Electric Discharge Machining

P R E S E N T E D B Y,
UMA .B. S
II SEM MTECH
( 1 M S 11 M S C 0 1 3 )
D E PA R T M E N T O F M E C H A N I C A L E N G I N E E R I N G

L E C T. M R . M O H A N D A S . K . N
 Unit 2: Thermal metal removal process
2

 Principle of operation – Uma. B. S

 EDM basic circuitry – Gajaana Anne, Anand Babu

 Dielectric fluids, process parameter – Mrudula

Prashanth

 Benefits, limitations and applications - Manjunath

 Presentation Content
3

 Introduction

 Popularity of EDM

 Basic principle of EDM

 Mechanism of metal removal

Nontraditional Machining and Thermal Cutting
Processes 4
Nontraditional machining :
Material removal process- mechanical, thermal,
electrical or chemical energy
Do not use a sharp cutting tool in the conventional
sense
Thermal cutting process :
Thermal energy generally applied to a small portion of
the work surface, causing removal by erosion and/or
vaporization
Thermal energy is generated by conversion of electrical
energy
 EDM highlights
5

Energy type: Thermal

Mechanics of metal removal: Erosion and/ or vaporization

Energy source: Electric spark

Medium: Dielectric fluid

Spark Gap: 10-125µm

Maximum metal removal rate: 5*10³ mm³/min

Spark frequency: 200-500,000Hz

Peak voltage: 30-250 volts

 6

History  In1770s,
Priestly.
discovered by Joseph

 In 1943 first EDM Machine

(Lazarenko & Lazarenko)
EDM
 Developed in the mid 1970s
 In the mid 1980s, the EDM
techniques were transferred to a
machine tool
 Today, it is a viable technique that
helped shape the metal working
industry
 Popularity of EDM
7
 Electrically conductive materials

 Physical properties of w/p not a barrier

 (Hastalloys, nimonics, waspalloy) HSTR metals

 No mechanical deformation

 Surface produced – contains multitude of small craters

(helps in oil retention)

 Metal removal due to thermal effect – no bulk heating

 Process can be automated with less difficulty

 Thermal (Thermoelectric) Processes
8

 EBM - electron beam machining

 EDM - electrical discharge
machining
 EDG - electrical discharge
grinding
 EDWC - electrical discharge wire
cutting
 LBM - laser beam machining
 PAM - plasma arc machining
 Ion beam machining
 Classification
9
EDM

Sinking by EDM Cutting by EDM Grinding by EDM

Drilling Die sinking

External Form
EDM grinding
grinding
Internal
EDM
grinding
Slicing using Slicing using
Wire cutting
ribbon ribbon disc
 Terms in EDM
10

 Spark - The electrical

discharge between two
conductors
 Spark Gap - The space
between the workpiece and
the electrode at the point of
discharge
 Overcut - measurement
difference between the
dimensions of the cavity
EDMed and the dimensions
of the electrode used to cut
the cavity
Basic scheme of EDM
11
 Component of EDM system
12

 EDM system:
 A tool (electrode)
 Work piece
 A dc power supply
 Servomotor
 Dielectric fluid
 13

Detailed view of spark gap

Exact
Difficult
Machining
Overall view of workpiece and tool
 Principle of operation
12

Application of an electrical potential between tool (electrode) and

workpiece
Creation of an ionized channel
Spark
Implosion of the plasma channel
Material ejection (Erosion and/or vaporization) 14
Mechanism of metal removal
15

Diagram of electroerosive machining: (1) tool,

(2) work-piece, (3) liquid dielectric, (4) electric
discharges
 Fig A. Crater formed on the workpiece
Fig B. The finished EDM workpiece - several distinct layers
16

Fig B.
1. Layer with small globules of
removed workpiece metal and
electrode
2. the “white” or “recast” layer
Fig A. 3. Heat affected zone or annealed layer
 References
17

 Advanced Machining Processes – V. K Jain (Pg

No.,126)
 Unconventional Manufacturing process – M. K. Singh
(Pg No.,81)
 “Manufacturing science ” – Amitabh Ghosh (Pg No.,
329)
 HMT production technology
 Questions?
18

THANK YOU