IPE 3105

Modern Machining Process

ELECTRICAL DISCHARGE MACHINING (EDM)

Sheikh Salman
Lecturer, MPE, AUST
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EDM

• Electrical or Electro Discharge (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.
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EDM
nickel-chromium-iron A austenitic nickel-
molybdenum alloy; chromium-based
1 Work material to be machined
combines goodby superalloy; well suited
EDM has to be electrically conductive.
oxidation
resistance, high-temperature for service in extreme
strength and exceptional environments subjected
stress-corrosion resistance to pressure and heat.

2 Mainly used to machine difficult-to-machine materials and high strength

temperature resistant alloys like- titanium, hastelloy, kovar, & inconel.

nickel–cobalt ferrous
alloy; it allows a tight
3 Sometimes it is referred to as “spark machining”, because it removes metal
mechanical joint between
by producing a rapid
theseries of repetitive
two materials electrical
over a discharges.
range of temperatures
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Major Components Of EDM

The main components of EDM are-

1 Electric power supply

2 Work piece & tool

3 Dielectric medium

4 Servo control unit

Schematic diagram of EDM process
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Working Principle
A potential difference is applied between the tool and workpiece.
Both the materials should be conductors of electricity

Tool and the work material are immersed in a dielectric medium -

kerosene or deionized water

A gap is maintained between the tool and the workpiece

An electric field is established depending upon the applied potential

difference and the gap between the tool and workpiece
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Working Principle
The tool is connected to the negative terminal (cathode) & the
workpiece is connected to the positive one (anode)

The free electrons on the tool are subjected to electrostatic forces due
to the electric field established between the tool & job

Due to the thermal energy produced, electrons are emitted from the
tool; such emission are termed as ‘cold emission’

The “cold emitted” electrons are then accelerated towards the job
through the dielectric medium
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Working Principle
When the potential difference (voltage) across the gap becomes
sufficiently large, the dielectric fluid becomes ionized

The ionized dielectric fluid breaks down to produce an electrically

conductive spark channel

Due to the transferred heat, current is discharged across the channel

in the form of a spark

When the voltage drops to about 12 volts, the spark discharge

extinguishes and the dielectric fluid once again becomes deionized
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Working Principle
The spark occurs in an interval of from 10 to 30 microseconds and
with a current density of approximately 15-500 amp/mm2

The repetitive sparks release their energy in the form of local heat &
local temperature of 12000°C is reached at the spot hit by electrons

At such a high pressure and temperature some metal is melted and

eroded

Some of it is vaporized and fine material particles are carried away

by dielectric medium, forming a crater on the workpiece
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Working Principle

EDM spark description

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EDM

Schematic diagram of experimental set-up for EDM process

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EDM

https://www.youtube.com/watch?v=L1D5DLWWMp8&t=2s
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Mechanism of Material Removal

For a particular machining

condition there are numerous
phenomena involved, i.e., heat
conduction and radiation, phase
changes, electrical forces, bubble
formation and collapse, rapid
solidification etc.

Thermo-electric phenomenon is the most appropriate theory for the

explanation of the electrical discharge machining process!!
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Mechanism of Material Removal

The material removal rate depends on the following factors:

1 Peak amperage or intensity of the spark

2 Length of the ON time

3 OFF time influences the speed and stability

4 Duty cycle: percentage of on-time relative to total cycle time

5 Gap distance: better accuracy and higher material removal rate for smaller gap
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Material Removal Rate

• In EDM the metal is removed from both the workpiece and the tool electrode.
• A material of low melting point has a high metal removal rate and hence a rougher surface.

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

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Material Removal Rate

The material removal rate, or volumetric removal rate (VRR), in mm3 /min, was described by
Kalpakjian (1997):

𝑽𝑹𝑹 = 𝟒 × 𝟏𝟎𝟒 𝒊 𝑻𝒘 −𝟏.𝟐𝟑

Where,
i = EDM current (A)
Tw = melting point of the workpiece material (°C)
EDM removal rates and roughness for different
materials (El-Hofy, 1995)
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Modeling of MRR
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Modeling of MRR
• 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 material removal in a single spark can be expressed as

2 3
Ґ𝑠 = 𝜋𝑟
3
E = QΔV
• The energy content of a single spark is given as
𝐸𝑠 = 𝑉𝐼𝑡𝑜𝑛
• 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
𝐸𝑤 ∝ 𝐸𝑠
» 𝐸𝑤 = 𝑘𝐸𝑠
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Modeling of MRR
• Now it can be logically assumed that material removal in a single spark would be proportional
to the spark energy. Thus
Ґ𝑠 ∝ 𝐸𝑠 ∝ 𝐸𝑤
⸫ Ґ𝑠 = 𝑔𝐸𝑠
• Now material removal rate is the ratio of material removed in a single spark to cycle time. Thus

Ґ𝑠 Ґ𝑠
𝑀𝑅𝑅 = =
𝑡𝑐 𝑡𝑜𝑛 + 𝑡𝑜𝑓𝑓

𝑉𝐼𝑡𝑜𝑛 𝑉𝐼
𝑀𝑅𝑅 = 𝑔 =𝑔 𝑡𝑜𝑓𝑓
𝑡𝑜𝑛 + 𝑡𝑜𝑓𝑓
1+ 𝑡
𝑜𝑛
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Surface Integrity
• The spark-machined surface consists of a multitude of overlapping craters that are formed by the
action of microsecond-duration spark discharges.
• These craters depend on the physical and the mechanical properties of the material and the
composition of the machining medium as well as on the discharge energy and duration.
• The depth of the resulting craters usually represents the maximum surface roughness 𝑅𝑡 . The
maximum depth of the damaged layer can be taken as 2.5 times the average surface roughness 𝑅𝑎 .

• The average roughness can be expressed in terms of pulse current 𝑖𝑝 (A) and pulse duration 𝑡𝑝 (μs) by

𝑅𝑎 = 0.0225 𝑖𝑝 0.29 𝑡𝑝 0.38

• Surface roughness increases linearly with an increase in the material removal rate.
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Heat-affected Zone (HAZ)

• With the temperature of the discharges reaching 8,000 to 12,000°C, metallurgical changes occur
in the surface layer of the workpiece. Additionally, a thin recast layer of 1 μm at 5 μJ powers to 25
μm at high powers is formed.

• Some annealing of the workpiece can be

expected in a zone just below the machined
surface.
• The remaining melted material is quickly
chilled, primarily by heat conduction into
EDM heat-affected zones
the bulk of the workpiece, resulting in an
exceedingly hard surface.
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Process Parameter & Performance Measure

EDM Process

Process Parameters Performance Measures

Electrical Non electrical

1. MRR
2. TWR
1. Peak Volatge
1. Flushing
2. Peak Current
2. Electrode MRR – Material Removal Rate
3. Pulse Duration
Rotation TWR – Tool Wear Rate
4. Polarity
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Process Parameter
The process parameters in EDM are mainly related to the waveform
characteristics!!

Waveform used in EDM

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Process Parameter
The waveform is characterised by the
• The open circuit voltage - Vo
• The working voltage - Vw
• The maximum current - Io
• The pulse on time – the duration for which the voltage pulse is applied - ton
• The pulse off time - toff
• The gap between the workpiece and the tool – spark gap - δ
• The dielectric medium
• External flushing through the spark gap.
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Dielectric Fluids

Flush the eroded particles from the machining gap

Provide insulation between the electrode and the workpiece

Cool the section that was heated by the discharging effect

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Dielectric Fluids
Thermal Surface Dielectric
Evaporation Conductivity Resistance

Material removal mainly

Oxidation often leads to
occurs due to thermal Further, it should have
poor surface conductivity
evaporation and melting. enough strong dielectric
(electrical) of the
As thermal processing is resistance so that it does
workpiece hindering
required to be carried out not breakdown electrically
further machining. Hence,
in absence of oxygen, so too easily but at the same
dielectric fluid should
that the process can be time ionize when electrons
provide an oxygen free
controlled and oxidation collide with its molecule.
machining environment.
avoided.
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Electrode
Electrode material should be such that it would not undergo much tool wear when it is impinged
by positive ions. Further, the tool should be easily workable as intricate shaped geometric features
are machined in EDM.

Commonly used electrode material in the industry:

➢ Graphite

➢ Electrolytic oxygen free copper

➢ Tellurium copper – 99% Cu + 0.5% tellurium
➢ Brass

Different types of electrode

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Electrode - Basic characteristics

High electrical conductivity

High thermal conductivity

Higher density

High melting point

Easy manufacturability

Low cost or cheap & availability

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Electrode

https://www.youtube.com/watch?v=9oPmFb4liVM
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Tool Wear Ratio

One of the major draw back of EDM is the wear ratio of the tool!!

𝐿𝑜𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑖𝑛 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑡𝑖𝑚𝑒

𝑊𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 =
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑚𝑒𝑡𝑎𝑙 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑤𝑜𝑟𝑘 𝑎𝑡 𝑡ℎ𝑒 𝑠𝑎𝑚𝑒 𝑡𝑖𝑚𝑒

✓ The less the wear ratio, the better it is!

Brass electrode 1:1

Metallic electrodes 3:1 or 4:1
Graphite 5:1 upto 50:1
(with the highest melting point, 3500°C)
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Tool Wear
• The melting point is the most important factor
in determining the tool wear.
• Electrode wear ratios are expressed as end
wear, side wear, corner wear, and volume wear.
• The wear rate of the electrode tool material Wt
and the wear ratio R w , described by Kalpakjian
(1997), are:
−2.38
𝑊𝑡 = 11 × 103 𝑖 𝑇𝑡

𝑅𝑤 = 2.25 𝑇𝑟 −2.3
Types of electrode wear in EDM
(Metals Handbook, 1989)
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Tool Wear

Where,
𝑊𝑡 = wear rate of the tool, mm3 /min
i = EDM current, A
𝑇𝑡 = melting point of the tool electrode, °C
𝑇𝑟 = ratio of the workpiece to tool electrode
melting points

Corner wear ratios for different electrode

materials (El-Hofy, 1995)
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Design Considerations
• Product quality issues in EDM are: Surface finish,
Overcut, Taper cut.
• Parts should be designed in this manner that the
required electrodes can be shaped properly and
economically.
• Deep slots and narrow openings should be avoided.
• For economic production, the surface finish specified
should not be too fine. Schematic depiction of taper cut and over
cut and control of taper cut
• To achieve a high production rate, the bulk of material
removal should be done by conventional process.
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Wire EDM (WEDM)

• Also known as wire-cut EDM and wire cutting.
• A thin metallic wire (typically 0.20 mm for finish cut, 0.30 mm for rough cut) is fed on-to the
work piece, submerged in a tank of dielectric fluid such as de-ionized water.

Schematic diagram of WEDM process

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Wire EDM (WEDM)

The wire-cut EDM Erosion of the metal

uses a very thin wire utilizing the
0.02 to 0.3 mm in phenomenon of
diameter as an spark discharge is the The prominent
Machines a feature of a moving
electrode very same as in
workpiece with wire is that a
conventional EDM
electrical discharge complicated cutout
like a band saw by can be easily
moving either the machined without
workpiece or wire using a forming
electrode
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Wire EDM (WEDM)

Wire-cut EDM machine basically consists of:
• A machine proper composed of a workpiece contour movement control unit (NC power
supply which applies electrical energy to the wire electrode)
• Workpiece mounting table and wire driver section for accurately moving the wire at constant
tension.
• A unit which supplies a dielectric fluid (distilled water) with constant specific resistance.
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Wire EDM (WEDM)

The various features of wire EDM process are:
▫ Electrode wear is negligible
▫ Machined surfaces are smooth
▫ Geometrical and dimensional tolerances are tight
▫ Relative tolerance between punch and die is extremely high and die life is extended
▫ Straight holes can be produced to close tolerance
▫ EDM machine can be operated unattended for long time at high operating rate
▫ Machining is done without requiring any skill
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Wire EDM (WEDM)

https://www.youtube.com/watch?v=pBueWfzb7P0
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MRR - WEDM

𝑴𝑹𝑹 = 𝑽𝒇 × 𝒉 × 𝒃

Where,
Slot, b = dw + 2s

𝑉𝑓 = Feed rate of wire into the w/p (mm/min)

h = Thickness of the w/p
dw = Wire diameter (mm)
s = Spark Gap between wire and w/p
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Example - WEDM
• Given,

h = 300 mm; rough cut; 𝑉𝑓 = 0.5 m/min; s = 0.27 mm.

Calculate MRR.
• Here,
for rough cut, 𝑑𝑤 = 0.3 mm
So, MRR = 0.5 × 1000 × 300 × [0.3 + (2 × 0.27)] = 126,000 𝐦𝐦𝟑 /min
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Die-Sinker EDM
• Die-Sinker EDM is known by Ram EDM, sinker EDM, vertical EDM or plunge EDM.
• Generally used for producing blind cavities.
• In die-sinker EDM, the electrode and work piece are submerged in an insulating liquid
such as oil or other dielectric fluids.
• The electrode and work piece are connected to a suitable power supply through which
an electrical potential is generated between the tool and the work piece.
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Die-Sinker EDM
• As the electrode approaches work piece, the dielectric break down starts taking place in the fluid.
Due to this activity, a plasma channel starts forming and sparks jump from the electrode to the work
piece leading to material removal from the work piece.

Principle of Die-Sinking EDM

Schematic of Die-Sinking EDM
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Die Sinking EDM

https://www.youtube.com/watch?v=VeHmgG4LoM0
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Other EDM Processes

• EDM Drilling
• EDM Grinding
• EDM Sawing
• Micro EDM, etc.

ED sawing schematic

Micropin
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Advantages
• Materials, regardless of their hardness, strength, toughness and microstructure can be
easily machined
• The tool (electrode) and work piece are free from cutting forces
• Edge machining and sharp corners are possible
• Good accuracy and repeatability are attainable
• Cavities with thin walls and fine features can be produced
• Burr-free process
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Limitations
• Material removal rates are low, making the process economical only for very hard and
difficult to machine materials.
• Recast layers and micro cracks are inherent features of the EDM process, thereby
making the surface quality poor.
• The EDM process is not suitable for non-conductors.
• Rapid electrode wear makes the process more costly.
• The surfaces produced by EDM generally have a matt type appearance, requiring
further polishing to attain a glossy finish.
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Applications
• Hardened steel dies, stamping tools, wire drawing and extrusion dies, header dies, forging dies,
intricate mold cavities can be made
• Widely used in aerospace and automotive industries.
• Well suited for making fragile parts which cannot take the stress of machining. The parts that fit
such profiles include washing machine agitators; electronic components, printer parts and
difficult to machine features such as the honeycomb shapes.
• Cavities, slots and ribs can be easily made.
• Micro-EDM process can successfully produce micro-pins, micro-nozzles and micro-cavities.
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Commercial EDM
• 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
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