Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies

Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012
Department of Mechanical Engineering

DIELECTRIC FLUID IN ELECTRO DISCHARGE MACHINING

Prasad Bari1, Suvarna Rode2, Arfat Duduke3, Prashant Shinde4, Vipul Srivastav5
12

, Assistant Professor, 3, 4, 5 Students, Mechanical Engineering Department,

Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Maharashtra

Email address:3arfatduduke@gmail.com, 4prashant.shinde991@gmail.com.com,5vipuls2@yahoo.com
Abstract:
Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on
thermoelectric energy between the work piece and an electrode. Material removal rate (MRR) and Tool wear rate (TWR) are
important performance measures in EDM process. Since long, EDM researchers have explored a number of ways to improve and
optimize the MRR including some unique experimental concepts that depart from the traditional EDM sparking phenomenon.
Despite a range of different approaches, all the research work in this area shares the same objectives of achieving more efficient
material removal rate (MRR) coupled with reduction in tool wear rate (TWR) and improved surface quality. This report deals with
finding the best suitable dielectric fluid for a given workpiece and tool material in order to increase MRR and reduce TWR. This
paper also deals with the effects powder mixed dielectric fluid on MRR and TWR.

1.0 INTRODUCTION:
ELECTRO DISCHARGE MACHINING
EDM process is nonconventional machining process based on the thermoelectric energy. This energy is
created between a work piece and an electrode submerged in a dielectric fluid with the passage of electric current. The
work piece and the electrode are separated by a specific small gap called spark gap. Pulsed arc discharges occur in this
gap filled with a dielectric medium, preferably a dielectric liquid like hydrocarbon oil or de-ionized (de-mineralized)
water. Localized regions of high temperatures are formed due to the sparks occurring between the two electrode
surfaces. Work piece material in this localized zone melts and vaporizes. Most of the molten and vaporized material is
carried away from the inter-electrode gap by the dielectric flow in the form of debris particles. To prevent excessive
heating, electric power is supplied in the form of short pulses. Spark occurs wherever the gap between the tool and the
work piece surface is smallest. After material is removed due to a spark, this gap increases and the location of the next
spark shifts to a different point on the work piece surface. In this way several sparks occur at various locations over the
entire surface of the work piece corresponding to the work piece-tool gap.

Fig.1.0

Working principle of EDM [1]

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Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies

Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012
Department of Mechanical Engineering

2.0 PRODUCT DESIGN APPROACH:

2.1 METHODS
Various methods of improving MRR and TWR:
Electrical methods:

Peak voltage

Peak current

Pulse duration

Polarity

Non electrical methods:

Proper dielectric fluid

Powder mixed dielectric

Flushing

Electrode rotation

Tool design.

Our project will deal with improving the MRR and TWR by use of proper dielectric fluid and by mixing powder
particles in dielectric fluid i.e. PMEDM.
2.2 DIELECTRIC FLUID IN EDM
FUNCTIONS OF DIELECTRIC FLUID
Dielectric fluid plays an important role in the EDM process. Because of a high dielectric strength, the
dielectric medium prevents premature discharge between the electrodes until a low discharge gap is established between
them. Continuous dielectric flow in the discharge gap helps in carrying away the debris formed during the discharge
and ensures a proper flushing. Also, dielectric medium cools the machining zone by carrying away excess heat from the
tool electrode and the work piece.
PROPERTIES OF DIELECTRIC FLUID
The most important properties of dielectric are its dielectric strength, viscosity, thermal conductivity and
thermal capacity. Dielectric strength characterizes the fluids ability to maintain high resistivity before spark discharge
and the ability to recover rapidly after the discharge. High dielectric strength leads to a lower discharge gap which in
turn leads to a low gap resistance. Hence, high discharge currents may flow leading to a higher material removal rate.
Also, fluids with high dielectric strength need lower time for the recovery of dielectric strength. Thus, low pulse-off
times are sufficient. This not only improves the MRR but also provides better cutting efficiency because of a reduced
probability of arcing. Liquids with low viscosity generally provide better accuracies because of a better flow ability of
the oil leading to improved flushing. Also, the sideward expansion of the discharge plasma channel is restricted by high
viscosity fluids. This focuses the discharge energy over a small region and leads to a deeper crater which reduces the
surface finish. Dielectric fluids with high thermal conductivity and thermal heat capacity can easily carry away excess
heat from the discharge spot and lead to a lower thermal damage.
TYPES OF DIELECTRIC
Selection of dielectric medium is an important consideration for EDM performance. Mineral oils are
commonly used as the dielectric medium for die sinking EDM operations. Mineral oils exhibiting high dielectric
strength and a low viscosity are preferred because of their higher performance. For safety reasons oils with a high flash
point are usually used. Kerosene is one such oil which is used commonly for EDM. Water based dielectrics are used
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Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies

Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012
Department of Mechanical Engineering

almost extensively for wire EDM operations. Water has a high specific heat capacity which leads to a better cooling
effect required for wire cut operations. To prevent chemical reactions, deionized water is used in such applications.

Table2.2: Comparison of electrical, thermal and mechanical properties of mineral oil, deionized water and air

[2]

In comparison to mineral oils and water, air has the lowest dielectric strength, viscosity, thermal conductivity
and thermal capacity as shown in Table. Low viscosity air medium favors higher cutting accuracy and better surface
finish. However, low dielectric constant suggests a lower MRR with air medium. Low thermal capacity and thermal
conductivity suggests higher thermal damage of work piece. However, for a complete analysis of the thermal damage
an opposing effect caused by the expansion of plasma channel due to low viscosity must also be accounted. Thus,
overall it seems that using air as dielectric may be a better alternative for improving some of the process performance
such as surface finish and accuracy at the expense of the MRR
2.3 POWDER MIXED EDM (PMEDM)
Powder mixed electric discharge machining (PMEDM) is one of the new innovations for the enhancement of
capabilities of electric discharge machining process. In this process, a suitable material in fine powder is properly mixed
into the dielectric fluid. The added powder improves the breakdown characteristics of the dielectric fluid. The insulating
strength of the dielectric fluid decreases and as a result, the spark gap distance between the electrode and work piece
increases. Enlarged spark gap distance makes the flushing of debris uniform. This results in much stable process
thereby improving material removal rate and surface finish. Fig. below shows the principle of powder mixed EDM.

Fig.2.3

Working principle of PMEDM [1]

When voltage is applied the powder particles become energized and behave in a zigzag fashion. These charged
particles are accelerated due to the electric field and act as conductors promoting breakdown in the gap. This increases
the spark gap between tool and the work piece. Under the sparking area, these particles come close to each other and
arrange themselves in the form of chain like structures. The interlocking between the powder particles occurs in the
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Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies

Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012
Department of Mechanical Engineering

direction of flow of current. The chain formation helps in bridging the discharge gap between the electrodes. Because of
bridging effect, the insulating strength of the dielectric fluid decreases resulting in easy short circuit. This causes early
explosion in the gap and series discharge starts under the electrode area. The faster sparking within a discharge causes
faster erosion from the work piece surface and hence the material removal rate increases.
VARIOUS POWDERS USED IN PMEDM ARE

Silicon carbide

Boric acid

Graphite

Chromium powder

Aluminium etc.

PROPERTIES OF POWDER AFFECTING MRR AND TWR

Concentration

Size

Electrical and thermal conductivity.

A number of research works have been reported for different combinations of materials, powders and operating
conditions. Erden and Bilgin

[1]

investigated mixing of copper, aluminum, iron and carbon powders in kerosene oil as

dielectric for machining of brasssteel and coppersteel pairs. The machining rate was found to increase with powder
particle concentration obtained due to the decrease in time lag at high impurity concentrations. It was found that the
concentration, size, density, electrical resistivity and thermal conductivity of powders significantly affect the machining
performance. Addition of appropriate amount of powders to the dielectric fluid resulted in increased MRR and
decreased TWR. For a fixed concentration of particles, the smallest size of the particle led to highest MRR and lowest
TWR.
Jeswani

[1]

investigated the effect of the addition of fine graphite powder into kerosene oil as dielectric. The

experimentation resulted in 60% increase in MRR and 28% reduction in wear ratio. The results indicate that Al and Cr
mixture in kerosene fluid reduces the isolation and increases the spark gap. With this, the process gets stabilized and the
MRR is enhanced considerably.
3.0 EXPERIMENTAL ANALYSIS:
Experiments will be performed on EDM by using various powders mixed in dielectric fluid and output
parameters like MRR and TWR will be calculated. The details of experiments to be performed are given below:
Work piece Material: D3 steel
Electrode Material: Copper
Powders to be used: Aluminium, Chromium, Silicon Carbide.
The experiments will be performed by varying the concentration of powders and varying electrical parameters
like pulse ON time, pulse current, etc.

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Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies

Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012
Department of Mechanical Engineering

3.1 EXPERIMENT SETUP

Fig.3.1

Line diagram of experimental setup [3]

The points considered in designing PMEDM set-up are

The powder should not enter the main dielectric tank to avoid filtering of

The dielectric should be continuously stirred or circulated to prevent settling of the powder and to maintain

powder particles

uniform concentration.
4.0 FORMULAS:
MATERIAL REMOVAL RATE (MRR):
MRR=

Work piece weight loss (g)

Machining time (sec)

TOOL WEAR RATE:

TWR=

Electrode weight loss (g)

Machining time (sec)

5.0 CONCLUSION:
The effect of powder mixed dielectric fluid on MRR and TWR will be seen experimentally.MRR and TWR for various
powders will be compared.
References:
[1]

Kuldeep Ojha, R. K. Garg, K. K. Singh. MRR Improvement in Sinking Electrical Discharge Machining: A Review.
Journal of Minerals & Materials Characterization & Engineering, Vol. 9, No.8, pp.709-739, 2010.

[2]

Sourabh Kumar Saha. Experimental Investigation of the Dry Electric Discharge Machining (Dry EDM) Process

[3]

Kuldeep Ojha, R. K. Garg a, K. K. Singh. Experimental Investigation and Modeling of PMEDM Process with Chromium
Powder Suspended Dielectric.

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