555.mp4
Developing a functional EDM (Electric Discharge Machine) for cutting thin 1mm metal sheets:
❌ 10 VOLT mini model SETUP & explain with LED 💡 & SOUND WAVE 🔊
- EDM works by generating electrical sparks to erode metal surfaces.
- It requires a power supply, an electrode, a workpiece, and a dielectric fluid.
- The electrode (cathode) and workpiece (anode) are submerged in dielectric fluid, and a high-frequency electrical discharge removes metal from the workpiece.
| Component | Specification |
|---|---|
| Step-down Transformer | Converts 230V AC to 50-100V AC |
| Bridge Rectifier | 50A capacity for AC to DC conversion |
| Capacitors | 4.8µF, 450V |
| Electrode Material | Copper (35-70mm) |
| Dielectric Fluid | Distilled Water or Kerosene |
| Workpiece | Thin Steel or Copper Sheet |
| Control Circuit | Pulse Generator for Spark Regulation |
| Frame & Tub | 60x30 cm size |
| Wires & Connectors | High-voltage insulated wires |
| Cooling & Flushing System | Pump to circulate dielectric fluid |
-
Use a Step-Down Transformer
- Converts 230V AC to 12-24V AC.
- Must have multiple voltage outputs for flexibility.
-
Bridge Rectifier
- Converts AC to DC for controlled spark generation.
- Choose a 50A diode bridge for sufficient power handling.
-
Capacitor (for Smoothing DC Output)
- Use 450V, 4.8µF capacitor to stabilize voltage and reduce ripples.
- Electrode: Use copper due to its excellent conductivity.
- Workpiece: Choose thin steel or copper sheet for easier cutting.
- Spark Gap: Maintain 5-10mm gap between electrode and workpiece.
- Use distilled water or kerosene to act as an insulator and coolant.
- Ensure continuous circulation with a pump to flush debris and cool the cutting area.
- Mount the Workpiece & Electrode inside the dielectric tub.
- Connect the Power Supply (transformer, rectifier, capacitor).
- Ensure Proper Spark Gap for controlled erosion.
- Install the Pulse Generator Circuit to regulate spark intensity and frequency.
- Test with low voltage (50V) and gradually increase up to 100V.
- Observe spark discharge and material removal rate.
- Adjust gap, pulse frequency, and voltage for optimal performance.
- Cut a thin steel or copper sheet to show EDM functionality.
- If sparks are inconsistent, adjust capacitor values and pulse timing.
- Ensure safety measures (proper insulation, emergency cutoff).
-
The project document provides detailed calculations (e.g., spark voltage = 48.42V, power consumed = 2370W).
-
The machine does not need to be industry-grade, but it should demonstrate material removal effectively.
Component: 230V to 24V Step-Down Transformer
- Specification: 230V AC input → 24V-0-24V AC output, 1.5A current rating
- Function: Reduces high-voltage AC (230V) to a lower AC voltage (24V), preventing excessive current flow.
- Reason for Use: Protects circuit components from high voltage and provides suitable power for further rectification.
- Cost (India): ₹250 - ₹400
Connections:
- Primary winding connected to 230V AC mains.
- Secondary winding gives 24V-0-24V AC output, which will be converted to DC.
Component: 50A Bridge Rectifier Module
- Specification: Input: 24V AC, Output: 24V DC, Diode rating: 50A, 1000V PIV
- Function: Converts the AC output of the transformer into pulsating DC.
- Reason for Use: Needed to supply stable DC power for the EDM spark generation circuit.
- Cost (India): ₹150 - ₹300
Connections:
- AC input terminals connected to 24V AC output of the transformer.
- DC output terminals provide smooth DC voltage.
Component: Electrolytic Capacitor 450V, 4.8µF
- Specification: Voltage rating: 450V, Capacitance: 4.8µF
- Function: Filters out AC ripples and provides smooth DC voltage.
- Reason for Use: Ensures steady and continuous spark generation by maintaining constant voltage.
- Cost (India): ₹200 - ₹350
Connections:
- Positive terminal of the capacitor to the positive DC output of the rectifier.
- Negative terminal to the ground (0V).
Component: 555 Timer IC or PWM Controller
- Specification: Frequency: 1 kHz – 50 kHz adjustable, Duty cycle: 10% - 90%
- Function: Generates high-frequency pulses to control the discharge of sparks in EDM.
- Reason for Use: Prevents continuous current flow, allowing controlled spark discharges for efficient machining.
- Cost (India): ₹100 - ₹250
Connections:
- VCC (Power Supply): Connected to 24V DC output from the rectifier.
- Output Pin: Controls MOSFET for spark discharge.
- GND (Ground): Connected to circuit ground.
Component: IRF540N MOSFET (N-Channel, 100V, 33A)
- Specification: Voltage: 100V, Current: 33A, Rds(on): 44mΩ
- Function: Acts as a high-speed electronic switch, allowing controlled discharge through the electrode.
- Reason for Use: Can handle high currents and operates efficiently in switching applications.
- Cost (India): ₹80 - ₹200
Connections:
- Drain: Connected to negative terminal of the electrode.
- Source: Connected to ground.
- Gate: Connected to PWM output from the 555 timer.
Components:
-
Electrode: Copper rod (Ø 3mm – 10mm)
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Workpiece: Thin steel sheet (1mm – 3mm)
-
Function: The electrode releases sparks that erode the workpiece surface.
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Reason for Use: Copper has excellent electrical conductivity and withstands EDM erosion.
-
Cost (India):
- Copper Electrode: ₹300 - ₹600
- Steel Workpiece: ₹200 - ₹500
Connections:
- Electrode connected to the MOSFET drain.
- Workpiece connected to positive terminal of power supply.
Component: Distilled Water or Kerosene + Pump
- Function: Cools the spark zone, removes debris, and maintains insulation.
- Cost (India): ₹250 - ₹600
Connections:
- Pump circulates dielectric fluid around the electrode and workpiece.
- Fuse (10A, 250V) – ₹30 - ₹50
- Emergency Stop Switch – ₹100 - ₹250
| Component | Estimated Cost (₹) |
|---|---|
| Step-Down Transformer | ₹250 - ₹400 |
| Bridge Rectifier (50A) | ₹150 - ₹300 |
| Capacitor (450V, 4.8µF) | ₹200 - ₹350 |
| Pulse Generator (555 Timer) | ₹100 - ₹250 |
| Power MOSFET (IRF540N) | ₹80 - ₹200 |
| Copper Electrode | ₹300 - ₹600 |
| Workpiece (Steel Sheet) | ₹200 - ₹500 |
| Dielectric Fluid & Pump | ₹250 - ₹600 |
| Safety Components | ₹130 - ₹300 |
| Total Estimated Cost | ₹1,660 - ₹3,500 |
- 230V AC → Step-Down Transformer (24V AC output)
- Transformer Output → Bridge Rectifier (Converts to 24V DC)
- Rectifier Output → Capacitor (Removes AC Ripples)
- Smooth DC Power → Pulse Generator (Controls Spark Pulses)
- Pulse Generator Output → MOSFET (Switching)
- MOSFET Drain → Electrode (Cathode)
- Workpiece (Anode) → Connected to 24V DC positive
- Electrode & Workpiece submerged in Dielectric Fluid
- Pump continuously circulates the dielectric fluid
⭕ explain with LED pulse 💡
555.LED.mp4
⭕ explain with sound wave pulse 🔉🔊
555.Sound.mp4
- The 10 ms pulse duration (957 Hz frequency) means each pulse occurs in about 1.04 milliseconds, which is extremely fast.
- This is normal for EDM because metal cutting occurs due to rapid, repetitive electrical discharges.
- Since these pulses are too fast for the human eye, a storage oscilloscope or high-speed data logger is required to analyze them.
✅ For testing the circuit: Yes, using an LED is a great way to check if the circuit is generating pulses correctly.
❌ For actual metal cutting: No, because EDM requires high voltage (~50-300V) and high current pulses, whereas your 555 timer circuit only operates at 10V with limited current.
- Your current 10V setup is too low for metal cutting.
- EDM typically requires a capacitor discharge circuit (CDM) with higher voltage (50V-300V) and high peak currents.
- The 555 timer can only drive small loads.
- For EDM, use a MOSFET (IRF540, IRFZ44N) or IGBT (like GT50J325) to handle the high voltage and current needed for discharge.
- Modify the resistors (10kΩ, 1kΩ) and capacitor (100µF) to adjust the pulse width and frequency for better discharge performance.
❌ 300V 50amp model SETUP
To create a functional EDM circuit, we need:
- High Voltage (50V–300V) for Breakdown of Metal
- High Current Pulses (~5A–20A) for Effective Erosion
- Controlled Pulse Timing (Microsecond to Millisecond)
- Dielectric Fluid (Oil or Water) to Cool the Electrode and Workpiece
- A Discharge Circuit (MOSFET/IGBT) to Control Sparks
| Component | Specification |
|---|---|
| High Voltage Power Supply | 50V-300V DC |
| Capacitor Bank | 10µF - 100µF (High Voltage) |
| 555 Timer or Microcontroller (Arduino/PIC) | Pulse Generator |
| MOSFET/IGBT (Switching Device) | IRFP250, IRF540, or GT50J325 |
| Resistors (Control Discharge Rate) | 1kΩ - 10kΩ |
| Inductor (Current Limiting) | 100µH - 1mH |
| Dielectric Fluid | Kerosene, EDM Oil, or Distilled Water |
-
Charging Phase:
- The capacitor charges to high voltage (50V-300V).
- The resistor controls the charging speed.
-
Discharge Phase (Cutting Metal):
- The MOSFET/IGBT switches ON for a short duration (microseconds to milliseconds).
- High voltage discharges across the electrode and metal workpiece, creating sparks.
- Metal erodes due to high-energy sparks.
- Dielectric fluid removes debris and cools the workpiece.
🍥 Use a Pulse Width Modulation (PWM) Circuit
- A 555 Timer or Arduino can generate pulses for better control.
🍥 Heat Management
- Use a heatsink for the MOSFET/IGBT.
- Submerge the workpiece and electrode in EDM oil or water to cool the cutting area.
🍥 Workpiece and Electrode Setup
- The electrode (copper, graphite, or tungsten) should be small and precise for a 1mm sheet.
- Electrode gap (0.1mm - 0.5mm) is critical for stable cutting.
🌀 Why I not using 555 IC ?
both the 555 timer IC and Arduino Uno (or any microcontroller) can generate PWM signals and control timing. However, the reason 555 IC is not recommended in many cases, especially for applications requiring precise PWM control
- Precision & Stability
- 555 Timer: Frequency and duty cycle depend on passive components (resistors, capacitors, potentiometers), which can drift over time due to temperature changes, component tolerances, and aging.
- Arduino: Generates highly accurate PWM with software control, and timing is managed digitally by the internal crystal oscillator, making it much more stable.
- Frequency Adjustability
- 555 Timer: You can change frequency with a potentiometer, but the adjustment is not smooth or linear. Also, if you need real-time changes, you would need additional circuits like digital potentiometers.
- Arduino: You can adjust frequency and duty cycle dynamically using code (e.g., analogWrite() or PWM libraries).
- Duty Cycle Control
- 555 Timer: Adjusting both frequency and duty cycle independently is complicated and requires extra components.
- Arduino: Full control over duty cycle and frequency independently, which is crucial for motor control, signal generation, etc.
- Multiple Outputs & Complexity
- 555 Timer: If you need multiple PWM outputs, you need multiple 555 ICs, making the circuit bulky.
- Arduino: Can generate multiple PWM signals (on different pins) simultaneously and synchronize them easily.
- Software Control & Customization
- 555 Timer: Once designed, changing the behavior requires modifying hardware (resistors, capacitors).
- Arduino: Just update the software; no need to change hardware.
I using arduino you know to control the PWM signal using potentiometer, using 555 IC we can easily change the frequency what you have to control the time.
- Arduino Nano (recommended) or Uno Mega (1 piece)
- Potensiometer 10 kΩ or 5kΩ (2)
- one for changing the pulse ------ ılıılıılıılıılıılıılıılıı => ıllııllııllııllııllııllıı
- and another for frequency ------ ıllııllııllııllııllııllıı => ılılılılılılılılılılılılıl
- IGBT (take any one option from below)
- IRG4PC40S (3) or,
- H20R1203 / 20R1203 (5) or,
- IRG4PC40UD (2) or,
- KGF25N135NDH (3)
- Capacitor --| |-- (Voltage may change bec of availability But you need the exect uF)
- 200V 100uF
- 200V 470uF
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✅ Pulse On-Time (Ton)
✅ Pulse Off-Time (Toff)
✅ Total Discharge Cycles
✅ Voltage & Current Monitoring (using sensors)
✅ Data Logging to SD Card or Serial Monitor
| Component | Specification | Purpose |
|---|---|---|
| Arduino Nano/UNO | 1 piece | Generates PWM signals |
| Potentiometer | 10kΩ (2 pieces) | Adjusts Ton & Toff |
| IGBT | IRG4PC40S / H20R1203 / IRG4PC40UD / KGF25N135NDH | High-voltage switching |
| Capacitors | 200V 100µF & 200V 470µF | Energy storage |
| SMPS | 80-100V, 3-5A | Power supply |
| Current Sensor | ACS712 (5A/20A/30A) | Measures discharge current |
| Voltage Sensor | Voltage Divider (100:1) | Monitors EDM voltage |
| SD Card Module | (Optional) | Logs EDM data |
This Arduino sketch controls PWM pulses for EDM and records process parameters.
✅ Real-time adjustable pulse width & frequency
✅ IGBT high-speed switching
✅ Voltage & current monitoring
✅ Data logging to Serial Monitor / SD card
#include <SPI.h> // SD Card Library (if used)
#include <SD.h> // For SD Card Logging
#define pwmPin 9 // IGBT Gate Control
#define potWidth A0 // Potentiometer for Pulse Width
#define potFreq A1 // Potentiometer for Frequency
#define currSensor A2 // ACS712 Current Sensor
#define voltSensor A3 // Voltage Divider Sensor
#define chipSelect 10 // SD Card Module Chip Select Pin
unsigned long cycleCount = 0;
float voltage, current;
void setup() {
pinMode(pwmPin, OUTPUT);
Serial.begin(115200); // Serial Monitor
if (!SD.begin(chipSelect)) {
Serial.println("SD Card Initialization Failed!");
} else {
Serial.println("SD Card Ready.");
}
}
void loop() {
int pulseWidth = analogRead(potWidth); // Read Pulse Width
int freq = analogRead(potFreq); // Read Frequency
int onTime = map(pulseWidth, 0, 1023, 10, 500); // Ton (10-500 µs)
int offTime = map(freq, 0, 1023, 10, 500); // Toff (10-500 µs)
// Start Discharge Pulse
digitalWrite(pwmPin, HIGH);
delayMicroseconds(onTime);
digitalWrite(pwmPin, LOW);
delayMicroseconds(offTime);
// Read Sensor Data
voltage = analogRead(voltSensor) * (5.0 / 1023.0) * 100; // Convert to actual voltage
current = analogRead(currSensor) * (5.0 / 1023.0) * 30; // Convert to actual current
// Increment Discharge Cycle
cycleCount++;
// Serial Monitor Output
Serial.print("Cycle: ");
Serial.print(cycleCount);
Serial.print(" | Voltage: ");
Serial.print(voltage);
Serial.print("V | Current: ");
Serial.print(current);
Serial.println("A");
// Logging to SD Card
File dataFile = SD.open("edm_log.txt", FILE_WRITE);
if (dataFile) {
dataFile.print("Cycle: ");
dataFile.print(cycleCount);
dataFile.print(" | Voltage: ");
dataFile.print(voltage);
dataFile.print("V | Current: ");
dataFile.print(current);
dataFile.println("A");
dataFile.close();
}
}Cycle: 1 | Voltage: 90.5V | Current: 4.2A
Cycle: 2 | Voltage: 89.8V | Current: 4.1A
Cycle: 3 | Voltage: 90.2V | Current: 4.3A
...
-
PWM Signal Generation
- Ton & Toff adjustable via potentiometers.
- Generates precision-controlled sparks for metal cutting.
-
Voltage & Current Monitoring
- Voltage Sensor (reads EDM voltage).
- Current Sensor (monitors discharge current).
- Ensures stable operation & prevents overheating.
-
Cycle Counting & Data Logging
- Counts discharge cycles for process tracking.
- Saves readings to SD card (or displays on Serial Monitor).
✅ Test on an oscilloscope for PWM tuning.
✅ Use IGBT heatsink & fan for cooling.
✅ Implement emergency stop button for safety.
Using the Raspberry Pi Pico W, you can achieve:
✅ Precise PWM control for EDM pulses
✅ Mobile monitoring (pulse waveform & EDM status)
✅ Wi-Fi control (turn EDM on/off via web interface)
✅ Replace Oscilloscope (view pulse on phone screen)
| Component | Specification | Purpose |
|---|---|---|
| Raspberry Pi Pico W | (Built-in Wi-Fi) | Main controller |
| IGBTs | IRG4PC40S / H20R1203 / IRG4PC40UD | High-voltage switching |
| Capacitors | 200V 100µF & 200V 470µF | Energy storage |
| Current Sensor | ACS712 (5A/20A/30A) | Measures discharge current |
| Voltage Sensor | Voltage Divider (100:1) | Monitors EDM voltage |
| SMPS | 80-100V, 3-5A | Power supply |
| OLED Display (optional) | SSD1306 | Local pulse monitoring |
✅ Web-based Control: Start/Stop EDM remotely
✅ Live Pulse Monitoring: View waveforms in a web UI
✅ Adjustable PWM: Change pulse width/frequency in real time
✅ Wi-Fi Connectivity: Data logging & remote control
✅ Safe Power Switching: Control IGBT safely
This code will:
1️⃣ Generate adjustable PWM for EDM
2️⃣ Stream live pulse data to a mobile web page
3️⃣ Allow power control via Wi-Fi web interface
import network
import socket
import machine
import utime
# Pin Configuration
pwm_pin = machine.Pin(16) # GPIO for PWM
led = machine.Pin(25, machine.Pin.OUT) # Onboard LED for status
pwm = machine.PWM(pwm_pin)
pwm.freq(500) # Default frequency 500 Hz
pwm.duty_u16(32768) # 50% duty cycle
# Wi-Fi Setup
ssid = "Your_WiFi_Name"
password = "Your_WiFi_Password"
wlan = network.WLAN(network.STA_IF)
wlan.active(True)
wlan.connect(ssid, password)
while not wlan.isconnected():
utime.sleep(1)
print("Connected to Wi-Fi")
# Web Page for Control
html = """<!DOCTYPE html>
<html>
<head><title>EDM Control</title></head>
<body>
<h2>EDM Machine Control</h2>
<p>Pulse Frequency: <span id="freq">500</span> Hz</p>
<p>Power: <span id="power">ON</span></p>
<button onclick="sendCommand('increase')">Increase Frequency</button>
<button onclick="sendCommand('decrease')">Decrease Frequency</button>
<button onclick="sendCommand('toggle')">Turn On/Off</button>
<script>
function sendCommand(cmd) {
fetch('/' + cmd).then(response => response.text()).then(data => {
document.getElementById("freq").innerText = data;
});
}
</script>
</body></html>
"""
# Handle Web Requests
def handle_request(request):
global pwm
if '/increase' in request:
freq = pwm.freq() + 50
pwm.freq(freq)
elif '/decrease' in request:
freq = pwm.freq() - 50
pwm.freq(freq)
elif '/toggle' in request:
if pwm.duty_u16() > 0:
pwm.duty_u16(0)
else:
pwm.duty_u16(32768)
return str(pwm.freq())
# Web Server
addr = socket.getaddrinfo('0.0.0.0', 80)[0][-1]
s = socket.socket()
s.bind(addr)
s.listen(5)
print("Web server running...")
while True:
cl, addr = s.accept()
request = cl.recv(1024).decode()
response = handle_request(request) if "GET" in request else html
cl.send("HTTP/1.0 200 OK\r\nContent-type: text/html\r\n\r\n" + response)
cl.close()✅ Web-Based EDM Control
- Start/Stop EDM remotely
- Adjust pulse frequency in real-time
- Monitor EDM pulse status
✅ Wi-Fi Integration
- Connect to Wi-Fi
- Host a control webpage
✅ PWM Control for EDM Pulse
- Adjust pulse frequency dynamically
- Ensure stable IGBT switching
1️⃣ Connect Raspberry Pi Pico W to Wi-Fi
2️⃣ Open IP Address in your mobile browser
Example: http://192.168.1.100
3️⃣ Use buttons to:
- ✅ Increase/Decrease frequency
- ✅ Turn EDM ON/OFF 4️⃣ Monitor pulse status on mobile screen
✅ Send Pulse Data to a Cloud Dashboard (MQTT / Firebase)
✅ Connect an OLED Display for Local Monitoring
✅ Use Bluetooth Instead of Wi-Fi for Offline Control
🔹 Do you need a real-time pulse waveform display in the web UI?
🔹 Want to log data to an SD card or cloud server?
🔹 Need a custom PCB design for your EDM project?
click the image
