOMENCLATURE Viii

1 INTRODUCTION 1
1.1. EDM 2
2 LITERATURE SURVEY 3
2.1. INTRODUCTION 3
2.2 JOURNAL STUDIES 3
2.3 PURPOSE OF STUDY 4
3 Ti-6Al-4V 5
3.1. COMPOSITION 5
3.2. PROPERTIES 5
3.3. APPLICATION 5

3.4. DIFFICULTY IN TRADITIONAL MACHINING OF

5
Ti-6Al-4V
3.5. DIFFICULTIES IN EDM MACHINING OF Ti-6Al-4V 6
3.6. DEVELOPMENT OF GPMKD
7
3.6.1. PROPERTIES OF GRAPHITE POWDER 7
3.6.2. PROPERTIES OF GKMKP 7

4 MODIFIED EDM 8
4.1. CONSTRUCTION 8
4.2. MAJOR PARTS 8
4.3. WORKING 9

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 RESULTS ANALYSIS & DISCUSSION 10
5.1. COMPARISON 10
5.2. METAL REMOVAL RATE 11
5.2.1. EFFECTS 11
5.2.2. FACTORS 11
5.3. SURFACE ROUGHNESS 12
5.3.1 EFFECTS 12
5.3.2 FACTORS 12
5.4. SURFACE FINISH 13
5.4.1. EFFECTS 14
5.4.2. FACTORS 14
5.5. ADVANTAGES OF MODIFIED EDM 14
5.6. DISADVANTAGES OF MODIFIED EDM 14
5.7. A MACHINED Ti-6Al-4V 15
6 CONCLUSION 16
7 REFERENCES 17

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 LIST OF FIGURES

LIST OF FIGURES PAGE NO

Figure 1.1 EDM 2

Figure 4.1 MODIFIED EDM 10

Figure 5.2 METAL REMOVAL RATE 14

Figure 5.3 SURFACE ROUGHNESS 16

Figure 5.4 SURFACE FINISH 17

Figure 5.7 A MACHINED Ti -6A1 -4V 20

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 LIST OF TABLES
LIST OF TABLES PAGE NO

Table 6.1 COMPARISON ON GPMKD 13

viii
 NOMENCLATURE

MRR Material removal rate

EWR Tool electrode wear rate
RW Relative wear (EWR/MRR)
Ra Average surface roughness
Rz(DIN) Average of the highest peak to
valley measurements found for
each cut-off length.
ts Pulse time (pulse on time)
tp Pause time (pulse off time)
id Discharge current
Cp Powder concentration
Pd Dielectric flushing pressure

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