Group E, F and G - Labsheet Mastercam DJJ40142

POLITEKNIK MERLIMAU
DEPARTMENT OF MECHANICAL ENGINEERING

DJJ40142 MECHANICAL WORKSHOP PRACTICE 4
Upon completion of this course, students should be able to:
CLO2: Construct programs for EDM and CNC machining process using ISO codes or any related machining
software. (P5, PL03)
PLO3: Apply appropriate techniques, resources, and modern engineering and IT tools to well defined
engineering problems, with an awareness of limitations (P5)
1.0 Title Computer Numerical Control Electrical Discharge Machine (CNC and EDM Wire Cut)
2.0 Objective To understand the CNC and EDM machines according to prescribed procedures/ manual
and write CNC program
3.0 Apparatus CNC Machine, EDM Wire cut, Mastercam 2022-2023 software
4.0 Theory
The CNC milling process begins with the creation of a 2D or 3D CAD part design. The finished design is then
exported to a CNC-compatible file format, where CAM software transforms it into a CNC machine programme that
directs the machine's operations and the tooling's motions over the workpiece. The workpiece is fixed to the machine's
work surface (i.e., worktable) or workholding device (i.e., vise) before the operator starts the CNC programme, and the
milling tools are attached to the machine spindle. Depending on the specifications and needs of the milling application,
horizontal or vertical CNC-enabled milling machines are used, as well as spinning multi-point (i.e., multi-toothed)
cutting tools like mills and drills. The machine starts spinning the cutting tool at speeds up to thousands of RPM as soon
as the CNC milling process is started. As the tool cuts into the workpiece, the machine will carry out one of the
following operations to create the required cuts on the workpiece, depending on the type of milling machine used and
the needs of the milling application.
Schematic Diagram of CNC

Schematic Diagram of EDM Wire Cut
The wire-cut EDM is a discharge machine that uses CNC movement to produce the desired contour or shape. It
does not require a special shaped electrode, instead it uses a continuous-traveling vertical wire under tension as the
electrode. The electrode in wire-cut EDM is about as thick as a small diameter needle whose path is controlled by the
machine computer. It removes metal by producing a rapid series of repetitive electrical discharges.
5.0 Work Procedure

5.1 Machining Procedures
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.
6.0 CNC Program Data Analysis

Part 1: Write program code for diagram shown below Drawing 1
(EDM Wire Cut)
Drawing 2 (EDM Wire Cut)

Written down the Codes obtained by Software into table below. Program
Code Drawing 1 (EDM Wire Cut)
Absolute (G90) Incremental (G91)
Program Code Drawing 2 (EDM Wire Cut)
Absolute (G90) Incremental (G91)
Discussion
1) Explain step by step process of CNC and EDM Wire Cut of both Picture above with photo screenshot and
explanation from start drawing until obtained G-Codes.
2) Explain the function of CNC and EDM Wire Cut machine
3) Determine FOUR (4) main parts / operating system of CNC and EDM Wire Cut machine and its function
4) Describe the program language used for your CNC program
5) Is there any error / mistake during your workshop work? If yes, describe the error / mistake and justify your
recommendation to it.
6) Discuss the advantages of electrical discharge machining compare to other machining process
8.0 Conclusion
Conclude your workshop practice
9.0 Reference
Prepared by, Verified by,
(AKBAR BIN OTHMAN) (KHADIJAH BINTI ZAINUDDIN)

Lecturer Head of Mechanical Engineering Programme
Department Mechanical Engineering Department Mechanical Engineering
Date: 5/09/2023

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POLITEKNIK MERLIMAU

DEPARTMENT OF MECHANICAL ENGINEERING

Upon completion of this course, students should be able to:

Schematic Diagram of CNC

5.0 Work Procedure

6) The wire electrode is positioned to work piece.

6.0 CNC Program Data Analysis

Drawing 2 (EDM Wire Cut)

Code Drawing 1 (EDM Wire Cut)

Absolute (G90) Incremental (G91)

Program Code Drawing 2 (EDM Wire Cut)

Absolute (G90) Incremental (G91)

Conclude your workshop practice

Prepared by, Verified by,

(AKBAR BIN OTHMAN) (KHADIJAH BINTI ZAINUDDIN)

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