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KP Reddy

Electric discharge machining (EDM) is a non-traditional machining process that uses thermal energy from electric sparks to erode material from a workpiece. In EDM, an electrode is moved close to the workpiece to generate sparks across a dielectric fluid, removing small amounts of material through erosion and vaporization. Key aspects of EDM include using thermal energy from electric sparks below 125 micrometers to machine electrically conductive materials like hardened steels, with no mechanical forces applied and leaving a recast surface layer on the finished workpiece.

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57 views17 pages

KP Reddy

Electric discharge machining (EDM) is a non-traditional machining process that uses thermal energy from electric sparks to erode material from a workpiece. In EDM, an electrode is moved close to the workpiece to generate sparks across a dielectric fluid, removing small amounts of material through erosion and vaporization. Key aspects of EDM include using thermal energy from electric sparks below 125 micrometers to machine electrically conductive materials like hardened steels, with no mechanical forces applied and leaving a recast surface layer on the finished workpiece.

Uploaded by

prashanthreddy26
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Electric Discharge

Machining
1

P R E S E N T E D B Y,
K.PRASHANTH REDDY
A S S I S TA N T P R O F E S S O R
GOKARAJU RANGARAJU COLLEGE OF
ENGINEERING AND TECHNOLOGY
D E PA RT 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
Presentation Content
2

Introduction

Popularity of EDM

Basic principle of EDM

Mechanism of metal removal


Nontraditional Machining
and Thermal Cutting
Processes 3
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
4

Energy type: Thermal

Mechanics of metal removal: Erosion and/ or vaporization

Energy source: Electric spark

Medium: Dielectric fluid

Spark Gap: 10-125m

Maximum metal removal rate: 5*10 mm/min

Spark frequency: 200-500,000Hz

Peak voltage: 30-250 volts


5

In1770s, discovered by Joseph


History Priestly.
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
6
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)
7
Processes
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
8
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
9

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
10
Component of EDM system
11

EDM system:
A tool (electrode)
Work piece
A dc power supply
Servomotor
Dielectric fluid
12

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) 13
Mechanism of metal
removal
14

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
15

Fig B.
1. Layer with small globules of
removed workpiece metal and
electrode
2. the white or recast layer
3. Heat affected zone or annealed layer
Fig A.
References
16

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?
17

THANK YOU

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