Submitted by:- Vikram Singh

Roll No:-2511666
Mechanical Engineering Dept.
Non-conventional machining processes are used to
manufacture high quality components EDM is a non-
conventional machining process, in which the material
erodes from the work piece by a series of electric sparks
between the tool and work piece immersed in a dielectric
medium. Material removal occurs due to instant
vaporization of the material as well as due to melting. The
dielectric fluid acts as a de- ionizing medium between the
electrode and work piece. The tool and work piece are
separated by a small gap called spark gap generally varies
from 0.01 mm to 0.5 mm. The electric discharges melt and
vaporize the small amounts of material, which are then
flushed away from the machining area by the dielectric
fluid. The sparks occurring at high intensity and frequency,
continuously and effectively remove the material from the
work piece by melting and evaporation. The tool is made
cathode and work piece is made anode or vice versa.
 SinkerEDM
Wire Cut EDM
 Basically the EDM process is working on the principle of
conversion of electrical form of energy into thermal energy
with help of producing the series of discrete spark between
the tool and workpiece are electrically conductive and are
immersed in the dielectric fluid are separated by the small
electrode gap which separates the tool and workpiece. In
EDM machining process electrical energy is responsible for
the spark generation and thermal energy is for the material
removal from the surface of the workpiece. During the
EDM process the tool is movable and the workpiece is
fixed. The moment of tool towards the workpiece is proceed
until a suitable gap is maintained for the ionization of
dielectric. The flush of dielectric eroded particle from the
spark gap is to be done through the regular flushing.
 Pulse off Time
Pulse on Time
Flushing Pressure
Voltage
Discharge Current
Duty Cycle
Polarity
Inter-Electrode Gap
Dielectric Fluid
 MRR
SR
TWR
OC
HAZ
 It helps in initiating the discharge by serving as a
conducting medium between tool and work piece
when ionized, and conveys the spark.
It carries away the debris from the machining area.
It helps in quenching the spark.
It acts as a coolant.
It concentrates the energy to a very narrow region.
It helps in cooling the work piece, tool and enables
arcing to be prevented.
 EDM process, can machine any electrical conductive
material.
XY and Z axes moments are allow machining the
complex shapes at lower cost.
High degree of automation and automatic tool changer
make it unattended working to overnight.
Fragile section like fins and webs are easily machined
Hardened material can machine easily without
deformation due to the heat treatment.
In EDM process, there is no physical contact between
the tool and workpiece therefore there are no
mechanical forces between the electrodes.
 Workpiece and tool both are must be electrical conductive,
by this only discharge is possible.
Many times the tool wear is higher, so it requires more than
one tool for finish a single job.
The spark gap is not easily predictable special in complex
shape jobs.
Material removal rate is lower.
EDM processes consume higher power.
Parameter selection always depends on tool and workpiece.
 EDM process is used in mould making tool and die industries and
has further use in prototyping and part production in aerospace
and electronic industries.
It is used for machining of extremely hard materials like as
tungsten carbide and steel tool.
It is used in wire drawing, extrusion and thread cutting process.
EDM process can achieve high tolerance limits, so it is used
where surface finish is a primary requirement.
It has demand in production of smaller components in complicated
shape used in micro-electronics.
EDM operation is done by the application thermal energy, but
there is no bulk heating in workpiece material.
Sharp corners and edges are can easily produced by EDM process.
EDM has application in new fields such as medical and surgical
industries
Gupta V.K et. al. (2016), optimized the material removal rate for
sinking EDM using generic algorithm technique. The experiments
were performed on titanium alloy Ti 6-4 using copper electrode.
Pulse on time, pulse off time and discharge current were the
process parameters selected for this study. Material removal rate
was selected as a response parameter. Each process parameter was
varied up to six levels. The experiments were performed with
normal polarity i.e. work piece was taken as cathode and electrode
was taken as anode. Analysis of variance and regression analysis
was done to optimize the process parameters. Further, generic
algorithm was done to create the model. From the results obtained,
it was concluded that the discharge current was the most important
process parameter that affects the material removal rate followed
by pulse on time and pulse off time. It was also concluded that, as
the discharge current and pulse on time increases, the material
removal rate also increase. On the other hand as the pulse off time
increases, the material removal rate decreses.
Abrol A. et. al. (2015), investigated the effect of chromium
powder mixed with dielectric fluid on machining characteristics of
EDM during machining of AISI D2 die steel. Cylindrical shaped
rod of copper with 14 mm diameter was used as a tool with
positive polarity. Peak current, pulse on time, pulse off time,
concentration of powder were the machining parameters. The
process performance characteristics were measured in terms of
material removal rate, tool wear rate and surface roughness. The
design of experiment was based on Taguchi L27 orthogonal array
and analysis of variance was used to determine the percentage
involvement of each process parameter for optimizing the
performance characteristics of EDM. It was found that all the
process parameters except pulse on time have a significant effect
on material removal rate. Current was found to be the most
significant parameter for material removal rate, tool wear rate.
With increase in current, material removal rate, tool wear rate also
increases. The authors also concluded that, surface roughness
increases with increase in pulse off time.
 Prajapati U. et. al. (2014), studied the process parameters
of electric discharge machining by using Taguchi method.
Three process parameters viz. pulse on time, pulse off time
and current were selected for this experiment. These three
process parameters were varied with their three levels. The
machining of AISI SS304 work piece material was done by
using copper electrode. Taguchi L9 orthogonal array was
used to plan the design of experiment and analysis of
variance was used to analyze the effect of control
parameters on performance parameters and find the
optimum process parameters. Kerosene oil diluted with
water was used as a dielectric fluid. From results it was
concluded that, pulse on time has most effect on material
removal rate while the pulse off time has least effect on
material removal rate. It was also found that; material
removal rate is directly related to the Pulse on Time and
Discharge Current.
 The effect of tool material on electric discharge
machining of SS 304 has not been fully explored.
Literature review clears that, limited work has
been carried on analysis and optimization of
process parameters like pulse on time, pulse off
time and current etc. of EDM process using
different tool material.
Most of the researchers have observed the effect
of pulse on time, current, electrode material,
duty cycle on the material removal rate of EDM
process, but small work has been carried out to
compare the MRR by using copper and aluminium
electrode.
For the satisfactory selection of machining parameter is the
most important aspect to take into mind in the majority of
EDM manufacturing process. From previous chapter we
take knowledge about the EDM and its components and
working, here a experimental work is to be done by using
the sinker type EDM machine. Here we take pulse on time,
voltage, current and pulse off time as machining parameters
and material removal rate is be the response parameter for
measurement of machining characteristic.
 Experimentally investigate the effect of tool material on
material removal rate of EDM process during machining of
SS 304.
Experimentally determine the influence of various process
parameters viz. pulse on time, pulse off time and current on
material removal rate of EDM process.
Experimentally determine the optimum value of machining
parameters like pulse on time, pulse off time and current for
high material removal rate.
The layout of design of experiment is based on Taguchi L9
orthogonal array. Taguchi design technique is one of the
most important statistical tools for designing high quality
process at low cost. Taguchi design technique uses a special
design of orthogonal array to investigate the entire process
parameter space with a less number of runs. In the present
work three process parameters selected as current, pulse on
time and voltage and each process parameter are varied at
their three levels. In Taguchi design of approach, Signal to
Noise ratio (S/N Ratio) is the measure of quality
characteristics and Signal to Noise ratio (S/N) for MRR is
determined as higher the better criterion and Signal to
Noise ratio (S/N) for SR is determined as smaller the
better criterion. Further, Analysis of Variance (ANOVA) is
used to analyze the results obtained from Taguchi design
technique.
The Taguchi Design approach was developed by Dr. Genichi
Taguchi of Japan. Dr. Genichi Taguchi developed a method
for designing experiments to investigate how different
variables affect the process performance characteristic that
defines how well the process is functioning. The quality in
the process can be achieved by lowering the deviations
from the target value. The process should be so designed
that it is immune to uncontrollable environmental variables.
The Taguchi method involves minimizing the variation in a
process through robust design of experiments. The overall
objective of Taguchi Design approach is to produce quality
products at low cost of manufacturing. The design of
experiment proposed by Taguchi involves orthogonal arrays
to organize the variables affecting the process performance
and the levels at which they should be varied
 CONTROL FACTOR
NOISE FACTOR
SINGLE TO NOISE RATIO
The selection of orthogonal array was based on three factors
are as follows
Number of process parameters

Interactions between process parameters

Number of levels for each process parameter

Table L9 Orthogonal Array in Terms of Actual Parameters
Run I Ton Toff
1 6 100 7
2 6 150 9
3 6 200 11
4 9 100 9
5 9 150 11
6 9 200 7
7 12 100 11
8 12 150 7
9 12 200 9
Work Piece Material: - SS-304
Tool Material: - Copper and Aluminium
Machine Tool: - ELEKTRA EMS 5535
Dielectric Fluid:- Commercial Grade EDM Oil
For an EDM process the electrode material should also be electrical
conductive, high thermal conductive and high melting point. Shape of the
Electrode produces their mirror image in work piece. In this experiment
cylindrical shaped copper rod having 6 mm diameter is used as an
electrode.
Table - Properties of Copper

Properties Value
Brinell hardness 35HB
Co efficient of thermal expansion at 25 C (m/mK) 16.5
Thermal Conductivity (W/mK) 268-389
Density (g/cm3) 8.96
Boiling point (C) 2562
Melting point (C) 1082.62
 Table - Properties of Aluminium

Properties Value
Brinell Hardness 120HB
Co efficient of Thermal Expansion at 25 C
23.4
(m/mK)
Thermal Conductivity (W/mK) 121
Density (g/cm3) 2.7
Boiling point (C) 2467
Melting point (C) 660.4
1 Performance Parameters
Material Removal Rate
2 Process Parameters
Pulse on Time
Pulse off Time
Current
3 Constant Parameters
Polarity
Voltage
Duty Cycle
Flushing Pressure
Spark Gap
 In EDM process, the material removal is to be basically
based on the conversion of electrical energy in to thermal
energy. There are discrete sparks are produced between the
spark gap while performing the experiments. A small crater
is produced in each spark due to material melting from the
workpiece surface as per shape of the tool. The mechanism
of material removal is to transforms elements of material in
phases between the tool and workpiece under the solid-gas
phase transformation reaction. Small amount of material
from the workpiece is removed directly by vaporization
process under the application of high heat.
 Where,
Wwa = Weight of work piece after machining
Wwb = Weight of work piece before machining
T = Machining time (machining time is 30 min in
this experiment)
 To perform this experiment, I used ELEKTRA EMS5535
Die-sinking EDM machine tool. Copper and aluminium
electrode are used as a tool and SS 304 is used as
workpiece. Commercial grade EDM oil is used as a
dielectric fluid with external flushing. A Pulse voltage
discharge is supplied in the various steps. The main work of
the pressure flushing is to flush the oil in the spark gap. The
whole experiment work is to be designed on the basses of
Taguchi L9 array method. In whole process a constant spark
gap is to be maintained constantly with the help of servo-
control system. Total 18 no. of experiment is to be
performed, 9 experiments are performed by using copper
electrode and rests of experiments are performed by using
aluminium electrode. An electrical weighing machine is
used to weight up the workpiece after and before the
experiment for calculating the MRR. The weight capacity of
machine is 500g.
Run Ton Toff I MRR WITH MRR WITH
COPPER ALUMUNIUM
ELECTRODE ELECTRODE
1 6 100 7 0.00332 0.00160
2 6 150 9 0.00457 0.00225
3 6 200 11 0.00663 0.00310
4 9 100 9 0.00757 0.00371
5 9 150 11 0.00896 0.00441
6 9 200 7 0.01137 0.00559
7 12 100 11 0.01224 0.00605
8 12 150 7 0.01666 0.00826
9 12 200 9 0.01974 0.00978
larger is better is for Material Removal Rate
Run I Ton Toff Copper Aluminium
Electrode Electrode
1 6 100 7 -49.5772 -55.9176
2 6 150 9 -46.8017 -52.9563
3 6 200 11 -43.9717 -50.1724
4 9 100 9 -42.4181 -48.6125
5 9 150 11 -40.9538 -47.1112
6 9 200 7 -38.8848 -45.0518
7 12 100 11 -38.8848 -44.3649
8 12 150 7 -35.5665 -41.6604
9 12 200 9 -34.0931 -40.1932
Level I Ton Toff
1 -46.78 -43.41 -14.34
2 -40.75 -41.11 -14.10
3 -35.97 -38.98 -14.06
Delta 10.81 4.43 0.28
Rank 1 2 3
Level I Ton Toff
1 -50.02 -49.63 -47.54
2 -46.93 -47.24 -47.25
3 -42.07 -45.14 -47.22
Delta 7.95 4.49 0.32
Rank 1 2 3
 The Analysis of Variance for S/N ratio are shown in table . P value
determines the most significant process parameter. The parameter
whose P value is less than 0.05 will be most effective factor. So
current is the most significant parameter on MRR followed by
pulse on time and voltage.
Table - Analysis of Variance for S/N Ratio

Source DF Seq SS Adj MS F P

I 2 176.245 88.122 137.99 0.007
Ton 2 29.454 14.727 23.06 0.042
Toff 2 0.141 0.071 0.11 0.901
Error 2 1.277 0.639
Total 8 207.116
 Copper electrode provides more MRR as compare to an
aluminium electrode.
The most significant machining parameter for MRR is
current followed by pulse on time and pulse off time.
As the current and pulse on time increases, the MRR also
increases i.e. MRR is directly proportional to the current
and pulse on time.
Pulse off time has negligible effect on MRR.
As the pulse off time increases, the MRR decreases i.e.
MRR is inversely proportional to the pulse off time.
 Table 5.1 Optimum Value of Machining Parameters for Copper
and Aluminium Electrode

S.No. Machining Parameter Optimum Value

1. Current 12 Amp
2. Pulse on Time 200 s
3. Pulse off Time 7 s
 Gupta V.K., Prasad R.B., Optimization of MRR in Sinker EDM
Process Using Generic Algorithm Technique. International
Journal of Advance Engineering and Research Development, Vol.
3, PP. 357-362, 2016.
Abrol A., Sharma S., Effect of Chromium Powder Mixed
Dielectric on Performance Characteristics of AISI D2 Die Steel
Using EDM. International Journal of Research in Engineering
and Technology, Vol. 4, PP. 232-246, 2015.
Prajapati U., Prajapati J., Modi P., Banker K.S., A Review of
Parameter Optimization of Electro Discharge Machine by Using
Taguchi Method. International Journal of Scientific Research and
Development, Vol. 2, PP. 94-96, 2014.