ELECTRICAL DISCHARGE MACHINING

INTRODUCTION
Most extensively used non-conventional material removal process. The concept of erosive effect of electrical discharge or sparks was introduced by Joseph Priestly in 1770. The first EDM system was developed by Lazarenko and Lazarenko.

BASIC PRINCIPLE OF OPERATION

Melting and vaporization

EDM

1. Electrical energy turned into thermal energy through a series of discrete electrical discharges occurring between the electrode and workpiece immersed in a dielectric fluid. 2. The thermal energy generates a channel of plasma between the cathode and anode. 3. Its temperature range-8000 to 12,000 C or as high as 20,000 C initializing a substantial amount of heating and melting of material at the surface of each pole

COMPONENTS OF EDM

EDM CIRCUIT

EDM CIRCUITS
1. R C Pulse Discharge circuit

2. R C Relaxation circuit

Various relations & equations

As is clear from circuit dia above V, the voltage across the gap varies according to the relation

t = time when the voltage reaches value V R = Resistance C = Capacitance Vo= Maximum voltage

 If the tool-work gap and dielectric are such that a spark occurs at a voltage Vd a spark will occur and since the discharge time is very less compared to charging time, the frequency of sparking is given as

The energy released per spark is given by

If tc is the cycle time the average value of power is

 If u assume that the material removed per spark is then mrr is given as

For maximum power delivery prove that the discharge voltage should be 0.72 times the peak voltage?

PROB LEM
During EDM of a 5mm dia circular hole in CBN plate of 5mm thickness, brass tool and kerosene are used. The resistance and capacitance in the relaxation circuit are 40 and 20F. The supply voltage is 200V and gap is maintained such that maximum power is delivered during discharge. Estimate the time required to complete the drilling operation. Assume 70% of the power is used in material removal?

EDM Tools
Tool electrode is the means to provide electrical energy to the work material as well as necessary form to the latter. Basic desirable characters of tool material:I. High thermal conductivity II. High electrical conductivity
III. High melting point to reduce its wear rate. IV. Cheapness V. Ease to manufacture

Types of electrodes
In general electrodes are classified into four groups:
i. ii. iii. iv. Metallic electrodes Non-metallic electrodes Combined metallic & nonmetallic Metallic coating on insulators

The most commonly used materials are Brass, Copper, Graphite, Al alloys, Cu-W alloys & Ag-W alloys.

TOOL WEAR
The most important problem related with EDM machining. Factors affecting it are:
i. ii. iii. Polarity of electrode Discharge energy Pulse on time

DIELECTRIC FLUIDS
Basic requirements are:i. ii. iii. iv. v. Low viscosity Absence of toxic vapours Chemical neutrality Absence of inflaming tendency Low cost.

Wire-cut EDM (WEDM)

Able to machine conductive, exotic and high strength and temperature resistive (HSTR) materials with the scope of generating intricate shapes and profiles.

WEDM

WEDM Setup
A continuously travelling wire electrode made of thin copper, brass or tungsten of diameter 0.050.3 mm, which is capable of achieving very small corner radii. The wire is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. The material is eroded ahead of the wire and there is no direct contact between the work piece and the wire, eliminating the mechanical stresses during machining.

Small Hole EDM

An improved method of utilizing EDM to drill small holes in conductive material at speeds 10 times faster than those achieved with conventional Sinker EDM.

 Small Hole EDM- the third method of EDM Machining along with Sinker EDM and Wire EDM.

The essential elements of Small Hole EDM are: a) Rotating tubular electrode between .1mm and 6mm in diameter b) High pressure flush through the electrode of at least 600 psi c) Water dielectric d) Guide bushing for electrode just above the work piece surface

Recent Developments in EDM

The recent developments in the field of EDM is its extensive application in micromachining Micro-EDM is the most extensively used micromachining technique due to the following reasons:
1. Non contact machining 2. 3D machining 3. Any material irrespective of its hardness can be machined

EDM VS MICRO EDM

EDM Constant current and gap voltage throughout the discharge Inter electrode gap is 10s of m. User defined pulse on time The precision in the table feed axis in the range of few hundred microns MICRO EDM Variable current and gap voltage throughout the discharge The inter electrode gap is 1 5 m. Pulse on time is not constant. Depends on initial voltage and capacitance The precision in the range of few microns

Whats here at NITC

Machine Accuracy : Resolution : 0.1 m (100nm) Accuracy : +/- 1 m/100mm Repeatability : 1m for all axes

ADVANTAGES OF EDM
Can produce complex shapes
Machine extremely hard material to very close tolerances Very small work pieces where conventional cutting tools may damage the part from excess cutting tool pressure.

CONT..
There is no direct contact between tool and work piece. Therefore delicate sections and weak materials can be machined without any distortion. A good surface finish can be obtained.

Very fine holes can be easily drilled.

DISADVANTAGES OF EDM
The slow rate of material removal.
The additional time and cost used for creating electrodes for ram/sinker EDM. Reproducing sharp corners on the workpiece is difficult due to electrode wear. Specific power consumption is very high.

CONT.
Power consumption is high. "Overcut" is formed. Excessive tool wear occurs during machining.

Electrically non-conductive materials can be machined only with specific set-up of the process

INNOVATIVE EDM TECHNOLOGIES

1. Electrical discharge coating and alloying 2. Coloring of Titanium alloy using WEDM process 3. Dry EDM

Electrical discharge coating and alloying

White layers formed on steel work piece during EDM using hydrocarbon dielectric absorb Carbon from discharge gases.

This carbon content (more than the base material ) shows more resistance to abrasion, corrosion

Coloring of titanium alloy using WEDM process Deionized water is normally used in WEDM, resulting in an oxide layer over the surface of the anode work piece due to electrolysis. Surface can be colored by anodic oxidation due to the interference of light in the oxide film

DRY EDM
A high velocity gas flow is supplied through a thin-walled pipe electrode. During the pulse interval, the gas jet blows off the plasma formed by previous pulse discharge and decreases the temperatures of the discharge spots. Environmentally clean process