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Electrical Discharge Machining

Objectives
Understand the principle, capabilities of EDM. Understand material removal mechanism in EDM.
Identify different subsystems of EDM system. Identify the process parameters & purpose of
dielectric fluid in EDM. Analyses the required properties of EDM tool. Develop models for
material removal rate in EDM. Analyses the effect of process variables on MRR.

Introduction
Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining process,
where material is removed by controlled erosion through a series of electric sparks. EDM is used
to produce very small and accurate parts as well as large items like automotive stamping dies and
aircraft body components. The largest single use of EDM is in die making. Materials worked with
EDM include hardened and heat-treated steels, carbide, polycrystalline diamond, titanium, hot
and cold rolled steels, copper, brass, and high temperature alloys. However, any material to be
machined with the EDM process must be conductive.

Process

Schematic representation of the basic working principle of EDM process.

In EDM, The tool and the work material (both conductor of electricity) are immersed in a
dielectric medium & a potential difference is applied between the tool and workpiece. Generally
kerosene or deionised water is used as the dielectric medium. A gap is maintained between the
tool and the workpiece. When a suitable voltage is built up across the gap, an electrostatic field of
sufficient strength is established causing cold emission of electron from cathode (tool). The “cold
emitted” electrons are then accelerated towards the anode (job) through the dielectric medium. As
they gain velocity and energy, and start moving towards the job, the electrons collide with
dielectric molecules, breaking them into positive ions & electrons. Thus, 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. Ultimately a narrow column of electrons will flow from the
tool to the job, (avalanche of electrons) and ions from the job to the tool. Such movement of
electrons and ions can be visually seen as a spark, as conductivity of ionised column is very large.
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 temperature rise which
o
would be in excess of 10,000 C. Such high temperature leads to material removal due to instant
vapourisation of the material as well as due to melting. The molten metal is not removed
completely but only partially. As the potential difference is withdrawn as shown in Fig. 1, plasma
channel collapse, & it generates pressure or shock waves. These compression shock waves
evacuate the molten material forming a crater of removed material around the site of the spark.
Similarly, the positive ions impinge on the tool leading to tool wear. For uniform distribution of
material removal sparking is used. To apply voltage pulses between tool & the job, for sparking
generator is used in EDM .for maintaining a predetermined spark gap; a servo control unit is
generally used.

Process Parameters
The process parameters in EDM are mainly related to the waveform characteristics. Fig. 2 shows
a general waveform used in EDM.

• The open circuit voltage - V


o
• The working voltage - V
w
• The maximum current - I
o
• The pulse on time – the duration for which the voltage pulse is applied - T
on
• The pulse off time - T
off
• The gap between the workpiece and the tool – spark gap - δ
• The polarity – straight polarity – tool (-ve)
• The dielectric medium
• External flushing through the spark gap.

Dielectric

In EDM, material removal mainly occurs due to thermal evaporation and melting. As thermal
processing is required to be carried out in absence of oxygen so that the process can be controlled
and oxidation avoided. Hence, dielectric fluid should provide an oxygen free machining
environment. Further it should remain electically nonconductor until the breakdown voltage
reached, but at the same time breakdown electrically in shortest possible time at breakdown
voltage. Moreover, rapidly quench the spark gap after discharge. Generally kerosene and
deionised water is used as dielectric fluid in EDM. It is also a must that the carbon particle
produced during erosion should be cleared from the sparking zone with Dielectric. For that
dielectric medium is generally flushed around the spark zone. It is also applied through the tool to
achieve efficient removal of molten material. The dielectric should be filtered before reuse. A
well designed dielectric system to give trouble free circulation of dielectric consists of pump,
valves, filters & drain

Electrode (tool)

There is a physical tool & geometry of the tool is positive impression of geometry feature to be
machined. The Electrode material should be such that it would not undergo much tool wear when
it is impinged by positive ions. When temperature increases, there would be less melting. Further,
the tool should be easily workable as intricate shaped geometric features are machined in EDM.
Thus the basic characteristics of electrode materials required are: high electrical conductivity,
high thermal conductivity, higher density, high melting point, easy manufacturability, cheap.
The followings are the different electrode materials which are used commonly in the industry:
• Graphite
• Copper
• Tungsten copper (Aconite)
• Brass

Spark generator

Wave form used in EDM

Different power generators are used in EDM and some are listed below:
• Resistance-capacitance type (RC type) Relaxation generator
• Rotary impulse type generator
• Electronic pulse generator
• Hybrid EDM generator

Pulse / fine generator


The controller supplies electrical energy to the spark gap in form of Square wave pulses.
Precision timing & control of the pulses in the spark controller results in stable sparking
(machining). The controller works on 415 V AC, 3 Phase, and 50 Hz power supply. Various
parameters can be controlled from the control panel for eg. Pulse duration T on & T off, Sparking
current, feed, speed, mode of flushing etc. it controls :
• Consistent sparking in low and high frequency operations.
• Auto lift of electrode at adjustable timing
• Stepper motor drive for rapid movement in manual mode & controlled speed in sparking
mode.
• Gap sense facility
• Zero setting, position of electrode & precise depth setting.
Servo control
During machining as material is removed gap between tool & work piece increases. For
maintaining the predetermined spark gap servo control unit is used. The gap is sensed through the
average voltage across it & this voltage is compared with the preset value .The difference is used
to control servomotor.

Equipment
EDM machine has the following major subsystems
• 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

Procedure
¾ First of all mount of work piece on work table, workpiece material is
____________________.
¾ Electrode clamping on quill, electrode material is ______________________
¾ Alignment of electrode & workpiece.
¾ Before switching mains on checking of all the subsystems of EDM is working properly or
not.
¾ Priming of pump, if pump not getting started.
¾ Once all subsystems are working properly, press mains on.
¾ Manually move the quill down and keep some distance between electrode & workpiece ,
manual movement is obtained with the help of switch provided on quill.
¾ Turn auto mode on, press autopos on , LED glows and electrode comes down.
¾ When electrode touches job, buzzer starts & electrode goes up by sense pot.
¾ Press pump switch on, indicator on.
¾ Pump motor starts, dielectric fluid flows in tank.
¾ Control its flow & hence level in dielectric tank with the help of flow control valves.
¾ Press erosion on switch, if erosion indication on voltage is shown.
¾ Electrode comes down, sparking takes place.
Modeling of Material Removal and Product Quality
Material removal in EDM mainly occurs due to intense localised heating almost by point heat
source for a rather small time frame. Such heating leads to melting and crater formation as shown
in Figure

Schematic representation of crater formation in EDM process.

The molten crater can be assumed to be hemispherical in nature with a radius r which forms due
to a single pulse or spark. Hence,

Γ S= 2/3πr3

The energy content of a single spark is given as,

ES= VIT
on
A part of this spark energy gets lost in heating the dielectric, and rest is distributed between the
impinging electrons and ions. Thus the energy available as heat at the workpiece is given by

E ∞ E
W S

E = KE
W S
Now it can be logically assumed that material removal in a single spark would be proportional to
the spark energy. Thus

Γ S ∞ EW ∞ E
S

Γ S = g ES

Now material removal rate is the ratio of material removed in a single spark to cycle time.
Thus
ΓS ΓS
MRR = ---------------- = ------------------------
Tc T on + T off
V I T on
MRR = g ---------------
Ton + T off

The model presented above is a very simplified one and linear relationship is not observed in
practice. But even then such simplified model captures the complexity of EDM in a very efficient
manner. MRR in practice does increase with increase in working voltage, current, pulse on time
and decreases with increase in pulse off time.

Observation table
T on
Duty Factor = --------------- * 100
Ton + T off

Effect of Duty Factor (on time) on MRR

Current ____________________Open Circuit Voltage______________________

T off ________________________________

Actual Theoretical
SR. No. Ton Duty Factor % MRR MRR
Effect of Duty Factor (off time) on MRR

Current ____________________Open Circuit Voltage______________________

T on ________________________________

Actual Theoretical
SR. No. T off Duty Factor % MRR MRR

Effect of open circuit Voltage on MRR

Current ____________________ T off ______________________

T on ________________________________

Actual Theoretical
SR. No. Voltage MRR MRR
Effect of Ampere on MRR:

T off ____________________Open Circuit Voltage______________________

T on ________________________________

Actual Theoretical
SR. No. Ampere MRR MRR

Conclusion

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