Electric Discharge Machining (EDM)

Electric Discharge
Machining (EDM)
BY- MOHIT BHATIA
0341483605
MAE, 8th SEMESTER
Introduction
Electro Discharge Machining (EDM) is an electro-
thermal non-traditional machining process, where

electrical energy is used to generate electrical
spark and material removal mainly occurs due to
thermal energy of the spark.
EDM
is mainly used to machine difficult-tomachine materials and high strength temperature

resistant alloys. EDM can be used to machine
difficult geometries in small batches or even on
job-shop basis. Work material to be machined by
EDM has to be electrically conductive.
Characteristics of EDM
The process can be used to machine any work
material if it is electrically conductive

Material removal depends on mainly thermal
properties of the work material rather than its
strength, hardness etc
In EDM there is a physical tool and geometry
of the tool is the positive impression of the
hole or geometric feature machined
The tool has to be electrically conductive as
well. The tool wear once again depends on the
thermal properties of the tool material
Apr 18, 2015
Characteristics of EDM
Though the local temperature rise is rather high,
still due to very small pulse on time, there is not

enough time for the heat to diffuse and thus
almost no increase in bulk temperature takes
place. Thus the heat affected zone is limited to 2
4 m of the spark crater
However rapid heating and cooling and local
high temperature leads to surface hardening

which may be desirable in some applications
Though there is a possibility of taper cut and
overcut in EDM, they can be controlled and

compensated.
Apr 18, 2015
Equipment
Dielectric reservoir,
pump and circulation

system
Power generator and
control unit
Working tank with work
holding device
X-y table
accommodating the
working table
The tool holder
The servo system to
feed the tool
Apr 18, 2015
Power
generator
Resistance-capacitance type (RC type)
Relaxation generator
Rotary impulse type generator
Electronic pulse generator
Hybrid EDM generator
Schematic representation of the basic

working principle of EDM process.
Apr 18, 2015
Electrical-Discharge-Machining
Process
Cavities made with electrical-dischargemachining process
(a) Examples of cavities produced by the electrical-discharge-machining
process, using shaped electrodes. The two round parts (rear) are the set of
dies for extruding the aluminum piece shown in front. (b) A spiral cavity
produced by a rotating electrode. (c) Holes in a fuel-injection nozzle made
by electrical-discharge machining. Material: Heat-treated steel.
Stepped Cavities
Stepped cavities produced with a square electrode by EDM. The work
piece moves in the two principal horizontal directions, and its motion is
synchronized with the downward movement of the electrode to
produce various cavities. Also shown is a round electrode capable of
producing round or elliptical cavities.
Mechanics Of EDM
Apr 18, 2015
Mechanics Of EDM
Generally the tool is connected to the negative
terminal of the generator and the work-piece is

connected to positive terminal.
Due to electric field established between the tool
and the job, the free electrons on the tool are
subjected to electrostatic forces. electrons would be
emitted from the tool (assuming it to be connected
to the negative terminal). Such emission of electrons
are called or termed as cold emission.
The cold emitted electrons are then accelerated
towards the job through the dielectric medium. As

they gain velocity and energy, and start moving
towards the job, there would be collisions between
the electrons and dielectric molecules.
Apr 18, 2015
Mechanics Of EDM
Collision may result in ionisation of the dielectric
molecule. As the electrons get accelerated, more

positive ions and electrons would get generated due
to collisions. This cyclic process would increase the
concentration of electrons and ions in the dielectric
medium between the tool and the job at the spark
gap.
The concentration would be so high that the matter
existing in that channel could be characterized as
plasma.
The electrical resistance of such plasma channel
would be very less. Thus all of a sudden, a large
number of electrons will flow from the tool to the job
and ions from the job to the tool. This is called
avalanche motion of electrons.
Apr 18, 2015
EDM Video
YouTube - EDM - Electrical Discharge Machining.flv
Apr 18, 2015
Mechanics Of EDM
Such movement of electrons and ions can be visually seen
as a spark. Thus the electrical energy is dissipated as the

thermal energy of the spark.
The high speed electrons then impinge on the job and ions
on the tool. The kinetic energy of the electrons and ions
on impact with the surface of the job and tool respectively
would be converted into thermal energy or heat flux. Such
intense localised heat flux leads to extreme instantaneous
confined rise in temperature which would be in excess of
10,000oC.
Such localised extreme rise in temperature leads to
material removal. Material removal occurs due to instant
vapourisation of the material as well as due to melting.
The molten metal is not removed completely but only
partially.
The material removal in EDM mainly occurs due to
formation of shock waves as the plasma channel collapse
owing to discontinuation of applied potential difference.
Dielectric
In EDM material removal occurs due to thermal
evaporation and melting.

Thermal processing is required to be carried out in
absence of oxygen so that the process can be
controlled and oxidation avoided.
Oxidation often leads to poor surface conductivity
(electrical) of the work-piece hindering further
machining. Hence, dielectric fluid should provide an
oxygen free machining environment.
It should have enough strong dielectric resistance so
that it does not breakdown electrically too easily but
at the same time ionize when electrons collide with
its molecule.
During sparking it should be thermally resistant as
well.
Dielectric
Generally
kerosene and demonized water is

used as dielectric fluid in EDM.
Tap water cannot be used as it ionizes too early
and thus breakdown due to presence of salts as
impurities occur.
Dielectric medium is generally flushed around
the spark zone. It is also applied through the tool
to achieve efficient removal of molten material.
Mainly
used
dielectric
mediums
are
Hydrocarbon(petroleum oil), Kerosene, liquid
paraffin & silicon oil etc.
It should have low viscosity, absence of toxic
vapour, chemical neutrality , absence of
inflaming tendency , low cost.
The fluid serves the following three
purposes:
1.Flushes material away
2.Serves as a coolant to minimize the heat
affected zone (thereby preventing

potential damage to the work piece)
3.Acts as a conductor for the current to
pass between the electrode and the work
piece.
Electrode Material Properties

Electrode material should be such that it would not
undergo much tool wear when it is impinged by positive

ions.
High electrical conductivity electrons are cold emitted
more easily and there is less bulk electrical heating
High thermal conductivity for the same heat load, the
local temperature rise would be less due to faster heat
conducted to the bulk of the tool and thus less tool wear
Higher density for the same heat load and same tool
wear by weight there would be less volume removal or
tool wear and thus less dimensional loss or inaccuracy
High melting point high melting point leads to less tool
wear due to less tool material melting for the same heat
load
Easy manufacturability & Cost cheap
Electrode Material
The followings are the different electrode
materials which are used commonly in the
industry:
Graphite
Electrolytic oxygen free copper
Tellurium copper 99% Cu + 0.5% tellurium
Brass
Copper-tungsten alloys
Silver-tungsten alloys
Al-alloys
EDM characteristics
Mechanics of metal removal: Melting and
Summary
evaporation aided by cavitations' .
Medium: Dielectric fluid
Tool Materials: Cu, brass, Cu-W alloy, Ag-W alloy,
graphite.
Material removal rate: 510mm/min.
Gap between tool & W.P.: 10-125m.
Specific power consumption: 1.8W/mm/min
Critical parameters: voltage , capacitance , spark
gap, dielectric circulation , melting temp.
Material application: all conducting metals and
alloys.
Shape application: blind complex cavities , micro
holes for nozzles , through cutting of non-circular
holes , narrow slots.
Summary
Limitations :high energy consumption when
forced circulation of dielectric is not

possible , removal rate is quite low, surface
tends to be rough for larger removal rates ;
not applicable to non-conducting material.
TOOLS OF EDM
Power supplies
Pulsed DC
10 to 1000Amps
Electrodes
High electrical conductivity
Ease of fabrication
Resistance to wear (high melting point)
Copper, Graphite and Brass most common
Dielectric
Spark conductor
Coolant
Flushing medium
Petroleum Oil Base (EDM) & Ionized Water (EWDM) most
popular
Computer controlled servo
Wire EDM
In wire EDM a very thin wire serves as the
electrode. Special brass wires are typically

used; the wire is slowly fed through the
material and the electrical discharges actually
cut the work piece. Wire EDM is usually
performed in a bath of water.
The wire itself does not actually touch the
metal to be cut; the electrical discharges

actually remove small amounts of material and
allow the wire to be moved through the workpiece.
Wire EDM Process
FIGURE 9.35 Schematic illustration of the wire EDM process. As much as 50
hours of machining can be performed with one reel of wire, which is then
discarded.
Fundamentals of wire EDM
Wire EDM
Super precision band saw
To better understand the

wire EDM process,
visualize the wire EDM
machine as a super
precision band saw with
accuracies capable up
to +/-0.001
(0.0025mm), and under
certain circumstances
even closer.
The step by step Wire Cut EDM process
Deionized water surrounds the wire electrodes as the power supply generates
voltages and amps to produce the spark
The generated spark precisely melts and vaporizes the material
During the off cycle, the pressurized dielectric fluid immediately cools the
material and flushes out the eroded particles
New wire is constantly fed, while the eroded particles are removed and separated
by a filter system
EDM Machine
APPLICATIONS
Only conductive materials can be machined
Hardness/Toughness of material is not a
concern
Popular in dies and molds
Well suited for machining difficult or
intricate parts
Longer machining time limits use to
prototyping or limited run parts
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What are the main characteristics of EDM?

What are the main characteristics of EDM?

What are the main components of an EDM machine?

What are the main components of an EDM machine?

Electric Discharge

thermal non-traditional machining process, where

is mainly used to machine difficult-tomachine materials and high strength temperature

material if it is electrically conductive

still due to very small pulse on time, there is not

high temperature leads to surface hardening

overcut in EDM, they can be controlled and

pump and circulation

Apr 18, 2015

Schematic representation of the basic

Apr 18, 2015

Cavities made with electrical-dischargemachining process

(a) Examples of cavities produced by the electrical-discharge-machining

Stepped cavities produced with a square electrode by EDM. The work

Apr 18, 2015

terminal of the generator and the work-piece is

towards the job through the dielectric medium. As

molecule. As the electrons get accelerated, more

YouTube - EDM - Electrical Discharge Machining.flv

Apr 18, 2015

as a spark. Thus the electrical energy is dissipated as the

evaporation and melting.

kerosene and demonized water is

The fluid serves the following three

affected zone (thereby preventing

Electrode Material Properties

undergo much tool wear when it is impinged by positive

forced circulation of dielectric is not

Computer controlled servo

electrode. Special brass wires are typically

metal to be cut; the electrical discharges

Wire EDM Process

FIGURE 9.35 Schematic illustration of the wire EDM process. As much as 50

Fundamentals of wire EDM

Super precision band saw

To better understand the

The step by step Wire Cut EDM process

The generated spark precisely melts and vaporizes the material

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