ELECTRO-DISCHARGE

MACHINING

1
Introduction
Erosion of metals by spark was first reported by
Joseph Priestily in 1878
Controlled machining by electrical sparks was first
introduced by Lazarenko in Russia in 1944.
The first British patent was granted to Rudorff in
1950.
USA, Japan, Switzerland developed their machines
around 1950.

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Working principle of EDM
 Thermoelectric process
 The w/p & tool –electrically conductive materials
 Spark is produced bt the two electrodes
 Cycle time- micro seconds
 Effective area is small
 Partly melting & partly vaporizes
 Removed in the form of craters
 Approximately replica of the tool
 Debris are mixture of irregular shaped particles & hollow spherical
particles
 Pulsed DC of 80-100V at 5kHz
 Ionization takes place in the inter-electrode gap(IEG)
 Kinetic energy is converted into heat energy-discharge
 Servomechanism- feed rate of the tool
Fig .1 Schematic representation of the basic working principle of EDM process

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Advantages
 Electrically conductive materials. Physical and metallurgical properties of the
work material are no barrier.
 Simple and straight forward method of form producing drop-forging, drawing
and extrusion dies and complex cavities in moulds and dies for plastics, die
casting, glass and ceramic manufacturing.
 No physical contact between the tool and workpiece-no mechanical
deformation
 Process involves temperature rise at local spot around 10,000° C. No heating in
the bulk of the material but presents HAZ of about few microns.
 high rates of heating and cooling at the treated surface renders case hardening
to the surface.
 Simple geometrical shape configurations can easily be produced by piercing or
die sinking in hardened die plates with required accuracy and surface finish.
 Surface produced by EDM consists of a multitude of small craters. Better
lubrication
 Less attention is required from the operator
5
 EDM – Equipment
Power generator & control
unit
Servo system to feed the tool
X-Y table accommodating the
working table
Tool holder
Working tank with work
holding device
Dielectric reservoir, pump &
circulation system

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EDM Machine
 Power supply
 convert AC current into pulsed DC current to produce unidirectional
spark discharges.
 Solid state rectifier is used to convert AC to DC and a pulser to
generate DC pulses or unipolar pulses
 Pulsing units: Rotary Impulse Generator, Relaxation Generator, Pulse
Generator, and Hybrid Generator
 By sensing the voltage between the tool & w/p, desired gap can be
maintained by servo system
 Able to control: voltage, current, duration and frequency of a pulse,
duty cycle and electrode polarity.
 Also equipped with cut-of protection circuit. As soon as the arc , due
to short circuit between the electrodes , occurs the cut-of circuit
terminates the power.

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 Dielectric system
 Consists of dielectric fluid, reservoir, filters, pump, and delivery
devices

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Flushing
 Correct circulation of dielectric fluid between the
electrodes and workpiece
 Injection flushing
 Suction flushing
 Side flushing
 Flushing by dielectric pumping

9
 Categories of EDM Machines

EDM

Sinking by Cutting by Grinding by

EDM EDM EDM

10
Process Parameters in EDM
The open circuit voltage – Vo
The working voltage – Vw
The maximum current – Io
The pulse on time – ton
The pulse off time – toff
The gap between the work piece and the
tool – spark gap – 
The polarity – straight polarity – tool (-ve)
The dielectric medium
External flushing through the spark gap.

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 Dielectric
Material removal mainly occurs due to thermal evaporation
and melting. As thermal processing is required to be carried
out in absence of oxygen so that the process can be
controlled and oxidation avoided.
Oxidation often leads to poor surface electrical
conductivity of the work piece hindering further
machining.
Hence, dielectric fluid should provide an oxygen free
machining environment.
Further it should have enough strong dielectric resistance
so that it does not breakdown electrically too easily but at
the same time ionise when electrons collide with its
molecule.
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Dielectric
 Moreover, during sparking it should be thermally resistant as well.
 Generally kerosene and deionised water is used as dielectric fluid in
EDM.
 Tap water cannot be used as it ionises too early and thus breakdown
due to presence of salts as impurities occur.
 Dielectric medium is generally flushed around the spark zone.
 It is also applied through the tool to achieve efficient removal of
molten material
 Properties of dielectric fluid:
o High dielectric strength
o Minimum possible time to breakdown (ignition delay time)
o Deionize the gap immediately
o Cooling medium
o High degree of fluidity
Transformer oil, paraffin oil, kerosene, lubricating oils, and
deionized water

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 Tool Materials
Electrode not undergo much tool wear when it is impinged
by positive ions
Localised temperature rise has to be less
By tailoring or properly choosing its properties
Or even when temperature increases there would be less
melting
Further, the tool should be easily workable as intricate
shaped geometric features are machined in EDM.

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 Tool Materials
High electrical conductivity – electrons are cold emitted
more easily and there is less bulk electrical heating
High thermal conductivity – for the same heat load, the
local temperature rise would be less
Higher density – for the same heat load and same tool wear
by weight there would be less volume removal or tool wear
and thus less dimensional loss or inaccuracy
High melting point – high melting point leads to less tool
wear due to less tool material melting for the same heat
load
Easy manufacturability & Cost – cheap

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Tool Material
 (i) Metallic electrodes: Electrolyte copper
Tellurium or chromium copper
Copper tungsten
Brass
Aluminium
Aluminium alloy (Silumin)
Tungsten (mostly coated or wire)
Silver tungsten
Steel
 (ii) Non-metallic: Graphite
 Combined metallic and non-metallic: Copper- graphite
 Metallic coating as insulators: Copper on moulded plastic and copper
on ceramic
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 Copper-low wear ratio-high MRR(rough)-high cost-on all metals-
easily machinable
 brass-high wear ratio-high MRR(finish)-low cost-on all metals -easily
machinable
 Tungsten-lowest wear ratio-Low MRR-high cost-small holes
-difficulty machinable
 Tungsten copper alloys-low wear ratio-Low MRR-high cost-accurate
jobs -difficulty machinable.
 Cast Iron-low wear ratio-Low MRR-low cost-few materials -easily
machinable
 Steel-high wear ratio-Low MRR-low cost-finishing work -easily machinable
 Zinc based alloys-high wear ratio-high MRR(rough)-low cost-on all metals-
easily machinable
 Copper graphite-low wear ratio-high MRR-high cost- on all metals–very
delicate
 Silver tungsten electrode-most efficient. 17
Taper Cut and Over Cut

Though there is a possibility of

taper cut and over cut in EDM,
they can be controlled and
compensated.

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Characteristics of EDM
Though the local temperature rise is rather high, still
due to very small pulse on time, there is not enough
time for the heat to diffuse and thus almost no
increase in bulk temperature takes place. Thus the
heat affected zone is limited to 2 – 4 m of the spark
crater
However rapid heating and cooling and local high
temperature leads to surface hardening which may be
desirable in some applications

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Characteristics of EDM
 The process can be used to machine any work material if it is
electrically conductive
 Material removal depends on mainly thermal properties of the
work material rather than its strength, hardness etc
 In EDM there is a physical tool and geometry of the tool is the
positive impression of the hole or geometric feature to be machined
 The tool has to be electrically conductive as well. The tool wear
once again depends on the thermal properties of the tool material.
 Surface integrity: surface topography and surface metallurgy
 Three layers: recast layer (2.5 to 50µm, extremely hard and brittle,
porous, contain micro-cracks), HAZ ( 25µm heating, cooling and
diffusion , thermal residual stresses, grain boundary weakness, and
grain boundary cracks), and converted layer ( change in grain
structure)

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 2 3
s  r Es  VIton
3
Ew  Es Ew  kEs
s  Es  Ew

 s  gEs
s s VIton VI
MRR  g g
MRR   ton  toff  toff 
tc ton  toff 1 
 ton 
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Product Quality Issues in EDM
Surface finish
Over cut
Taper cut

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 2
hm  r and s  r 3
3

1/ 3
3 
 r  hm    s  s  gEs  gVIton
2 

 hm   s    VIton 
1/ 3 1/ 3 1/ 3
 Es 23
 Types of EDM Generators
Resistance-capacitance type (RC type) Relaxation
generator
Rotary impulse type generator
Electronic pulse generator
Hybrid EDM generator

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25
 Relaxation type generator:
 A resistance and a condenser is used to generate a nearly saw tooth
voltage wave form.
 Condenser gets charged from no voltage to a required voltage when it is
connected to a DC source.
 Charged condenser is connected to the machine to discharge to the
spark gap in the machine and so relaxed to zero voltage ( cannot sustain
the spark).
 Electronic Pulse Generators:
 Electronic Amplifier type generators would escalate with the power.
 Switching the operation from linear mode to saturation mode of the
devices.
 Vacuum tube amplifier and solid state amplifier give square wave form
voltage .
 Hybrid generators: trapezoidal wave form in place of square wave form.
 Slopes are provided to match with ionization and deionization
characteristics of the dielectric fluid.
 Voltage wave form matches with the current waveform
26
-
Rc

C
Vo C Vd id VC id
iC

27
Rotary Pulse Generators:
To increase MRR, motor generator sets are developed to
supply the required power.
Produce asymmetric output waves equivalent DC
power supply maintained

Motor c
Tool
Generator D
work

 Capacitor is charged through the diode on half cycle.

 For the following half cycle , the sum of the voltage
from the generator and charged capacitor is applied.
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Controlled pulse generators
 Lack of ability to cut off current in case of short circuit
 Development of circuits with electronic tubes and transistors
 Faster removal rate and low tool electrode wear with high accuracy

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 dV 1
Rc  dt
C Vc
Vo  Vc CRc
V0
ic
Vc *
dVc 1 tc
   dt
0 Vo  Vc CRc 0

tc Vc *
  c   ln  Vo  Vc 
t
  
Vc  Vc *  Vo 1  e RcC  Rc o
 
 
t 
t
Vo  Vo  1  e RcC   t
RcC 
Vo  Vc 


 Vo e RcC
ic   ic   io .e
Rc Rc Rc
30
 Vc dVc
id   C
Rm dt
Vd C id
Vd*
dVc 1 td
   dt
V*
Vc CRm 0
c
*
td Vd
   ln *
CRm Vc
* td
Vc 
* RmC
 Vd  .e Vd Vc* 
t
Rm id   .e RmC
Rm Rm 31
EDM Wave Form for RC Generator
Vo
Vc*
V
Vd*
t
tc td

iC

id

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Vc* = 0.716 Vo for maximum power output
RcC RmC
tc   td   *
 Vc *
 Vd 
ln  1   ln  * 
 Vc   Vc 
1 1
f  
tc  td RcC RmC

 Vc*   Vd 
ln  1   ln  * 
 Vc   Vc 
33
Total energy discharged through spark gap
*2 2t
td td
Vc 
RmC
Es   id2Rm dt   2 m R e dt
0 0 Rm
td
2t *2 2t

Vc*2 td  Vc RmC RmC
 e
RmC
dt  . e
Rm o Rm 2t
0

  d 
2t
1 *2 
 CVc 1  e RmC  1 *2
2 


Es  CVc
2

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Electrical Parameters in R-C Circuit

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Gap setting (dielectric strength):
 Increase in relative voltage at discharge increases
relative capacitance up to optimum level .
 Gap is larger than the optimum, the consequent
reduction in frequency and it is not compensated
by increase in energy per spark.
 Shorter gaps the power decreases because the
increased frequency in to compensate the
reduction in stored energy.
 The dielectric gets contaminated with metal
particles and break down will occur at lower
voltage
36
Process Variables
 Increase in current results in increased MRR & surface
roughness
 Similar trend with increase in spark voltage
 Increase in spark frequency improved surface finish
 Decrease in inter electrode gap lowers MRR, better surface
finish, and high accuracy.
 Increase in pulse duration decrease in MRR and lowers surface
finish
Dielectric pollution
Dielectric contamination influence breakdown, ignition
delay, short circuit, machined surface characteristics,
spark gap and machining rate.
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Process Characteristics
 Drilling, slotting, multiple hole drilling etc
 High degree of repeatability and high accuracy(±0.025 to ±0.127mm)
 Taper ranges from 0.005 to 0.05mm/cm
 MRRv is low(0.1 to 10mm3/min-A)
 Surface integrity ( surface topography and surface metallurgy) effects the
performance, life and reliability of the component
 Three layers: recast layer, HAZ and converted layer
 Recast layer: resolidification and harden(2.5 to 50µm).
extremely hard and brittle. Porous and may contain micro cracks.
 HAZ: Heating, cooling, and diffused material are responsible. Thermal
residual stresses, grain boundary weakness, and grain boundary cracks
are some imp characteristics.
 Conversion layer: chain in grain structure from the original structure.

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Electrode rotating and Orbiting EDM
 Electrode rotating : consists of precision spindle, drove
mechanism, and a speed control.
Spindle drive is either electrical or pneumatic.
Spindle speeds are set manually and generally low (max up to
200rpm)
Rotation assist flushing while machining small holes and to
achieve high profile accuracy and finish and also increases speed
of machining.
 Electrode Orbiting: orbiting produces a shaped hole and size of
the hole depends on size of the electrode and the orbiting radius
(limit to 2.5mm).
• Average space between the electrode and workpiece is larger
than the gap in standard operations because of orbiting radius.
• Improves flushing (pumping effect) . Finishing work
• Electrode end –wear is less 39
Applications
 Any material: hard, tough, brittle , exotic etc
 Hardened die steel
 Aerospace, automobile, tools, and machine tool
components
 Making dies for moulding, casting, forging, stamping,
coining, forming, extruding, wire drawing, etc.
 Common application is removal of broken taps, drills,
studs, reamers, pins, etc.
 cavities, small deep holes, narrow slots, turbine blades,
and intricate shapes.

40
Cavities produced by EDM Stepped cavities

41
Limitations
A hard skin, or recast layer is produced which may be
undesirable in some cases.
Beneath the recast layer is a heat affected zone which
may be softer than parent material.
Finishing cuts are needed at low MRR.
Produces slightly tapered holes, specially if blind

42
1. In a RC type generator, the maximum charging voltage
is 80 V and the charging capacitor is 100 F. Determine
spark energy.
2. If in a RC type generator, to get an idle time of 500 s
for open circuit voltage of 100 V and maximum
charging voltage of 70 V, determine charging resistance.
Assume C = 100 F
3. For a RC type generator to get maximum power
dissipation during charging Vc* = Vox0.716. Determine
idle time for Rc = 10  and C = 200 F
4. Determine on time or discharge time if Vo = 100 V and
Vd* = 15 V. Spark energy = 0.5 J. Generator is expected
for maximum power during charging. Machine
resistance = 0.5 . 43
1. 1 1
E s  CV  x100 x10 6 x80 2  0.32J
2
2 2
2. Rc C
tc  
 
 Vc * 
ln1  
 V0 
3.  
Rc C 10 x200 x10 6
tc   
 V * ln1  0.716 
ln1  c 
 Vo 
4.
Vc*  0.716 Vo  71.6 V

1 1
E s  CV 2  0.5 J  C  2 x 0 .5 x
 71.6 2
 195 F
2
RmC
td    62 F
 Vd 
*
ln *  44
 
Wire EDM

45
46
Thin diameter (0.05 to 0.3mm) wire is used as
electrode.
Unwinds from a spool, feeds through the w/p, and is
taken up on a spool.
High frequency pulses DC power supply
Gap is flooded with Deionized water
Material eroded ahead of the tool by spark discharges
Either w/p or electrode(wire) can be moved
The gap ranges usually -0.025 to 0.05mm
High degree of accuracy with fine surface

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Equipment
Positioning system:
• Two axis or multi axis table- wire positioning
• Adaptive control is used to maintain the correct gap bt the tool and
w/p
Wire drive system:
• Continuously deliver fresh wire under constant tension
• To avoid taper, machining streaks, wire breaks, and vibrations marks
• After wire leaves from the supply spool, it passes several wire-feed
and wire –removal capstan rollers.
• Wire diameters relatively large(0.15 to 0.30mm) copper or brass is
used

• Very fine wire(0.006 to 0.15mm) molybdenum steel is used

48
Power supply:
• Pulse frequency as high as 1MHz may be used
• Current is limited to 20 A
Dielectric system:
• Deionized water

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Electric Discharge Grinding
EDG is a spark erosion process used for machining
electrically conductive work pieces.
A rotating electrically conductive grinding wheel is
used as the electrode.
Pulsed electrical energy is delivered to the wheel and
work piece (up to 250,000pulses/sec)
The dielectric fluid flows through a small gap
between wheel and w/p
EDG is commonly used to perform operations on very
fragile or to produce thin sections without damage.
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Equipment
Power supply, dielectric delivery systems, filtration
system and work pan –identical as EDM
Axis motions, wheel mounting, and overall
appearance –similar to conventional grinding
Wheels: porous, low grade graphite
diameters : 100 to 305mm
wheel width: 0.25mm to 152mm
Servo drive system

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Process capabilities
Current range from 0.5 to 200 amp at 40-80V DC.
Current increase surface roughness increases, and
depth of HAZ also increases.
Gap increases surface finish becomes rougher.
Pulse frequency from 50,000 to 250,000Hz.
Higher the frequency, the smother the resulting
surface finish.
Speeds are less compared to the conventional
grinding.

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