Electrical

Discharge
Machining
Presented by : Guided by :
Dr. Kailash
Sachin Garg ,Tarun Upadhyay,
Chaudhary Sir
Vansh Kackar, Yuvraj Prajapat
 Introduction
• Electrical Discharge Machining, also referred to as spark machining, is an
alternative to traditional machining that uses thermal rather than mechanical
forces to remove material.
• It removes the metal by applying a rapid series of repetitive electrical
discharges. An electrode and the work piece is used for the conducting path of
these electrical discharges.
• EDM is a highly precise technique, well-suited for crafting complex and
intricate shapes, including those made from hard metals like titanium. For EDM
to be effective, the materials being machined must be electrically conductive.
 Operating Principle
• In an EDM machine, the workpiece electrode (anode) is connected to the positive
terminal of a DC power supply, while the tool electrode (cathode) is connected to the
negative terminal.
• It has been observed that if both the electrodes are made of the same material, the
electrode connected to the positive terminal generally erodes at a faster rate.
Therefore, the workpiece is made the anode.
• A suitable gap known as the spark gap, is maintained between the tool and the
workpiece surfaces. (0.05 to 0.25 mm)
• The EDM process must take place in the presence of a dielectric fluid, which creates a
path for each discharge as the fluid becomes ionized in the gap.
 Operating Principle
• Since the spark occurs at the spot where the tool and the workpiece surfaces are the
closest and since the spot changes after each spark (because of the material removal after
each spark), the sparks travel all over the surface.
• This results in a uniform material removal all over the surface, and finally the work face
conforms to the tool surface. Thus, the tool produces the required impression in the
workpiece.
• In the dielectric medium, the tool (- terminal) emits electrons which are accelerated toward
the work material. As these electrons gain velocity and energy, they collide with the
dielectric molecules. These collisions ionize the dielectric molecules.
• As the electrons continue to accelerate, they generate positive ions and additional electrons
through these collisions. This cyclic process enhances the concentration of electrons and
ions in the dielectric fluid between the tool and the work material at the spark gap.
 Operating Principle
• The concentration becomes so intense that the material in this region forms a “plasma.”
The plasma channel has very low electrical resistance, allowing a significant flux of
electrons to move from the tool to the work material.
• The sudden movement of electrons and ions creates the thermal energy of the spark
with a heat range of 8,000°C up to 12,000°C. The rapid motion of the electrons hits the
work material and the ions on the tool. The impact of the electrons and ions on the
surface of the workpiece is converted into thermal energy or heat flux.
 Setup of EDM
1. A DC power generator is the power supply for the EDM machining process. The negative terminal
is connected to the tool while the positive terminal is connected to the part being machined (i.e.
the workpiece).
2. The workpiece is the component being machined. It is secured in the dielectric container with a
fixture and is connected to the positive terminal of the power supply.
3. The fixture is used for holding the workpiece properly in the dielectric container.
4. A pump is used to channel the dielectric fluid from the base of the container to the tool and
workpiece, facilitating increased material removal rate (MRR).
5. A filter, positioned just above the pump, removes any impurities or dust particles present in the
dielectric medium.
6. The tool holder serves to hold the tool properly.
 Electrode tool
• In EDM machining, any electrically conductive material can serve as the electrode tool. The tool's
shape is replicated in the cavity created during machining, making the shape and precision of the
machined surface directly dependent on the electrode's form and accuracy.
• Both the electrode and the workpiece experience erosion during the process, with a typical wear
ratio ranging from 5:1 to 100:1.
• The wear ratio is the comparison between the wear of the tool and the amount of material removed
from the workpiece. This ratio is influenced by the physical and chemical properties of both the tool
and work material, the type of dielectric fluid used, and the operating conditions of the machining
process.
• EDM tools need to have high melting and vaporization temperatures, or high thermal
conductivity, such as those found in graphite or copper. In addition to these thermal properties, tool
materials should also be easy to fabricate or shape and resistant to wear.
 Electrode tool
• Key factors that determine the suitability of a material for use as an electrode tool in EDM machining
include: higher metal removal rate, lower tool wear & high degree of electrical efficiency.
• While any electrically conductive material can be used as an electrode in EDM, graphite is the most
commonly chosen due to its favorable properties.
 Dielectric fluid
• The dielectric medium is crucial to the EDM machining process. Typically, the dielectric fluid used is low-
viscosity hydrocarbon oil. It acts as a separator between the workpiece and the electrode.
• During machining, as sparks occur, the dielectric fluid ionizes to create a conductive path between the
tool and the workpiece.
• The spark discharge will be at around 10,000°C and thousands of atmospheric pressure in a micro small
area. It takes less than a microsecond for this to take place for each spark.
• The dielectric fluid must remain electrically non-conductive to the time when the breakdown voltage
is reached (i.e. its dielectric strength must be high)
• Once the breakdown voltage is attained, instantly, it should breakdown electrically.
• The dielectric fluid must deionize the spark gap (i.e. after the discharge has occurred, it must quench
the spark rapidly)
• It carries away the metal particles that have been removed from the arc gap.
• The dielectric fluid acts as a good coolant.
Essential properties of dielectric
• High level of electrical strength for proper insulation
• High fire and flashpoints in order to prevent fire hazards
• Good wetting properties and low viscosity
• Chemically neutral in order to prevent corrosion
• Non-toxic in nature
• Low decomposition rate for a high life expectancy
• Low cost
• Good quenching properties
 Flushing of dielectric
• Flushing refers to the effective circulation of dielectric fluid between the workpiece and the
electrode tool in EDM machining. The efficiency of the cutting process heavily relies on proper
flushing of the dielectric fluid.
• During the machining process, the dielectric fluid becomes contaminated with eroded metal
particles and carbon from the breakdown of the fluid due to heat. This contamination decreases the
insulation strength of the dielectric fluid, potentially causing premature spark discharge .
• If contamination levels exceed permissible limits, it can lead to the formation of bridges between
the tool and workpiece, resulting in short circuits and damage to both.
• Pressure flow systems are commonly used to circulate dielectric fluid in EDM machining. The fluid is
directed through the gap between the tool and the workpiece by forcing it through holes in the
electrode. This pressurized flow helps to flush out solid metal particles, cooling both the workpiece
and the tool electrode.
• Dielectric fluids used in EDM include hydrocarbon oils, kerosene, and distilled or deionized water.
 Types of EDM processes
1. Conventional EDM utilizes shaped electrodes, making it particularly valuable for
creating dies and molds. It's well-suited for small-batch production and prototype
manufacturing. This method is widely used in industries like automotive and aerospace
due to its ability to precisely produce complex engine components.
2. Electric Discharge Wire Cutting or wire erosion systems, utilize a thin, electrically
charged wire as the electrode. A hard diamond guide maintains the wire’s stability. The wire is
moved through the workpiece to create a specific shape, but only the electrical discharges from the
wire come into contact with the workpiece; the wire itself does not touch it.
• As it cuts, the wire is slowly and continuously advanced between a supply spool and a take-up
spool to present a fresh electrode of constant diameter to the work. This helps to maintain a
constant kerf width during cutting.
 Applications
• It is used to make holes with sizes that are less than 0.1 mm.
• It is utilized in die sinking or die manufacturing, fixtures, and gauging.
• It is used to make holes in air brakes or pneumatic brakes.
• It is used in press tools and extrusion dies.
• It is utilized in die molds for plastics.
• It is utilized in the shaping of carbide tools and templates.
• It is used in the following applications: Aerospace; Medical; Electronics; Semiconductor.
• It is used in the manufacture of hard Electrodes.
 Advantages
• It can be used even in the heat-treated condition, and for any hard material.
• Complicated shapes made on the tool are able to be reproduced.
• A high accuracy can be achieved; about 0.005 mm.
• Economically, a good surface finish can be achieved; up to 0.2 microns.
• Machining time is not more than the conventional machining process.
• Mechanical stresses are not developed in this process (the tool and work do not have contact).
 Disadvantages
• Excessive wear of the tool
• Reproduction of the sharp corner is not possible
• Change in metallurgical properties of materials due to the development of high heat.
• The material to be machined must be an electrical conductor
• Requirement for redressing of a tool for deep holes

• Overcut in EDM is the distance by which the machined cavity in the work part
exceeds the size of the tool on each side of the tool. It is produced because the
electrical discharges occur at the sides of the tool as well as its frontal area.
Mathematical analysis
Example problem
 References
1. Fundamentals of Modern Manufacturing by Groover
2. Amitabha Ghosh, Asok Kumar Mallik - Manufacturing Science
3. https://www.iqsdirectory.com/articles/edm/edm-machining.html
4. https://mechanicalinventions.blogspot.com/2016/01/electrical-discharge-machining-edm.html
5. https://www.iqsdirectory.com/articles/edm/wire-edm.html
6. https://www.sciencedirect.com/topics/materials-science/electrical-discharge-machining
7. https://waykenrm.com/blogs/wire-edm-process/
8. https://www.mmsonline.com/topics/edm
9. https://blog.thepipingmart.com/other/what-is-electrical-discharge-machining-edm/
10. https://www.tribonet.org/news/general-topics/electric-discharge-machining-damages-in-bearings/