VT Uc Lo Ud: Module-4

NON-TRADITIONAL MACHINING 21ME751
MODULE-4
Electrical Discharge Machining (EDM)
Introduction:
Electrical Discharge Machining (EDM) is a non-traditional machining process used to

remove metal through electrical discharges (sparks). It is especially effective for machining
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hard, brittle materials and for producing complex shapes that are difficult to achieve using
traditional methods. EDM is widely used in tool and die making, mold fabrication, and
aerospace industries. The key advantage of EDM is that it can machine very hard materials,
such as hardened steels, carbides, and alloys, without applying physical cutting forces.
EDM operates in the presence of a dielectric fluid (usually deionized water or

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kerosene) that insulates the workpiece from the electrode until a spark is generated. It is
particularly suitable for materials that are electrically conductive, making it ideal for
precision machining of hard metals.
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Dept., of Mechanical Engg. SVIT, B’luru-64. Page 1

Mechanism of Metal Removal
The process of EDM is based on the principle of material removal by thermal energy
generated from electrical discharges. The metal removal mechanism in EDM involves the
following steps:
1. Gap Creation:
A small gap, known as the spark gap, is maintained between the electrode (tool) and the
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workpiece. This gap is filled with dielectric fluid, which acts as an insulator until a high
voltage is applied.
2. Spark Generation:
When a pulsed electrical current is applied between the electrode and the workpiece, a
high-intensity electric field is created, breaking down the dielectric fluid. This results in a
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series of high-energy sparks that occur in the gap.
3. Localized Melting and Vaporization:
The sparks create intense heat (up to 12,000°C) at localized points on the workpiece
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surface. This heat causes a small volume of material to melt and vaporize from both the
workpiece and the electrode. The material removal is purely thermal and does not involve
mechanical force.
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4. Erosion of the Workpiece:
The molten material is rapidly vaporized and expelled by the dielectric fluid, which also
helps cool the area and solidify any remaining molten material. The dielectric fluid then
flushes away the eroded material, ensuring a clean spark gap for the next discharge.
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5. Repetitive Process:
The process is repeated continuously in a controlled manner, with each spark removing a
tiny amount of material. This enables precise machining, allowing complex shapes and fine
details to be achieved.

EDM Equipment
1. Spark Erosion Generator (Relaxation Type)
The spark erosion generator is the core component of an EDM machine, responsible
for generating the electrical pulses (sparks) required to erode material from the workpiece.
The relaxation-type generator is one of the common types used in EDM.
Working Principle:
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 In a relaxation-type generator, a capacitor is charged by a DC power source until the
voltage reaches a threshold. Once this threshold is achieved, the dielectric medium in
the gap between the electrode and workpiece breaks down, causing a discharge (spark).
 The spark generates intense heat, melting and vaporizing a small amount of the
workpiece material. lo
 After the spark, the capacitor discharges, and the circuit is reset to begin charging again
for the next spark.
Advantages:
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 Simplicity in design and control.
 Suitable for machining hard materials and achieving fine details.
Disadvantages:
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 Slower machining rates compared to modern pulse generators.

 Limited ability to control individual spark characteristics, making it less suitable for
high-speed operations.
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2. Dielectric Medium
The dielectric medium is a crucial part of the EDM process. It is a non-conductive

liquid (commonly kerosene, deionized water, or mineral oil) that fills the gap between the
electrode and the workpiece.
Functions:
 Insulation: It prevents premature discharge by insulating the electrode and the

workpiece until the voltage reaches a high enough level to cause a spark.

 Cooling: The dielectric cools both the electrode and workpiece during the process,
preventing thermal damage and deformation.
 Debris Removal: It helps remove the molten material (debris) from the machining
zone after each spark, maintaining a clean work area for continuous sparking.
 Spark Control: The dielectric fluid controls the shape and intensity of the spark,
contributing to the precision of the machining process.
Desirable Properties:
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 High Dielectric Strength: To resist electrical breakdown at lower voltages.
 Low Viscosity: For easy flushing and removal of debris from the work zone.
 Chemical Stability: To ensure the fluid does not decompose under high temperatures
or cause corrosion to the workpiece or electrode.
 Cooling Efficiency: It should effectively dissipate heat from the machining zone.
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3. Electrode Feed Control System:
The electrode feed control system is essential in EDM for maintaining the proper gap
between the electrode and the workpiece, ensuring efficient sparking and material removal.
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Function:
 The system automatically adjusts the electrode's position relative to the workpiece
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during the machining process. As material is eroded from the workpiece, the electrode
is fed forward to maintain a constant and optimal gap (spark gap).
 The feed control system also adjusts the electrode feed rate based on the spark
frequency, ensuring stable machining conditions.
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Types of Feed Control Systems:
 Servo Mechanism: Uses a feedback loop to continuously monitor the spark gap and
adjust the electrode position accordingly. If the gap becomes too wide, the servo
system moves the electrode closer to the workpiece.
 Step-Feed Control: In this system, the electrode is moved in small steps rather than a
continuous motion, pausing briefly after each adjustment to allow stable sparking
before moving again.

Flushing Types in EDM
In Electrical Discharge Machining (EDM), flushing is a critical process to remove the

debris (eroded particles) generated during machining from the spark gap between the
electrode and workpiece. Proper flushing ensures a clean gap, prevents short circuits, and
enhances the overall machining efficiency and surface finish. There are several flushing
techniques used in EDM, each suited to different machining scenarios. The four main types
are pressure flushing, suction flushing, side flushing, and pulsed flushing.
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1. Pressure Flushing:
Principle: In pressure flushing, the dielectric fluid is injected into the spark gap at high
pressure through holes in the electrode or a nozzle. The force of the fluid pushes the debris
away from the machining area and clears the gap.
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Application: This method is commonly used when machining deep cavities or holes, where
the debris tends to accumulate in the narrow gap between the electrode and workpiece.
Advantages:
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 Efficient removal of debris.
 Improved surface finish and spark stability.
 Suitable for high-speed machining operations.
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Disadvantages:
 High-pressure fluid flow can sometimes damage delicate workpieces or disrupt

machining if not controlled properly.
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2. Suction Flushing:
Principle: In suction flushing, the dielectric fluid is drawn or sucked through the spark gap
by creating a vacuum. The debris is removed from the machining zone by the suction force,
helping to maintain a clean gap.
Application: This technique is useful when machining small, delicate parts or intricate
geometries where pressure flushing might be too aggressive.

Advantages:
 Gentle and effective flushing for fragile workpieces.

 Reduces the risk of short circuits by keeping the spark gap clean.
Disadvantages:
 Less effective for large workpieces or deep cavities.

 Slower debris removal compared to pressure flushing.
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3. Side Flushing:
Principle: In side flushing, the dielectric fluid is introduced from the side of the spark gap,
using a nozzle positioned near the machining zone. The fluid flows across the gap, pushing
debris away from the work area.
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Application: This method is commonly used in cases where the electrode does not have
internal channels for fluid flow, such as when machining flat surfaces or large areas.
Advantages:
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 Simple and easy to implement.
 Effective for shallow cuts or large surface area machining.
Disadvantages:
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 May not be as efficient as other methods for deep cavities or holes.

 Flushing may be uneven if the nozzle is not positioned correctly.
4. Pulsed Flushing:
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Principle: Pulsed flushing involves injecting the dielectric fluid intermittently in pulses
rather than a continuous flow. The fluid is pumped in short bursts, allowing time for debris to
be flushed out between pulses and for the spark gap to stabilize.
Application: Pulsed flushing is often used for machining complex geometries, deep holes, or
tight areas where continuous flushing might cause instability in the spark gap.

Advantages:
 Prevents turbulence in the spark gap, ensuring stable spark generation.

 Efficient debris removal while maintaining machining precision.
 Reduces wear on the electrode by minimizing unnecessary fluid force.
Disadvantages:
 Complex to control compared to continuous flushing methods.
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 May require specialized equipment to regulate the pulsing of the fluid.
EDM Process Parameters
The performance and quality of the Electrical Discharge Machining (EDM) process
are significantly influenced by various process parameters. These include spark frequency,
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current & spark gap, surface finish, and heat-affected zone (HAZ). Each of these parameters
plays a crucial role in determining the efficiency, precision, and quality of the machining
outcome.
1. Spark Frequency:
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Definition: Spark frequency refers to the number of electrical discharges (sparks) occurring
per second between the electrode and the workpiece during the EDM process.
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Impact:
 Higher spark frequency results in more sparks per unit of time, increasing the material
removal rate (MRR) and potentially speeding up the machining process.
 However, a very high spark frequency can also lead to unstable machining, where the
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dielectric fluid might not have enough time to cool down and remove the debris
between successive sparks, which can degrade the surface finish and accuracy.
 Lower spark frequency provides better cooling time and flushing efficiency, which
helps achieve a finer surface finish, but at the cost of slower material removal.
Control: Spark frequency is typically controlled by adjusting the pulse duration and pulse
interval in the EDM machine. Optimal spark frequency is required for balancing machining
speed and surface quality.

2. Current & Spark Gap:
Current:
 Current (measured in amperes) in EDM refers to the electrical energy supplied to

create the spark between the electrode and workpiece.
 Higher current increases the energy of each spark, resulting in a faster material
removal rate (MRR). It is useful for rough machining, where speed is more important
than surface finish.
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 Lower current generates less energy, leading to finer machining with better surface
finish but at a slower material removal rate.
Spark Gap:
 The spark gap is the distance between the electrode and the workpiece where the
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spark is generated.
 Smaller spark gaps lead to more precise machining, as the spark is more concentrated,
providing better control over the removal process.
 Larger spark gaps are used for higher material removal rates but may lead to less
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accurate results and rougher surface finishes.
 Proper control of the spark gap ensures stable machining. If the gap is too small, it can
cause short circuits, while too large a gap will reduce the efficiency of material
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removal.
3. Surface Finish:
Definition: Surface finish in EDM refers to the texture or smoothness of the machined
surface. It is influenced by the size and energy of the sparks, the material being machined,
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and the dielectric fluid.
Impact:
 Fine Surface Finish: Achieved by using lower current, higher spark frequency, and
smaller spark gaps. This results in smaller craters formed by each spark, leading to a
smoother surface.

 Rough Surface Finish: Higher current, lower spark frequency, and larger spark gaps
result in larger craters, leading to a rougher surface texture. This is often preferred in
rough machining stages where speed is prioritized over precision.
Measurement: Surface finish is typically measured in terms of Ra (average roughness),

where lower Ra values indicate smoother surfaces. Achieving a fine surface finish is critical
for applications requiring high precision, such as mold making or medical components.
Control: Fine-tuning the current, spark gap, and pulse duration can help achieve the desired
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surface finish. Additionally, proper flushing of the dielectric fluid ensures that debris is
removed effectively, which contributes to a better surface finish.
4. Heat-Affected Zone (HAZ):
Definition: The heat-affected zone (HAZ) is the region surrounding the area where material
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is removed by the electrical discharge. This zone is exposed to high temperatures during
machining, leading to changes in the material's properties.
Impact:
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 During the EDM process, the intense heat generated by the sparks can cause thermal
damage to the workpiece in the form of micro-cracks, recast layers, and changes in
hardness within the HAZ.
 A larger HAZ can lead to more significant metallurgical changes, which might affect
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the mechanical properties and integrity of the final product.
Control:
 The size and impact of the HAZ can be minimized by using lower current and shorter
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pulse durations, which reduce the amount of heat transferred to the workpiece.
 Effective dielectric fluid flushing also helps by cooling the workpiece quickly,
reducing the extent of the heat-affected zone.
 In critical applications (e.g., aerospace, medical devices), controlling the HAZ is
crucial to ensure that the material properties of the workpiece are not compromised.

Advantages of Electrical Discharge Machining
1. High Precision: EDM can achieve tight tolerances and intricate shapes with
exceptional precision.
2. Material Versatility: It can be used on a wide range of electrically conductive
materials, including metals and alloys.
3. Burr-Free Results: EDM produces burr-free and exceptionally smooth surface
finishes.
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4. Complex Geometries: It is suitable for machining complex and intricate part
geometries that are difficult to achieve with traditional methods.
5. Hardened Materials: EDM can machine hardened materials, making it ideal for tool
and die manufacturing.
6. No Tool Wear: Unlike traditional cutting tools, there is no physical tool-to-workpiece
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contact, resulting in minimal tool wear.
7. Heat-Affected Zone Control: EDM minimises heat-affected zones, making it
suitable for heat-sensitive materials.
8. Thin Workpieces: It can machine thin and delicate workpieces without distortion.
9. Low Impact on Workpiece: EDM exerts minimal mechanical forces on the
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workpiece, reducing the risk of deformation.
Disadvantages of Electrical Discharge Machining

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1. Excessive tool wear.

2. High power consumption.
3. The sharp corner cannot be reproduced.
4. High heat development causes a change in the metallurgical properties of materials.
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5. The workpiece must be an electrical conductor.

6. Surface cracking may take place in some materials.
7. Redressing of a tool is required for deep holes.
8. Over-cut is formed.
9. Difficult finding expert machinists.

Applications of Electrical Discharge Machining
1. Helical profile milling.

2. Curved hole drilling.
3. Engraving operation on harder materials.
4. Drilling for micro holes in the nozzle.
5. Used in thread cutting.
6. Used in wire cutting.
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7. Rotary form cutting.
8. Cutting off operation.
Electrical Discharge Grinding (EDG)
Introduction: lo
Electrical Discharge Grinding (EDG) is a variation of Electrical Discharge Machining
(EDM) used for precision machining of conductive materials. It combines electrical discharge
erosion with mechanical grinding, making it suitable for complex profiles and hard materials
that are difficult to machine with traditional grinding processes.
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Working Principle:
EDG works on the same principle as EDM, where material removal occurs due to a
series of rapid electrical discharges between the tool (electrode) and the workpiece. However,
in EDG, a rotating conductive grinding wheel replaces the stationary electrode. The wheel

generates sparks that erode material from the workpiece, while the abrasive nature of the
grinding wheel simultaneously performs mechanical grinding.
Process Details:
1. Electrical Discharges: Similar to EDM, a dielectric fluid surrounds the workpiece and the
grinding wheel. The grinding wheel acts as the tool electrode. Electrical discharges occur
between the wheel and the workpiece, causing localized melting and vaporization of the
material.
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2. Abrasive Action: The rotating wheel also has abrasive particles that assist in material
removal mechanically. The combination of electrical and abrasive actions leads to more
efficient material removal, especially for difficult-to-machine materials like carbide or
hardened steel.
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3. Dielectric Fluid: A dielectric fluid (typically deionized water or oil) is used to remove
debris and cool the tool and workpiece. It also helps to control the electrical discharge and
prevent short-circuiting.
Advantages:
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1. High Precision: EDG provides excellent accuracy in shaping and grinding difficult
materials like tool steel, tungsten carbide, and other hard alloys.
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2. Complex Geometries: It is capable of machining complex shapes that are hard to

achieve through traditional grinding.
3. Minimal Tool Wear: As the material removal mainly occurs through electrical
discharges, the grinding wheel experiences less wear compared to conventional
grinding.
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4. Low Cutting Force: Since material removal is primarily achieved through electrical
discharges, there is minimal mechanical force, which reduces stress on the workpiece.
Applications:
1. Hard and Brittle Materials: EDG is ideal for machining very hard or brittle
materials that are otherwise difficult to grind, such as ceramics and high-strength
alloys.

2. Precision Tooling: It is often used in the production of cutting tools, mold

components, and dies.
3. Aerospace and Medical Components: EDG is used for machining complex and
delicate parts for high-precision applications in aerospace and medical industries.
Traveling Wire Electrical Discharge Machining (Wire EDM)
Introduction:
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Traveling Wire Electrical Discharge Machining, commonly known as Wire EDM or
simply Wire-Cut EDM, is a variation of EDM that uses a continuously traveling wire as an
electrode to cut through conductive materials. This process is widely used for producing
intricate and precise shapes in hard metals.
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Working Principle:
In Wire EDM, a thin metal wire (usually made of brass, copper, or tungsten) acts as
the tool electrode. The wire does not touch the workpiece; instead, electrical discharges
between the wire and the workpiece erode material, allowing for highly accurate cutting. The

process is carried out in a bath of dielectric fluid, which helps control the sparks and remove
the eroded particles.
Process Details:
1. Continuous Wire Movement: The wire is constantly fed from a spool, ensuring that a
fresh section of wire is always used in the cutting zone. This prevents wire wear from
affecting the precision of the cut.
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2. Electrical Discharges: High-frequency electrical pulses are applied between the wire and
the workpiece, generating a series of electrical sparks. Each spark removes a tiny amount of
material from the workpiece.
3. Dielectric Fluid: The wire and the workpiece are submerged in a dielectric fluid, typically
deionized water, which serves multiple purposes: it cools the wire and workpiece, removes
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eroded material, and helps control the electrical discharges.
4. CNC Control: The movement of the wire is controlled by CNC (Computer Numerical
Control), which enables the machine to produce highly complex and precise cuts. The wire
can move in X, Y, and Z directions, allowing for intricate 2D and 3D shapes.
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Advantages:
1. Precision and Accuracy: Wire EDM is known for its ability to create complex and
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detailed cuts with extreme accuracy, often within microns.

2. No Mechanical Stress: Since there is no physical contact between the wire and the
workpiece, there is no mechanical force, leading to minimal stress or deformation on
the workpiece.
3. Ability to Cut Hard Materials: Wire EDM can cut through hard and tough materials
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such as hardened steel, titanium, tungsten, and superalloys, which are challenging to
machine by traditional methods.
4. Complex Shapes: The process can produce complex geometries, fine features, and
intricate contours, making it highly suitable for precision tool making, dies, and mold
components.

Applications:
1. Mold and Die Making: Wire EDM is widely used for creating precise molds and
dies with intricate details.
2. Aerospace and Medical: The ability to machine complex shapes in hard materials
makes Wire EDM ideal for aerospace and medical components.
3. Tooling: Wire EDM is frequently used to manufacture precision tooling, gauges, and
fixtures.
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4. Prototyping: The high precision and flexibility of Wire EDM make it an excellent
choice for prototyping complex parts.
Limitations:
1. Slow Cutting Speed: Wire EDM tends to be slower than other machining processes,
making it less suitable for high-volume production.
2.
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Material Conductivity: Only conductive materials can be machined using Wire
EDM, limiting its application to metals and conductive alloys.
Comparison between EDG and Wire EDM:

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Feature EDG (Electrical Discharge Wire EDM (Traveling Wire
Grinding) EDM)
Tool Type Rotating grinding wheel Continuous traveling wire
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Material Electrical discharges with Electrical discharges only

Removal mechanical grinding action
Material Type Hard, conductive materials Conductive materials
Precision High precision in grinding Extremely high precision in
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cutting
Applications Tooling, hard material machining Intricate shapes, mold making,
precision tooling
Material Stress Minimal stress, but more than EDM Virtually no stress or deformation
Cutting Speed Moderate Slow compared to other
machining processes

Plasma Arc Machining (PAM)
Introduction
Plasma Arc Machining (PAM) is a thermal-based non-traditional machining process

that utilizes a high-velocity jet of ionized gas (plasma) to cut through electrically conductive
materials. The intense heat generated by the plasma jet melts and evaporates the material,
allowing for fast and efficient cutting of metals. PAM is widely used in industries where high
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precision, speed, and the ability to cut tough materials are essential, such as aerospace,
shipbuilding, and automotive manufacturing.
Working Principle:
Plasma Arc Machining operates by converting a gas (like nitrogen, argon, or oxygen)
into plasma—a superheated, electrically conductive state of matter. This is achieved by
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passing the gas through an electric arc, which ionizes the gas and produces a high-
temperature plasma jet. The plasma jet reaches temperatures as high as 30,000°C (54,000°F)
and can cut through even the hardest metals.
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1. Plasma Generation:
 A direct current (DC) arc is struck between an electrode (usually made of tungsten)
and the workpiece, or in some cases, between the electrode and a nozzle.
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 As the gas flows through the arc, it becomes ionized and turns into plasma, which
exits the nozzle as a focused high-energy jet.
2. Material Removal:
 The plasma jet impinges on the workpiece surface, melting and vaporizing the
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material due to the intense heat.

 A portion of the material is blown away by the force of the jet, and the rest melts,
enabling the cutting action.
3. Shielding and Cooling:
 A secondary gas stream (shield gas) is often used to shield the plasma arc and cool
the workpiece to prevent oxidation and material warping.

 Water cooling is also common in some setups to manage the extreme temperatures
generated.
Non-Thermal Generation of Plasma
In Plasma Arc Machining (PAM), plasma is typically generated using thermal energy
by heating a gas with an electric arc. However, non-thermal generation of plasma refers to
producing plasma in such a way that the electrons in the plasma are much hotter than the ions
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and neutral particles, resulting in a condition where the gas remains at a relatively low
temperature while the plasma is still ionized and active.
In non-thermal plasmas, ionization occurs without requiring extremely high

temperatures to be applied to the entire gas. Non-thermal plasma generation can be used in
some advanced cutting and surface treatment processes but is not the primary mechanism in
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traditional PAM. Nonetheless, understanding non-thermal plasma generation offers insights
into how plasma can be produced in other industrial applications.
Methods of Non-Thermal Plasma Generation:
1. Dielectric Barrier Discharge (DBD): A commonly used method for generating non-
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thermal plasma. It involves applying high-voltage alternating current across electrodes
separated by a dielectric material (insulator). The electric field ionizes the gas without
generating significant heat, producing non-thermal plasma. DBD is often used in surface
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treatments, pollution control, and sterilization, but it can’t reach the cutting capabilities
required for PAM.
2. Microwave Discharge: In microwave plasmas, microwaves are used to excite the
electrons in a gas, ionizing it without significantly heating the gas. This results in a non-
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thermal plasma where the gas remains cool while still being ionized. Microwave-
generated plasma finds applications in surface modifications, coating deposition, and
chemical processing but is not used for high-energy cutting as in PAM.
3. Radio-Frequency (RF) Discharge: RF plasma is created by applying radio-frequency
energy to a gas. This generates non-thermal plasma by selectively heating electrons
while keeping the ions and neutral particles at a lower temperature. RF plasmas are used
in semiconductor manufacturing and thin-film deposition.

Equipment (Components) of Plasma Arc Machining
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1. Plasma Torch: Contains the electrode and nozzle through which the plasma jet is directed.
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2. Power Supply: Supplies high voltage to establish the electric arc and maintain the plasma.
The power supply can be either direct current (DC) or alternating current (AC), but DC is
more commonly used for its stability and control.
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3. Gas Supply System: Delivers the ionizing gas to the plasma torch. The gas flows through
the nozzle and gets ionized when it comes in contact with the electric arc.
4. Workpiece Table: A platform that holds the workpiece in place during machining. It may
have adjustable height and movement capabilities (such as CNC controls) to enable precision
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cutting.
5. Cooling System: Cools the plasma torch and the workpiece to prevent overheating and
warping. This system usually includes water-cooling channels in the torch.
6. Control System: Manages the parameters of the machining process, including gas flow
rates, arc voltage, cutting speed, and torch height, allowing for precise operation and
adjustments.

Mechanism of Metal Removal in Plasma Arc Machining
1. Plasma Generation: When the power supply is turned on, a high voltage is applied to the
electrode, creating a spark that ionizes the gas flowing through the nozzle. This generates a
plasma arc, which can reach extremely high temperatures (up to 30,000°C or 54,000°F).
2. Focusing the Plasma Jet: The ionized gas (plasma) exits the nozzle as a focused, high-
velocity jet. This concentrated stream of plasma carries both thermal energy and kinetic
energy, which are critical for cutting through the material.
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3. Material Interaction: As the plasma jet strikes the workpiece, the intense heat melts and
vaporizes the surface material. The high kinetic energy of the plasma jet helps to blow away
the molten metal, creating a kerf (the width of the cut). The cutting occurs due to a
combination of:
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a. Thermal Action: The heat generated by the plasma melts the metal.
b. Mechanical Action: The force of the plasma jet ejects the molten metal from
the cut.
4. Continuous Cutting: As the torch moves across the workpiece, the plasma continuously
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cuts through the material, maintaining a consistent kerf. The torch can be operated in various
modes, including manual, semi-automatic, or fully automated (CNC).
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5. Cooling and Shielding: The shielding gas helps protect the molten metal from
atmospheric contamination (oxidation), while the cooling system manages the heat in the
plasma torch and workpiece, ensuring that the machining process remains efficient and
stable.
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Plasma Torch

The plasma torch is a critical component in Plasma Arc Machining (PAM), serving as
the source of the plasma jet that cuts through electrically conductive materials. Its design and
operation are vital for the effectiveness and efficiency of the machining process. Below is an
in-depth look at the plasma torch, including its structure, operation, and significance in PAM.
Components of the Plasma Torch
1. Electrode:
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 Typically made from tungsten, the electrode serves as the cathode where the electric
arc is initiated.
 The electrode is responsible for maintaining the arc and generating the plasma. Its
durability and thermal resistance are critical for prolonged operation.
2. Nozzle: lo
 The nozzle surrounds the electrode and is designed to direct the flow of ionized gas
(plasma) towards the workpiece.
 It helps to focus the plasma jet to achieve high cutting precision and efficiency. The
design of the nozzle influences the shape and velocity of the plasma flow.
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3. Gas Supply Port:
 This port is where the shielding and plasma-forming gas (such as argon, nitrogen, or
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a mixture of gases) enters the torch.

 Proper gas flow is essential for effective plasma generation and protection of the
workpiece from oxidation.
4. Cooling System:
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 The plasma torch often includes cooling channels or jackets that allow for water or
air cooling preventing overheating during operation.
 Effective cooling extends the life of the torch and maintains consistent performance.
5. Power Supply Connection:
 The torch connects to a power supply that provides the necessary voltage to create
and sustain the electric arc.

 The power supply may be adjustable to control the current and voltage, allowing for
fine-tuning of the machining parameters.
Operation of the Plasma Torch
1. Ignition of the Arc:
 When the power supply is activated, a high voltage is applied between the electrode
and the workpiece (or the nozzle).
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 This voltage creates an electric arc, ionizing the gas and initiating plasma formation.
2. Plasma Generation:
 The gas flows through the nozzle and is ionized by the heat of the arc, forming a
high-temperature plasma jet.
 The plasma jet exits the nozzle at extremely high velocities (often exceeding the
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speed of sound), carrying significant thermal energy.
3. Cutting Action:
 As the plasma jet strikes the workpiece, it transfers heat to the material, melting and
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vaporizing it.
 The kinetic energy of the plasma flow assists in ejecting the molten material from
the cut, creating a kerf.
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4. Continuous Operation:
 The plasma torch can be moved across the workpiece to perform cutting along a
predetermined path. It can be operated manually or automatically through computer
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numerical control (CNC) systems.

 The torch maintains a consistent distance from the workpiece, ensuring optimal
cutting conditions.
Types of Plasma Torches
1. Transferred Arc Plasma Torch:
 In this configuration, the arc is established between the electrode and the workpiece.
 It provides higher cutting power and is commonly used for thick materials.

2. Non-Transferred Arc Plasma Torch:
 Here, the arc is maintained between the electrode and the nozzle, with the plasma jet
directed towards the workpiece.
 This type is often used for applications that require precise control and finer cutting.
Advantages of Plasma Torch in PAM
1. High Cutting Temperature: The plasma jet can reach temperatures of around
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30,000°C (54,000°F), enabling it to cut through tough materials effectively.
2. Versatile Material Compatibility: The plasma torch can handle various conductive
materials, including stainless steel, aluminum, and titanium.
3. Precision: The focused nature of the plasma jet allows for narrow kerf widths,
leading to high precision in cutting.
4. Speed: Plasma Arc Machining is generally faster than traditional cutting methods,
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making it suitable for large-scale industrial applications.
Applications of Plasma Torch in PAM
1. Aerospace: Cutting and shaping components from high-strength alloys.

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2. Shipbuilding: Efficiently cutting thick steel plates for hulls and structural elements.
3. Automotive: Fabricating metal parts for vehicles, including body panels and frames.
4. Metal Fabrication: General applications requiring precision cutting of metal sheets
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and parts.
Process Parameters in Plasma Arc Machining
1. Arc Current (Amperage):

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Definition: The arc current refers to the electrical current supplied to the plasma torch to
generate the plasma arc.
Effect on Machining:
a. Higher Current: Increases the plasma arc temperature and energy, enabling faster
cutting speeds and deeper penetration. It is typically used for cutting thicker
materials.

b. Lower Current: Reduces the arc temperature and is suitable for cutting thinner
materials with a finer cut and less material distortion.
c. Optimal Range: The current is usually in the range of 50 to 1000 amperes,
depending on the material thickness and cutting requirements.
2. Arc Voltage:
Definition: Arc voltage is the electrical potential difference between the electrode (cathode)
and the workpiece (anode).
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a. A higher voltage leads to a longer and more stable arc, which can improve the
cutting capability of thicker materials.
b. However, excessively high voltage can reduce precision and cause a wider kerf (cut
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width).
c. Optimal Range: The voltage typically ranges from 50 to 200 volts depending on the
cutting application.
3. Gas Flow Rate:

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Definition: The rate at which the plasma-forming gas (such as argon, nitrogen, or a mixture)
is supplied to the plasma torch.
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a. Higher Gas Flow Rate: Increases the velocity and concentration of the plasma jet,
improving cutting speed and cooling the workpiece faster. However, too high a flow
rate may disrupt arc stability.
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b. Lower Gas Flow Rate: Leads to a more focused and controlled plasma arc but may
slow down cutting and result in excess heat accumulation on the workpiece.
c. Optimal Range: The gas flow rate is usually in the range of 5 to 20 liters per minute
(LPM), but this can vary based on the material and cutting conditions.
4. Plasma Gas Composition:
Definition: The type and mixture of gas used in PAM, which can include argon, nitrogen,
hydrogen, oxygen, or mixtures like argon-hydrogen or nitrogen-hydrogen.

Different gases have varying ionization potentials and affect the heat transfer and cutting
efficiency.
For example:
a. Argon: Provides a stable plasma arc and is often used for precision cutting.
b. Nitrogen: Increases the energy of the plasma arc, making it suitable for cutting
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stainless steel and aluminum.
c. Hydrogen: Mixed with argon or nitrogen, it enhances heat transfer for cutting
thicker materials.
Selection: The gas composition is selected based on the material type, thickness, and desired
cut quality. lo
5. Cutting Speed:
Definition: The speed at which the plasma torch moves across the surface of the workpiece
during the cutting process.
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a. Higher Cutting Speed: Reduces the heat input per unit length, resulting in a
narrower heat-affected zone (HAZ) and less distortion. However, it may result in
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poor edge quality if the speed is too high.

b. Lower Cutting Speed: Increases the heat input, which can improve cut quality but
may also increase the HAZ, causing thermal distortion.
c. Optimal Range: Cutting speed depends on material thickness and the desired
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quality, with typical ranges between 0.5 m/min to 5 m/min.
6. Stand-Off Distance (Torch Height):
Definition: The distance between the plasma torch nozzle and the surface of the workpiece.
a. Optimal Distance: Ensures a focused plasma arc for efficient cutting. Too large a
distance reduces the arc's cutting power, while too short a distance may cause

excessive heating of the nozzle and workpiece, leading to material damage or poor
cut quality.
b. Optimal Range: The stand-off distance is typically maintained between 1.5 to 5
mm depending on the material and cutting conditions.
7. Nozzle Diameter:
Definition: The size of the opening at the tip of the plasma torch through which the plasma
jet exits.
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a. A smaller nozzle provides a more focused and narrow plasma jet, resulting in higher
precision but lower cutting power.
b. A larger nozzle allows for a wider plasma jet, which increases cutting speed and
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power but may reduce precision.
Selection: The nozzle diameter is chosen based on the material thickness and the type of cut
required.
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8. Shielding Gas Flow:
Definition: The auxiliary gas flow surrounding the plasma arc to protect the cut zone from
oxidation and cool the workpiece.
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a. Protects the molten metal from contamination and oxidation.

b. Assists in cooling the workpiece, reducing thermal distortion.
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Typical Gases: Shielding gases can include nitrogen, argon, or air, depending on the material
being cut.
9. Polarity (DC or AC Operation):
Definition: PAM can operate in either Direct Current (DC) or Alternating Current (AC)
modes, though DC is more commonly used.

a. DC Polarity: Provides a more stable arc and is generally used for most plasma arc
machining operations.
b. AC Polarity: Can be used for specific materials or applications where arc stability
or control needs to be optimized.
Influence of Process Parameters on Machining Performance
1. Cut Quality:
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The combination of cutting speed, arc current, and torch height greatly affects the
quality of the cut edges. Improper settings can lead to rough or jagged edges, excessive dross
(molten material that solidifies on the cut edge), or incomplete cuts.
2. Material Removal Rate (MRR):
Higher arc current and gas flow rates typically result in faster material removal, but
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they must be balanced with cutting speed and precision requirements to avoid poor surface
finish or thermal damage.
3. Heat-Affected Zone (HAZ):

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Higher cutting speeds and appropriate stand-off distances reduce the heat-affected
zone, minimizing distortion in the workpiece. However, low cutting speeds or excessive heat
input can enlarge the HAZ, affecting material properties.
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4. Kerf Width (Cut Width):
The nozzle diameter, arc voltage, and torch height influence the kerf (width of the
cut). A wider nozzle or higher arc voltage results in a wider kerf, which may reduce precision
but improve cutting speed.
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Process Characteristics of Plasma Arc Machining
1. High Cutting Temperature
Characteristic: The plasma jet generated by the torch can reach temperatures ranging from
20,000°C to 30,000°C (36,000°F to 54,000°F).
Impact:

a. This extremely high temperature allows PAM to cut through tough and thick
materials quickly and efficiently.
b. The high temperature also enables PAM to melt and vaporize almost any electrically
conductive material.
2. Material Versatility
Characteristic: PAM is effective for cutting a wide range of conductive materials, including
ferrous and non-ferrous metals.
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Common Materials: Stainless steel, aluminum, copper, titanium, and alloys.
Impact:
a. The versatility of PAM makes it suitable for diverse industrial applications in sectors
like aerospace, automotive, and shipbuilding.
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b. However, PAM is limited to electrically conductive materials, as non-conductive
materials (like plastics or ceramics) cannot be processed effectively.
3. High Cutting Speeds

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Characteristic: Plasma Arc Machining offers high cutting speeds compared to traditional
cutting methods like oxy-fuel cutting.
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Impact:
a. Faster cutting speeds lead to increased productivity and reduced machining time,
making PAM efficient for large-scale and repetitive operations.
b. The speed varies based on the material thickness, the type of gas used, and the
power supply, but PAM typically outperforms many mechanical cutting methods.
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4. Narrow Kerf (Cut Width)
Characteristic: PAM creates a narrow kerf, or cut width, due to the focused nature of the
plasma jet.
Impact:
a. The narrow kerf minimizes material wastage, which is especially important when
working with expensive materials like titanium or aerospace alloys.

b. A narrow kerf also contributes to higher precision in cutting, allowing for intricate
shapes and details.
5. Heat-Affected Zone (HAZ)
Characteristic: The process generates a localized heat-affected zone around the cutting area,
which can alter the material properties near the cut edge.
Impact:
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a. The HAZ is relatively small in PAM compared to traditional methods like oxy-fuel
cutting, but the heat can still cause microstructural changes, oxidation, or warping in
sensitive materials.
b. Careful control of process parameters, such as cutting speed and arc current, can
minimize the size of the HAZ.
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6. Minimal Mechanical Stresses
Characteristic: Since Plasma Arc Machining is a non-contact process, it does not apply
mechanical forces to the workpiece.
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Impact:
a. This reduces the risk of mechanical deformation, burrs, or cracks in the material.
b. It is particularly advantageous for cutting thin sheets or delicate materials that could
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be damaged by mechanical cutting tools.
7. Surface Finish
Characteristic: The surface finish achieved with PAM is generally smooth but depends on
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the material, cutting parameters, and the condition of the plasma torch.
Impact:
a. Smooth Edges: With optimal settings, PAM can produce clean cuts with minimal
post-processing required.
b. Dross Formation: At higher cutting speeds or improper settings, molten material
can accumulate at the bottom of the cut, resulting in dross that needs to be removed
manually.

8. Gas Requirements
Characteristic: Plasma Arc Machining requires a plasma-forming gas (e.g., argon, nitrogen,
or a mixture) and sometimes a shielding gas to protect the cut surface from oxidation.
Impact:
a. The type and flow rate of gas affect the quality of the cut, the cutting speed, and the
stability of the plasma arc.
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b. Gases like argon-hydrogen or nitrogen are commonly used for cutting stainless steel
and aluminum to ensure a stable and hot plasma arc.
9. Power Supply and Control
Characteristic: PAM uses a DC power source that typically operates in the range of 50 to
1000 amps. The power supply controls the arc current, voltage, and gas flow rate.
Impact:
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a. Precise control of these parameters is essential for maintaining a stable arc and
achieving desired cutting performance.
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b. Automated PAM systems with CNC (Computer Numerical Control) integration
allow for complex shapes and designs to be cut with high precision.
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10. Plasma Torch Design
Characteristic: The plasma torch plays a critical role in generating and directing the plasma
jet. The torch includes components like a tungsten electrode, a nozzle, and cooling systems to
handle the high temperatures.
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Impact:
a. The design and condition of the plasma torch (such as nozzle wear) significantly
affect cutting quality and process efficiency.
b. Proper maintenance of the torch is necessary to avoid irregularities in the plasma jet,
which can lead to poor cuts or increased wear on the electrode.
11. Environmental and Safety Considerations

Characteristic: PAM generates ultraviolet (UV) radiation, noise, and fumes during the
cutting process.
Impact:
a. UV radiation can be harmful to operators, requiring appropriate safety gear such as

welding shields and gloves.
b. Noise levels can exceed 100 dB in some applications, necessitating the use of
hearing protection.
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c. The fumes and gases produced during cutting, especially when working with
materials like stainless steel or aluminum, may require ventilation systems or fume
extraction to ensure a safe working environment.
12. Cost Factors

lo
Characteristic: The cost of Plasma Arc Machining is influenced by factors such as power
consumption, gas usage, and torch maintenance.
Impact:
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a. PAM can be cost-effective for cutting thick materials or for high-speed production,
but it may have higher operating costs compared to mechanical methods due to gas
consumption and wear on consumable parts like the electrode and nozzle.
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b. The initial setup cost for PAM equipment is higher than traditional cutting tools, but
the long-term benefits of high productivity and precision often justify the
investment.
13. Automation Compatibility

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Characteristic: Plasma Arc Machining can be easily integrated with CNC systems for
automated control of the cutting process.
Impact:
a. Automation allows for greater consistency, precision, and speed, making PAM
suitable for high-volume production runs.
b. CNC plasma cutting systems are commonly used in industries where precise and
repeatable cuts are essential, such as aerospace, automotive, and metal fabrication.

Safety Measures to Consider When Using Plasma Arc Machining (PAM)
1. Personal Protective Equipment (PPE)
Operators must wear appropriate PPE to protect themselves from the high-intensity plasma
jet, UV radiation, and hot metal splatter.
a. Welding Helmet with UV/IR Protection: Protects the eyes and face from harmful
ultraviolet (UV) and infrared (IR) radiation. The helmet should have the correct
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shade for plasma arc cutting to prevent eye damage (e.g., auto-darkening welding
shields).
b. Heat-Resistant Gloves: Protect hands from burns due to exposure to molten metal,
sparks, and heat.
c. Flame-Resistant Clothing: Ensures the operator’s skin is shielded from burns due
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to hot metal splatter and sparks. Clothing should be made of flame-resistant
materials like leather or heavy-duty cotton.
d. Safety Boots: Non-slip, heat-resistant boots protect feet from falling metal or
sparks.
e. Hearing Protection: Plasma cutting operations can generate noise levels exceeding
C
100 dB, so hearing protection such as earplugs or earmuffs is necessary to prevent
hearing loss.
f. Respiratory Protection: The cutting process generates toxic fumes, particularly
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when cutting metals like stainless steel or aluminum. Operators should wear an
approved respirator or use an exhaust ventilation system to prevent inhalation of
harmful gases and particulates.
2. Ventilation and Fume Extraction

V
a. Fume Extraction Systems: Plasma cutting produces harmful fumes that may
contain heavy metal oxides and other toxic substances. Installing local exhaust
ventilation (LEV) or fume extractors at the point of cutting is essential to minimize
inhalation risks.
b. Adequate Room Ventilation: Ensure that the room is well-ventilated, and the
ventilation systems are working properly to maintain air quality.

c. Use of Air Purifiers: In confined spaces, air purification systems may also be
necessary to ensure the removal of hazardous gases and particulates.
3. Electrical Safety
Plasma Arc Machining operates at high voltages and currents, creating significant electrical
hazards.
a. Proper Grounding: Ensure that the plasma cutting machine and workpiece are
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properly grounded to prevent electric shocks.
b. Inspection of Cables and Connections: Regularly inspect power cables, torch leads,
and connections for damage, fraying, or loose fittings. Replace or repair damaged
components immediately.
c. Dry Environment: Operators should work in dry conditions and avoid using PAM in
wet or damp areas to reduce the risk of electric shock.
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d. Use of Circuit Breakers and Fuses: Install circuit breakers and fuses to protect
against electrical overloads or short circuits.
4. Fire and Explosion Prevention

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Plasma cutting generates high temperatures and sparks that can ignite flammable materials in
the workspace.
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a. Keep Flammable Materials Away: Remove any flammable or combustible

materials such as paper, fuel, or oil from the cutting area.
b. Fire Extinguishers: Keep appropriate fire extinguishers, such as Class D
extinguishers for metal fires, nearby in case of emergency. Operators should be
trained to use them.
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c. Inspect for Gas Leaks: Regularly check gas hoses and fittings for leaks. Ensure that
gases such as hydrogen (often used in PAM) are stored safely, as they can be highly
flammable or explosive.
5. Handling of Compressed Gases
Plasma Arc Machining uses compressed gases like nitrogen, argon, or hydrogen to create the
plasma jet.

a. Proper Storage of Gas Cylinders: Gas cylinders should be stored in a cool, dry,
and ventilated area, away from sources of heat and direct sunlight. They should be
secured upright with chains or brackets to prevent tipping.
b. Inspection of Gas Hoses and Connections: Regularly inspect gas hoses, valves,
and regulators for leaks, cracks, or wear. Use leak detection solutions to check for
leaks in connections.
c. Correct Gas Handling: Only trained personnel should handle gas cylinders and
ensure the correct gas pressure and flow rate during operation.
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6. Thermal Safety
The plasma jet reaches temperatures above 20,000°C, creating intense heat and the risk of
burns.
a. Cooling Systems: Ensure that the torch cooling system is functioning correctly to
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prevent overheating of the equipment.
b. Cool down Time: Allow the equipment to cool down before performing any
maintenance or handling parts near the cutting area.
c. Safe Distance from the Cutting Area: Ensure operators maintain a safe distance
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from the cutting zone to avoid exposure to hot surfaces, molten metal, or plasma
arcs.
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7. Proper Workspace Setup
A well-organized workspace helps minimize accidents and improve efficiency.
a. Designated Cutting Area: Set up a designated area for plasma cutting, free from
clutter and trip hazards.
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b. Securing the Workpiece: Secure the workpiece properly using clamps to prevent
movement during cutting, which could lead to inaccurate cuts or accidents.
c. Use of Barriers: In larger workshops, welding curtains or shields should be placed
around the cutting area to protect other workers from exposure to the bright arc and
flying debris.
8. Plasma Torch Maintenance
Maintaining the plasma torch is crucial for safe operation and optimal performance.

a. Nozzle and Electrode Inspection: Regularly check the nozzle and electrode for
wear and tear, which could cause instability in the plasma arc or increase the risk of
torch failure.
b. Proper Torch Handling: Handle the torch carefully, and avoid dropping or
mishandling it, as this could damage internal components.
9. Arc Radiation Protection
Plasma cutting generates intense UV, IR, and visible light radiation, which can damage the
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skin and eyes.
a. Arc Flash Protection: As with welding, plasma arc cutting produces arc flashes that
can cause serious eye damage. Always ensure appropriate eye protection is worn.
b. UV-Resistant Barriers: Install barriers or welding curtains to shield others in the
area from radiation exposure.
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10. Training and Operational Guidelines
a. Operator Training: Ensure that all personnel operating PAM equipment are
properly trained in the use of the machine, safety protocols, and emergency
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procedures.
b. Emergency Shutdown Procedures: All operators should be familiar with
emergency shutdown procedures in case of equipment malfunction or accident.
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c. Safe Handling of Workpieces: Use appropriate tools and techniques to handle hot
or sharp workpieces after cutting to avoid burns or injuries.
11. Emergency Procedures
a. First Aid Kit: Have a first aid kit readily available in case of burns, cuts, or injuries.
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b. Emergency Exit Access: Ensure that all personnel know the locations of emergency
exits and that the paths to them are clear.
c. Fire and Electrical Emergency Protocols: Staff should be trained in how to
respond to electrical or fire emergencies, including how to shut off equipment safely.

Advantages of Plasma Arc Machining:
1. Cuts Hard Materials: Capable of cutting through hard and difficult-to-machine

materials like stainless steel, titanium, and other alloys.
2. High Cutting Speeds: PAM offers faster cutting speeds compared to conventional
methods such as oxy-fuel cutting.
3. Versatility: Can cut materials of varying thicknesses, from thin sheets to thick
plates.
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4. Precise Cutting: Produces narrow kerfs (cut widths), enabling detailed and precise
cuts.
5. Minimal Material Deformation: The high speed of the plasma jet minimizes heat-
affected zones (HAZ) and reduces thermal distortion in the material.
Disadvantages of Plasma Arc Machining:

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1. Limited to Conductive Materials: PAM can only be used for electrically
conductive materials, restricting its use for non-metals like plastics or ceramics.
2. High Energy Consumption: Plasma Arc Machining requires a significant amount
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of electrical power, making it less energy-efficient than some other methods.
3. Noisy and High Heat Generation: The process generates a lot of noise and extreme
heat, necessitating proper safety measures and cooling systems.
4. Surface Finish: The surface finish achieved by PAM may require additional
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processing or grinding for applications requiring smooth surfaces.
Applications of Plasma Arc Machining:
1. Aerospace Industry: Cutting heat-resistant alloys used in aircraft components.

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2. Automotive Industry: Fabricating parts from steel, aluminum, and other metals.
3. Shipbuilding: Cutting thick steel plates for hulls and other structures.
4. Manufacturing: General metal fabrication, especially for precision sheet metal
work.

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NON-TRADITIONAL MACHINING 21ME751

Electrical Discharge Machining (EDM)

Electrical Discharge Machining (EDM) is a non-traditional machining process used to

EDM operates in the presence of a dielectric fluid (usually deionized water or

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 1

Mechanism of Metal Removal

3. Localized Melting and Vaporization:

4. Erosion of the Workpiece:

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 2

1. Spark Erosion Generator (Relaxation Type)

 Slower machining rates compared to modern pulse generators.

The dielectric medium is a crucial part of the EDM process. It is a non-conductive

 Insulation: It prevents premature discharge by insulating the electrode and the

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 3

Types of Feed Control Systems:

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 4

Flushing Types in EDM

In Electrical Discharge Machining (EDM), flushing is a critical process to remove the

 High-pressure fluid flow can sometimes damage delicate workpieces or disrupt

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 5

 Gentle and effective flushing for fragile workpieces.

 Less effective for large workpieces or deep cavities.

 May not be as efficient as other methods for deep cavities or holes.

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 6

 Prevents turbulence in the spark gap, ensuring stable spark generation.

 Complex to control compared to continuous flushing methods.

EDM Process Parameters

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 7

2. Current & Spark Gap:

 Current (measured in amperes) in EDM refers to the electrical energy supplied to

and the dielectric fluid.

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 8

Measurement: Surface finish is typically measured in terms of Ra (average roughness),

4. Heat-Affected Zone (HAZ):

the mechanical properties and integrity of the final product.

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 9

Advantages of Electrical Discharge Machining

Disadvantages of Electrical Discharge Machining

1. Excessive tool wear.

5. The workpiece must be an electrical conductor.

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 10

Applications of Electrical Discharge Machining

1. Helical profile milling.

Electrical Discharge Grinding (EDG)

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 11

2. Complex Geometries: It is capable of machining complex shapes that are hard to

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 12

2. Precision Tooling: It is often used in the production of cutting tools, mold

Traveling Wire Electrical Discharge Machining (Wire EDM)

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 13

detailed cuts with extreme accuracy, often within microns.

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 14

Comparison between EDG and Wire EDM:

Material Electrical discharges with Electrical discharges only

Dept., of Mechanical Engg. SVIT, B’luru-64. Page 15

Plasma Arc Machining (PAM)

Plasma Arc Machining (PAM) is a thermal-based non-traditional machining process

material due to the intense heat.

3. Shielding and Cooling: