MACHINING EQUIPMENT

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PRE 314
NON-TRADITIONAL PROCESSES

Production Department
3rd Year
Dr. Shokria Abbas Ahmed

LECTURE 5
ELECTRODISCHARGE
MACHINING
(EDM)
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Part 2
Process parameters
The material removal rate and surface roughness
depends on the following process parameters:
Material of workpiece,
Material of tool electrode,
Electrode polarity,
Pulse conditions (frequency, current and voltage,..)
Machining medium.
  Effect of material of workpiece on MRR and S.R.
 The materials of low melting point has high metal removal rates and hence
rougher surfaces. Typical removal rates range from 0.1 to 400 mm3. the
volumetric material removal rate given by Kalpakjain(1997):

 Removal rates and surface roughness for different materials are shown in Fig.13.

Fig. 13. EDM removal rates and roughness for different materials (El-Hofy, 1995).
  Effect of Pulse conditions on MRR and S.R.

 MRR and surface roughness increase with the increase in current during
sparking and also with the increase in spark voltage. Effect of current on
MRR is shown in Figs. 14. [Pandey and Shan, 1980].

Fig. 14. Effect of current on MRR;

dielectric is Kerosene, tool material is
brass, work material is low carbon steel
and F is the tool electrode area.
Cont.
 Pulse on-time is defined as the time during which the machining is
performed. The machining process becomes faster after increasing the
pulse on time. By increasing the pulse on time the material removal rate
increase and poor surface finish on the material surface (Lee et al., 2003).
(Fig. 15 a, b).

Fig. 15 a. Effect of pulse on-time (energy) on removal rate and surface roughness
‫‪Fig. 15 b‬‬
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Cont.
 Pulse off-time is the time during which re-ionization of the dielectric take place. As the value of
pulse off time is too shot (15µs), so there is not enough time for the flushing to clear the debris
from the inter-electrode gap between the tool and work piece, so arcing take place
which result in decreasing the MRR (Saha et al., 2009).
 An increase in spark frequency results in an improved surface finish and reduce MRR (Fig. 14
c). Since the energy available for material removal during a given period of time is shared by a
larger number of sparks, the size of the crater is reduced.

Fig. 14 c
 The inter electrode gap (12-50 µm) is determined by the gap current and gap voltage. A decrease
in the gap results in lower MRR, better surface finish, and higher accuracy.
PROCESS CHARACTERISTICS
 Accuracy
 EDM gives high degree of repeatability and high accuracy of the
order of ± 0.025 to ± 0.127 mm. It can give tolerances as good as ±
2.5µm. When deep and accurate holes are to be drilled, use of
separate tools for roughing and finishing passes is recommended so
that the taper can be minimized. Taper ranges from 0.005 to 0.050
mm/cm depending upon the values of machining parameters
employed. Aspect ratio of 100:1 during drilling of small holes can be
achieved if special care about flushing of gap is observed.
 MRR
 Volumetric material removal rate (MRRV) achieved during EDM is
quite low (0.1 to 10 mm3/min-A). Actual value of MRRV depends
upon the machining conditions employed. It can be given by the
following empirical formula:
 Surface integrity
Fig. 14,,
2. surface metallurgy (i.e. possible alterations in the surface layers
after machining). (Fig. 15).
 Surface integrity greatly affects the performance, life and reliability of the
component.
 Microscopic study of the machined components reveals three kinds of
layers, e g
1) recast layer (white layer), 2) heat affected zone (HAZ), and
3) annealed layer.

Fig. 15. EDM effect on surface integrity.

Cont.
 Re-cast layer If molten material from the workpiece is not flushed
out quickly, it will resolidify and harden (as a martensite) due to
cooling effect of the dielectric, and gets adhered to the machined
surface. This thin layer is about 2.5 to 50 µm or so. It is extremely
hard (65 HRC) and brittle. The surface is porous and may contain
microcracks. Such surfaces should be removed before using these
products.
 Heat affected zone The layer next to the recast layer is called (HAZ
which is approximately 25 µm thick). Heating, cooling and diffused
material are responsible for the presence of this zone. Thermal
residual stresses, grain boundary weaknesses, and grain boundary
cracks are some of the characteristics of this zone.
 Conversion zone (or converted layer) is identified below the HAZ
and is characterized by a change in grain structure from the original
structure.
WIRE ELECTRIC DISCHARGE MACHINING (WIRE EDM)

Fig. 15 Schematic illustration of wire electric discharge machining.

WORKING
PRINCIPLE
In wire electric discharge machining (wire EDM), a wire (about
0.05-0.30 mm diameter) is used as an electrode and deionized
water as dielectric. A nozzle is employed to inject the dielectric in
the machining area in wire EDM. Electrodes (wire and
workpiece) are connected to a pulsed DC supply. Heat generated
due to sparking results in the melting of workpiece and wire
material, and sometimes part of the material may even vaporize
like in conventional EDM. A constant gap between tool (wire)
and workpiece is maintained with the help of a computer
controlled, positioning system. This system is used to cut through
complicated contours specially in difficult-to machine materials.
This process gives a high degree of accuracy and a good surface
finish. Fig. 15 shows details of the wire EDM system.
ELEMENTS OF WIRE EDM
MACHINE

There are four basic elements of this machine tool, e g

the power supply system,
the dielectric system,
the positioning system, and
the drive system.

i. Power Supply System

Wire EDM power supply system differs from conventional
EDM power supply system basically in pulse frequency
which is about 1 MHz. It results in reduced crater size or
better surface finish. However, because of very small wire
size, it usually cannot carry current more than 20A.
 ii. Dielectric System
o Deionized water is used in most of the wire EDM systems
because of its availability, desirable thermal properties, low
viscosity, no fire hazard, high cooling rate and high MRR and
better surface finish under the identical machining conditions.
o Low viscosity helps in efficient flow while high cooling rate
yields very thin recast layer.
o Water gives high MRR and high TWR. However, wire is not
reused hence high TWR does not adversely affect the process
performance. More efficient way of dielectric delivery is to
provide a stream of deionized water along the axis of the wire.
o Cost of the dielectric can be lowered down by reusing it after
proper filtration. About 5 µm size disposable paper filters are
used. To minimize rust formation on the machined part,
special additives are mixed with it.
iii. Positioning System

Usually positioning system is a computerized numerical

control (CNC) two-axes table. However, it operates in an
adaptive control mode so that in case wire approaches very
near to the workpiece, or the gap is bridged by debris and
causes a short circuit, the positioning system should be
capable to sense it. Instantaneously, it should move back to
re-establish proper cutting conditions in the gap.
iv. Wire Drive System
 This system serves two purposes, viz
1. continuously delivers fresh wire, and
2. always keeps the wire under appropriate tension so that it
moves in the machining zone as a straight wire.
 The latter requirement is important from the point of view
of quality of the machined surface. For example, it helps
to minimize taper, streaks as well as vibration marks. It
also minimizes the “wire breaks” during machining.
 On the way while moving to the machining zone, wire is
guided by sapphire or diamond “ wire guides” . As it
moves towards the take up spool, the wire passes through
a series of tensioning rollers.
Cont.

 To enhance the productivity as well as to make the

machine to run unattended, modern wire EDM machines
are equipped with the devices which permit automatic
reloading of wire after it has broken up during its use
[Anon, Feb. 1981].
 Large diameter (0.15-0.30 mm) wires, used in wire
EDM, are made of copper or brass while small diameter
wires are usually made of molybdenum steel.
 Wire is discarded after it has been used once because the
sparking takes place at its leading surface, hence, it no
longer remains round.
PROCESS
VARIABLES

Most of the variables that control the process are

common in case of EDM die sinking as well as
wire EDM. The linear cutting rate in wire EDM is
dependent on the thickness of the workpiece but
not on the complexity of the cut. Wire speed may
be as high as 40 mm/s.
Advantages of EDM
Some of the advantages of EDM process include the
following:
oMaterials that are extremely hard can be machined to
very close tolerances.
oComplex shapes that are too difficult to be produced by
the conventional processes can be machined using the
EDM process.
oFabrication of micro featured products which could be
damaged because of the tool forces and pressure if
machined using conventional processes.
oHoles with micro dimensions and high aspect ratios can
be obtained using the EDM process
oWorkpiece material can be machined with high surface
finish.
Disadvantages of EDM
o The process is time consuming.
o Low metal removal rates compared to chip machining.
o The use of oil dielectrics can lead to fire hazard.
o Additional cost is involved for the fabrication of
consumable electrodes.
o Power and specific power consumption is very high.
o Tool wear is excessive during the machining process.
o Non-conductive materials can be machined only with
special set of machining arrangements.
o Overcut is formed.
Types of EDM machine
1. Ram EDM machines are also known as diesinkers or vertical EDMs. They
range in size from tabletop models to large CNC units. CNC ram EDM
machines have automatic tool change capability allowing long unattended
running times, use of multiple electrodes for rough and fine metal removal,
orbiting controls for cavity enlargement, and contouring capability.
2. The wire EDM process uses a consumable, electrically charged wire to effect
very fine and intricate cuts. The process is particularly useful in cutting fine
details in pre-hardened stamping and blanking dies. A wire drive system
constantly presents fresh wire to the work so electrode wear is not a problem.
Typical wire diameters range from .002 to .013 inches. These wires will
produce
a kerf slightly larger than their own diameter. A .012 wire will leave a .015
kerf, just .003 inches larger. Wire EDM’s can run for long periods without
operator attention.
3. Hole drilling EDM is designed for drilling small, but very deep holes. These
holes may have a depth-to-diameter ratio of 30 to 1 or higher. Tubular
electrodes up to a foot long are rotated at speeds of about 100 RPM while
drilling. As the electrical discharges occur, this rotation aids in flushing and
provides for uniform electrode wear.
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Applications for EDM
The process can be used economically for the following
applications on workpieces, which are good conductors of
electricity:
For machining dies for moulding, casting, forging,
coining, stamping, extruding, header, wire drawing,
blanking, etc.,
For drilling fine deep holes (aspect ratio > 30) such as in
fuel injector nozzles or drilling of fine deep holes through
hardened ball bearing.
For machining hydraulic valve spools.
For slitting of hard alloys.
For manufacture of fragile components which cannot be
machined by conventional processes due to high tool
forces.
Cont.
 For milling of heat treated materials such as tool steels.
EDM allows tool steels to be treated to full hardness
before machining, avoiding the problems of dimensional
variability which are characteristic of post treatment.
 For EDM of advanced ceramics.
 For machining of metal matrix composites (MMC) and
particle reinforced MMC (PRMMC)
 Micro-EDM is capable of not only micro-holes and
micro shafts as small as 5µm in diameter but also
complex 3D micro cavities.
 Removal of broken taps, drills, studs, reamers, pins etc.
Types and some applications are shown in Figs 16 to 25.
Fig. 16.
Fig. 15.
Fig. 16.
Fig. 17.
Fig. 18.
Fig. 19.
Fig. 20.
Fig. 21.
Fig. 22.
Fig. 23.
Fig. 24.
Fig. 25