Electric discharge machine (EDM)

• Inception of EDM dates back to world war I and II when B.R. and N.I.
Lazarenko invented relaxation circuit (RC).
• Since, 1940 die sinking by EDM has been refined using pulse generator,
CNC
• Extensive research in 1960’s led to use of EDM in commercial domain
• In recent times, EDM machining speed has increased by 20%, cost is
reduced by at least 30% and surface finish has improved by a factor of 15.

✓ EDM is a electro-thermal non-traditional machining process.

✓ Electrical energy is used to generate electrical spark. Material removal mainly
occurs due to thermal energy of spark
✓ EDM is used for difficult to machine material and high strength thermal
resistant alloy
✓ Work material to be machined should be thermally conductive
 Basic working principle of EDM

✓ Tool and workpiece both are good conductors of electricity

✓ Potential difference between them is applied
✓ Dielectric medium: Kerosene or deionized water
✓ Tool is cathode while workpiece is anode
✓ Voltage range: 20-120V
✓ Gap : 0.01-0.5 mm
✓ Spark frequency: 200-50,000 Hz
✓ MRR up to 300mm3/min
✓ Specific power: 10W/mm3/min
 Mechanics of material removal in EDM
Local gap varies between the tool and workpiece

At min. point (say A) sufficient electrostatic field is developed

Cold emission of electrons from cathode at A and accelerate towards anode

Electron collide with molecules of dielectric fluid, breaking them into ions

A narrow column of ionized dielectric fluid molecules is established at A connecting two electrodes

This will cause generation of spark due to avalanche of electrons

Spark led to a compression shock wave. Also, high temperature at electrodes 10k-20k oC

This high temperature causes melting and vaporization of the electrode/workpiece material
And molten metal are evacuated by a mechanical blast.
Generally wear of cathode is lower than the anode
✓ Momentum of stream hitting anode is much higher than the momentum of positive ions hitting cathode
✓ Pyrolysis of dielectric medium creates a thin film of carbon on cathode
 Dielectric fluids
• Function of dielectric fluid are to
1) Flush the eroded particle from the machining gap
2) Provide insulation between the electrode and the workpiece
3) Cool the section that was heated by the discharging effect

• Properties of dielectric should be

• Adequate viscosity
• High flash point
• Good oxidation stability
• Minimum odour
• Low cost
• Good electric discharge efficiency

Kerosene or de-ionized water is generally used as dielectric medium. Others dielectric fluid are water
in emulsion, Ehtylene glycol

Additives are used to prevent gas bubbles and de-odoriing.

EDM Electrodes
• Material with high melting point and good electrical conductivity
• Graphite is most commonly used due to good wear
characteristics, easy machinability, and small flush holes can be
drilled
• Copper has good EDM wear and better conductivity
• Copper tungsten and silver tungsten are used for making deep
slots
 Wear rate= (11𝑥103 𝑖 𝑇𝑡−2.38 ) Electrode wear
Melting point of the electrode is an important
criteria for tool wear

Various types of electrode wear

Corner wear ratios for different electrode material

(Courtesy: El-Hofy 1995)
 EDM Machine setup

Servo motor: To maintain the gap between the tool and workpiece
Power supply: Responsible for generating required pulse voltage
and current
Dielectric circulation system:
Effect of process parameters
𝑀𝑅𝑅 = (4𝑥104 𝑖 𝑇𝑤−1.23 )

I is EDM current and Tw is melting temperature of

workpiece

EDM removal rates and surface roughness for different material

Effect of pulse current (energy) on removal rate and surface

roughness
Heat affected zone

Heat affected zone of EDM

Application
EDM Die milling

Wire EDM
Power generator