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Fundamentals of EDM
The process dates back to WW I & II when work as well
as substantial tool material was removed due to manual
feeding of electrode.
Later vibratory electrodes were used to control inter
electrode gap.
Two Russian scientists developed R-C circuit and servo
controller.
The Die sinking version of EDM was developed
sometime in 1940s.
The process modeling involves understanding of
complex hydrodynamic and thermodynamic behavior of
the fluid.
Fundamentals of EDM
Preparation Phase
Phase of Discharge
Interval Phase
Fundamentals of EDM
Voltage Current curves (Free, Normal, Stationary
located, and Short circuit discharges)
General observations
Difficult to start the process with very clean
dielectric
Firing of high current discharges at same voltage is
easy in contaminated dielectric
New ignition opt to ignite in prior discharge regions
Greater ignition preferences in more contaminated
regions
Fundamentals of EDM
DC pulses of appropriate shape, frequency and duty cycle
are used. This is used even for motor control now-a-days.
Frequency is ~ 100,000 Hz.
Spark is initiated at the peak between the contacting surfaces
and exists only momentarily. Spark temp is 12,000 C. Metal
as well as dielectric will evaporate at this intense localized
heat. A crater is caused by both due to the local evaporation
as well as the vapor action.
Vapor quenches and next spark it at another narrow place.
Thus, spark wanders throughout the surface making uniform
metal removal for the desired finish.
Fundamentals of EDM
Material removal in EDM is based on erosion effect.
Several theories have been proposed:
Electro-mechanical theory: electric field force exceeds the
cohesive force of lattice.
Thermo-mechanical theory: Melting of material by flame-jets.
Thermo-electric theory: Generation of extremely high
temperature due to high intensity discharge current.
Fundamentals of EDM
Fundamentals of EDM
Large number of Spherical particles with few nonspherical particles
Spherical particles are rich in workpiece material
and non-spherical particles are rich in tool material
Understanding of Erosion Mechanism and Oxide
free power production
Important parameters affecting Debris morphology
are
Current
Voltage
Pulse On-time
Capacitance
Input Energy
Fundamentals of EDM
Micro analysis reveals that there is movement of
material from workpiece to cathode and vice-versa
Normal distribution of particle size (Stochastic nature)
Structures of Debris Large Size & Small Size
Hollow & Solid Debris
Satellite structure
Hollow Spheres
Dents
Burnt Cores
Fundamentals of EDM
Microanalysis of Debris Low Energy
Densely populated,
Small diameter, solid
particles
Fundamentals of EDM
Larger population of
hollow satellites with
dents, surface cracks, and
burnt core
Fundamentals of EDM
Effect of Tool Rotation.
Results in fine debris particles and improved process
stability.
Fundamentals of EDM
Fundamentals of EDM
A series of voltage
pulses of magnitude
about 20 to 120 V and
frequency on the order
of 5 kHz is applied
between the two
electrodes, which are
separated by a small
gap, typically 0.01 to
0.5 mm.
When using RC
generators, the voltage
pulses are responsible
for material removal.
EDM performance
measures such as
material removal
rate, electrode tool
wear, and surface
finish, for the same
energy, depends
on the shape of the
current pulses.
EDM Schematics
Components of EDM
Flushing
EDM hazards
Process Stability
Indication of constantly moving spark
Operating parameters
Current and voltage: As
the voltage drops from A to
B, the current increases
because of the negative
voltage-current
relationship. At C, current
is interrupted, and voltage
goes to zero and reverses
to D; but since there is no
break down in opposite
direction, no current
reversal takes place. The
voltage now returns to
zero and waits for the next
pulse.
Operating parameters
The energy dissipated in the
system is voltage times current
times time, it remains fairly
constant.
At A energy is zero.
B represents the power going to
the work.
C, D, E and F represent traces
at where there are either voltage or
current is zero, hence no power.
In section B voltage times current
is nearly constant, indicates a
constant input of power during a
current pulse.
Operating parameters
In the inter electrode gap, there is
a mixture of electrons, ions, and
neutral atoms in the gaseous
form.
Cathode supplies electrons for the
flow of current so should be
enough to emit the electrons, also
positive ions in front of cathode
provide a pulling force.
Cathode material also matters
Cu is a low melting point alloy so it
melts (at 1083 C) and emits
electrons by heat and electric
field.
Graphite, W, Mo emit electrons at
the temperatures below there
melting points hence are more
stable as cathode.
Operating parameters
Resistance to the flow of current is higher near the electrodes.
The voltage drop near cathode is smaller as compared to that
of anode. It helps electrons in achieving high speed to ionize
the gases near cathode.
Cathode voltage drop ranges from 12V for Cu to 25V for
graphite.
The plasma generated is at 6000 to 10,0000 C.
(+) ions and electrons (-), due to the mass difference ions move
slowly therefore, 95% of the current is carried by electrons.
The electrons and ions provide major power input to the
cathode and anode surfaces.
When the current is high, evaporation of material from anode
occurs, the stream of atoms coming out of anode surface
interferes with the electrons going to the anode.
Some ions get ionized at the near anode drop but the electrons
get additional energy to cause more vaporization of anode.
Operating parameters
Straight polarity: in which
electrode is usually a
cathode (-). Here, work
surface energy can be
controlled by controlling the
current so that anode drop
energy provides proper wear
and desired surface finish.
Reverse polarity: in which
electrode anode (+) and
work (-), in which rough cut
higher cutting rates can be
obtained with virtually no
electrode wear.
Operating parameters
Electrode rotating:
Improves flushing
difficulties with speed of
about 200 rpm max. It
provides better surface
finish.
Electrode orbiting:
Electrode does not rotate
but revolve in an orbit.
Orbiting need not be
restricted to round shape.
Both actions reduce
electrode wear as it gets
distributed uniformly.
Operating parameters
No Wear EDM: It is defined as the condition when the electrode
to work wear ratio is 1% or less.
Effect of arc duration: Melting depth is a function of arc duration
for a circular non expanding heat source.
The maximum melting depth occurs at different durations for
different materials subjected to same energy. The melting depth
reaches a peak value with an increase in arc duration, it reduces
with further increase in the arc duration.
Thus, it should be possible to choose an arc duration which
maximizes the work erosion while holding the electrode to some
lesser value.
In Cu and steel system, at the arc duration suitable for maximum
melting of steel, the melting of Cu is at the minimum.
Operating parameters
Electrode polarity: The energy distribution between anode
and cathode is a function of
ratio of electron current to ion current at cathode
Physical constant (work function) of the cathode material.
In Cu as cathode current density decreases, the electron to ion
current ratio also decreases. As the arc duration increases, the energy
delivered to the gap concentrates at the cathode. Therefore, the
electrode must be of positive duration if long arc durations are used
to achieve the no-wear condition.
As frequency increases, the depth and width of the crater becomes smaller
although the MRR may not be affected as there will be more craters per unit
time. However, frequency has a limit since initiation of spark requires certain
minimum time required for the breakdown of the dielectric. Similarly the
spark needs some time to quench. In principle, one should operate as high a
freq as possible.
Gap
Voltage
Current
Current
Gap
Voltage
Current
MRR
Accuracy & finish
Poor flow of dielectric.
Machine Construction
50
40
30
20
10
0
1
Group Number
3
Normal Discharge
Open Circuit
Abnormal Discharge
Group Number
Planetary Motion
Yes
No
No
Debris Layer
Yes
Yes
No
Input Voltage
15mV
15mV
15mV
Without
Rotation
With
Rotation
1(05A,20s), 2( 20A,350s)
Condition of Adhesion
The combined process of EDM with USM had the potential to prevent
debris accumulation, improve machining efficiency, and modify the
machined surface.
Dielectric Fluid
Functions of Dielectric Fluid
It acts as an insulator until sufficiently high potential is
reached .
Acts as a coolant medium and reduces the extremely high
temp. in the arc gap.
More importantly, the dielectric fluid is pumped through
the arc gap to flush away the eroded particles between
the work piece and the electrode which is critical to high
metal removal rates and good machining conditions.
Dielectric Fluid
Work Material Fluid Medium
Aluminum
Brass
Mild Steel
Stainless
steel
Tool steel
Tungsten
Carbide
Hydrocarbon oil
or glycerin-water
(90:10)
Mineral oil
Application
Submerged
Dielectric Fluid
Dielectric fluids: should have very high flash point and very
low viscosity.
Petroleum based hydrocarbons
Silicon fluids mixture with petroleum oils for machining of titanium,
high MRR and good SF.
Kerosene, water-in oil emulsion, distilled water.
Dielectric Fluid
Insulation and conduction: Insulating characteristic is
measured by the maximum voltage that can be applied
before ionization.
Cooling: ability to resolidify vaporized material into chips ,
thermal transfer capability.
Flushing: Sufficiently viscous to pass through a small gap
&remove debris.
Methods of fluid
application
Normal flow
Reverse flow
Jet flushing
Immersion flushing
Copper
Smooth finish
Low accuracy for holes
Zinc Alloys
Copper-Graphite
Steel
Copper Tungsten
Graphite
Copper Graphite
For rough and finish machining of WC.
Tungsten
Tungsten carbide is used for cutting steel and WC.
Small holes of deeper dimensions.
Tool
Brass
Brass
Brass
W/P
Brass
Hard C.S.
WC
rw
0.5
1.0
3.0
Advantages
Disadvantages
High specific energy consumption (about 50 times that in
conventional machining)
When force circulation of dielectric is not possible,
removal rate is quite low
Surface tends to be rough for larger removal rates
EDM process is not applicable to non-conducting
materials
Applications
Mold and die making, slowly becoming a production
process.
Machining of difficult-to-machine materials.
Miniature and fragile parts that can not withstand the force
of conventional cutting. Holes of 0.05 mm, slots of 0.3 mm
As EDM is a very slow process, it can be justified only
where the hardness is too high or the features cannot be
realized by other means.
Tool making: sharp corners, small features, deep features
etc. With the advent of hard cutting tools, full sinking is out
of fashion.
Removal of broken drills or fasteners
Deep hole drilling of small holes. Eg.: turbine blades, fuel
injection nozzles, inkjet printer head etc.
Wire-EDM
Wire EDM
This process is similar to contour cutting with a band saw.
Slow moving wire travels along a prescribed path, cutting the
work piece with discharge sparks.
Wire should have sufficient tensile strength and fracture
toughness.
Wire is made of brass, copper or tungsten. (about 0.25mm in
diameter).
Wire EDM
Process
Thin wire of as low as 0.03mm
dia is used as the tool.
For through features dies for
punching, blanking and piercing;
templates and profile gauges;
extruder screws etc.
Taper also possible
Upto 4 axes available.
Water is the common di-electric
WEDM Process
Machining of hard and complex shapes with Sharp
corners.
Risk of wire breakage and bending has undermined the
full potential of the process drastically reducing the
efficiency and accuracy of the WEDM operation
WEDM utilizes a continuously travelling wire electrode
made of thin copper, brass or tungsten of diameter 0.05
0.3 mm, which is capable of achieving very small corner
radii
The material is eroded ahead of the wire and there is no
direct contact between the workpiece and the wire,
eliminating the mechanical stresses during machining
Machining of EXOTIC and HSTR alloys
WEDM Process
The material removal mechanism of WEDM is very similar
to the conventional EDM process involving the erosion
effect produced by the electrical discharges (sparks)
The WEDM process makes use of electrical energy
generating a channel of plasma between the cathode and
anode, and turns it into thermal energy at a temperature in
the range of 800012,000 C or as high as 20,000 C
A varying degree of taper ranging from15 degree for a
100 mm thick to 30 degree for a 400 mm thick workpiece
can also be obtained on the cut surface.
The microprocessor also constantly maintains the gap
between the wire and the workpiece, which varies
from0.025 to 0.05 mm
WEDM Process
WEDM Applications
Modern tooling applications - wafering of silicon and machining
of compacting dies made of sintered carbide
For dressing a rotating metal bond diamond wheel used for the
precision form grinding of ceramics
Advanced ceramic materials other common machining
processes for machining ceramics are diamond grinding and
lapping.
Machining of boron carbide and silicon carbide
MRR and surface roughness depends on processing parameters
as well as workpiece material
Machining of naturally
non-conductor by doping with
conducting material
Machining of modern composite materials
MMC and carbon fiber polymers
Applications
END
Micro-EDM processes
71
Outline
72
70 m - Human Hair
25 m - Characters
Micro-milling
Fanuc - Japan
Zeiss - Germany
Micro-parts
Klocke Nanotechnik
Micro-Motor
Micro-EDM
NTU - Taiwan
74
Why Miniaturization?
Minimizing energy and materials used for the
manufacture of devices
Integration with electronics; simplifying systems
Cost/performance advantages
Faster devices
Increased selectivity and sensitivity
Drawback-Size effect in mechanical micromachining
75
Machining
Definition
Material removal is micro/nano level
with no constraint on the size of the
component
Unfortunately, the
present day notion is
Macro-fabrication
Hybrid
Processes
Micro-fabrication
Micro-machining
Mechanical -
machining
-nano finishing
Chem. & EC -
machining
USM
EBM
PCMM
AJM
LBM
ECMM
AWJM
EDM
WJM
IBM
PBM
Micromachining processes
Energy Used
Principle
Mechanical
Force
Melting and
vaporization
Ablation
Decomposition of atoms
using incident photon energy
or direct vaporization of
material via high energy
pulses
Solidification
Micromachining processes
Energy Used
Principle
Dissolution
Chemical or electrochemical
reaction based ionic
dissolution
Plastic
Deformation
Lamination
79
80
Resistance
Capacitance
Relaxation
(RC-
81
Micro-EDM
Circuitry Elements
RC relaxation type
Single spark process
Forced process for constant voltage
and current
User defined pulse on time
Scaling Effects
Interelectrode gap is 10s of m
Low efficiency
82
Micro-analysis of Debris
Large number of Spherical particles with few nonspherical particles
Spherical particles are rich in workpiece material and
non-spherical particles are rich in tool material
Understanding of Erosion Mechanism and Oxide free
power production
Important parameters affecting Debris morphology are
Current
Voltage
Pulse On-time
Capacitance
Input Energy
Micro-analysis of Debris
Micro analysis reveals that there is movement of material from
workpiece to cathode and vice-versa
Normal distribution of particle size (Stochastic nature)
Structures of Debris
Large Size & Small Size
Hollow & Solid Debris
Satellite structure
Hollow Spheres
Dents
Burnt Cores
Low Energy
High Energy
Group Number
Group 1
Group 2
Group 3
Planetary Motion
Yes
No
No
Yes
Yes
No
1 Low energy
2 High Energy
Variants of micro-EDM
Process
Capability
Limitation
BEDG
Micro-WEDG
Micro-WEDM
Diamond milling
Electrode
Electrode and
workpiece
preparation
Machining
Process
Off-machine electrode
preparation
Parts
Drilling,
threading
holes (WEDM)
Process
Parameters
Mfg. Micro 3D
electrode
Stationery
block
Machine
Surface
quality
Dimensions
Electrode
Electrode
wear and
machining
strategies
Guided
running wire
Uniform wear
method
Sources of
Errors
Jigs and
Fixture
On-machine electrode
Rotating Disk
Measurement
Multi
electrode
Z-compensation
Wear
monitoring
system
88
Applications
Machining of mould and die in high strength materials (Carbides,
die steel, conducting ceramics) Recently replaced by high speed
milling process
Chemical aspects of EDM
Production of fine particle powders
RESA (for ultrafine powders)- Reactive Electrode Submerged Arc EDM
Diamond like carbon and nano-tubes (solidification of evaporated
material)
Large amount of energy is consumed in the chemical action during EDM
Supplying oxygen can enhance the MRR during the process
89
Bulk Rod
Micro-rods
90
91
Applications of micro-REDM
Applications
Mechanical
MEMS
Biomedical
Micromachining
As a electrode in
arrayed
hole/cavity
machining
Mask preparation
As a tool for generating
stable plasma
Heat Exchanging
Hexagonal and thin wall
structures
Automobile
Micronozzels
92
93
94
Experiments in micro-REDM
Workpiece geometry :
Machining of 400 m square
and 200 m cylindrical
electrodes, machined length 1
mm
95
Surface Morphology
Root Surface
Sample 3
A
96
97
98