5.

1 Abstract:
The experiment was performed to study machining with Electric Discharge Machine(EDM), it’s
working principle and to discuss its various performance factors including its application and
sustainability. Electric Discharge Machining (EDM) is a method of the fabricating and shaping
metals by using the electric discharges. The machine works by creating a voltage difference in
which the instrument acts as the positive electrode and the work piece acts as cathode. Kerosene
oil is used as electrolyte. After filling the tank to required level of kerosene oil, a particular
voltage and current value is provided by the control unit. The substance melts by the spark
produced due to potential difference. EDM is highly accurate and no after-machining is required.
There are three different types of EDM: Wire-Cutting, Hole-drilling, and Sinker EDM.

5.2 Procedure:
• The worktable guard door was opened, and fixing-magnet pedestal was placed.
• The tool part was attached to electrode. It was made sure that base of tool part was clean
and carbon-free to ensure proper electrical contact and to avoid any unexpected breaks in
the operation.
• The oil valve was opened, and worktable was allowed to fill with kerosene oil until work
piece was submerged in it i.e. top of work piece is 50mm below the oil surface. This was
done to ensure that no oxygen contacts the discharge region and avoid any chances of
oxidation and fire.
• The input was fed into control unit. Mostly Z-axis feed was used as we were performing
a die sinking operation. Feed can also be given manually using feed control wheels with
an accuracy up to 0.02 mm.
• Operation was started with a switch at bottom of control panel.
• On completion of the operation, oil was drained using drain valve. Machine was turned
off and the pedestal was removed.

5.3 Discussions:
Electric Discharge Machining is a manufacturing process with the ability to machine any
conductive material regardless of mechanical property. It is a thermoelectric process used to
remove metal via a series of discrete sparks between the metal and workpiece. This method is
extensively used in for precise cutting of metals into desired shapes. It has a major advantage in
cutting the hard metals with high precision that can be exceedingly difficult if traditional
machining techniques are used. The hardened metals like steel and any alloys can be machined
by EDM. The only requirement for the working of this method is the tool and the workpiece
must be conductors of electricity. The most intricate cavities can be machined without the need
to preheat the metals. In EDM an electric spark is used as the cutting tool to cut (erode) the
workpiece and produce the finished part to the required shape. Electricity flows through the
electrode in the form of a square wave attacking the points of least resistance on the workpiece.
Working Principle of EDM:
The working principle of the EDM is based on the removal of material by electric discharge
between two electrodes.

• The tool behaves as a positively charged electrode.

• The workpiece behaves as an oppositely charged electrode.
• Both the workpiece and the tool are submerged in the dielectric fluid.
• A small gap exists between the workpiece and the tool.
• The discharge occurs as the tool and workpiece are about to make contact which
produces thermal energy and thus melts or evaporates the material from the workpiece
leaving a mark.
• The tool keeps moving into the workpiece and thus removing the material continually.

Relationship of Discharge, Current and Frequency with Surface Finish:

The electrical spark that erodes the material from workpiece is called discharge in EDM. The
size and duration of discharge affect the surface finish of the workpiece. A longer discharge time
and a larger discharge energy leads to a rougher surface finish, while a shorter discharge time and
lower discharge energy result in a smoother surface finish.
The current in EDM is the amount of electrical current passing through the electrode and the
workpiece. The size and intensity of electrical discharge is affected by current which in turn
affects the surface finish of the workpiece. A higher current result in a larger and more intense
discharge, which leads to a rougher surface finish. On the other hand, a lower current result in a
smaller and less intense discharge, which leads to a smoother surface finish. Also, the material
removal rate of the workpiece can be increased by increasing the gap current as more material is
melted and removed by increasing current. The input voltage available for EDM also affects the
machining as the transformer in EDM decreases the voltage and increases the amperes of current
to perform better cutting. The proper choice of electrode is also necessary as the electrode erodes
during the sparking and the material removes from it causing wear on tool electrode. So hard
materials like steel or tungsten electrodes are the best choices for the machining in EDM.

Rate at which electrical discharges occur is called Frequency of EDM. By controlling the density
and distribution of electrical discharges, surface finish of workpiece is affected by frequency. A
higher frequency leads to a more uniform distribution of the electrical discharges, which results
in a smoother surface finish. Conversely, a lower frequency results in a less uniform distribution
of the electrical discharges, which leads to a rougher surface finish

Types of EDM:
There are three types of EDM: Wire-Cutting, Hole-Drilling and Sinker
In Wire-Cutting EDM, a wire is used as the cutting electrode in the machine. The wire is
constantly provided from a mechanism of spools to the EDM. The wire cuts the workpiece by
discharging and evaporates. More wire takes its place and thus the cutting continues. It can be
used to remove the material from the side of the workpiece as well as the middle of the
workpiece. The v wire cut EDM provides high feed rate and exceptionally fine surface finish of
the manufactured part. The dielectric can be deionized water in wire cut EDM.

In Hole-Drilling EDM, , the tool used to cut through the workpiece is a tubular electrode. The
electrode cuts though the workpiece providing a fine cut. The holes machined by hole drilling
EDM do not require surface finishing or deburring afterwards. The method can be used to
machine very deep holes in the workpiece. The di-electric is fed though the electrode for the
cutting process. The holes can be drawn with extensive accuracy in even the hardest metals by
this technique. The electrode is usually brass or copper in this machining.

In Sinker EDM, the tool electrode is of the shape of the negative of the part that is to be
manufactured in the workpiece. The manufactured die is then used as the tool and provided the
electric charge. This die then performs the cutting of the workpiece. It sinks into the workpiece
removing the material at the area of contact. The dielectric used in this is kerosene oil. It is
important to note that the negative of the die is machined on the workpiece by this method. The
die must be manufactured beforehand so it can be fixed on the tool post to convert it into an
electrode.
Pros and Cons:
The process can be used to cut, drill, or shape a wide range of materials, including metals,
ceramics, composites, and materials that are difficult to machine with other techniques such as
hardened steels. It can produce very precise cuts and shapes with tolerances as tight as 0.0001
inches. There is no tool wear as it does not require a cutting tool. Lastly, it does not create
mechanical stress in the workpiece which can be useful in structure applications.
EDM is a relatively slow process, particularly for larger workpieces or complex shapes. The
equipment needed for EDM is generally more expensive than that used for traditional machining
techniques. The rate at which material can be removed with EDM is relatively low, which may
be a disadvantage for certain applications.

5.4 Conclusion:
Machining through EDM can be a very effective technique for producing precise and complex
shapes in a wide variety of materials. However, it may not be the best choice for every
applications, particularly those that require fast material removal. Also, it can still cause some
inaccuracies which can be due to time delays or personal errors and can be avoided easily.
5.5 Applications and Sustainability:
EDM is used commonly to create complex shapes in dies and molds used for injection molding,
forging, and stamping. It is used in Aerospace and automotive parts manufacturing that are
complex in shapes, to create precise and intricate features in medical devices such as implants
and surgical tools. Also, in repairing damaged tools and dies to extend their lifespan and for
avoiding replacements. In manufacturing of micro-electromechanical systems(MEMS), and
refine features on semiconductor wafers, EDM is used for dimensional accuracy and accurate
design. It is also used to create surface textures on materials for aesthetic and functional
purposes.
The sort of EDM machine used, the energy source used to power the machine, and the materials
used in the manufacturing process are just a few of the variables that affect how sustainable
EDM is. EDM tools typically have a long lifespan and require less upkeep than other machining
techniques, which can help to increase their sustainability. EDM can be viewed as sustainable
from an economic perspective because of its capacity to lower expenses and boost productivity.
EDM eliminates the need for secondary operations or extra machining steps by enabling
manufacturers to create complex parts with high precision and accuracy. This reduces the overall
production time and costs associated with making a part. EDM is highly automated, which
means it requires less human intervention and oversight. This reduces labor costs and increases
overall productivity. EDM uses very little energy compared to other machining methods. This is
because the electrical discharge that shapes the material is highly focused and efficient, requiring
only a small amount of energy to create the desired effect. This reduces the amount of energy
required to produce a part, reducing the overall carbon footprint of the manufacturing process.
Additionally, the reduced production costs associated with EDM can allow manufacturers to
keep their operations in-house, rather than outsourcing to countries with lower labor costs. This
supports local economies and communities by providing jobs and generating revenue.