351-Chipless machining

2-Chipless Machining Processes:
2.1 Electro-discharge machining,

2.2 Water jet and abrasive water jet machining,
2.3 Laser beam machining,
2.4 Electro-chemical machining,
2.5 Chemical machining,
2.6 Electron beam machining.
1
2.1 Electro-discharge machining
.
2.11 Introduction
2.12 Working Principle
2.13 Components of EDM
2.14 Characteristics of EDM
2.15 Advantages and Disadvantages of EDM
2.16 Application of EDM
2.11 Introduction
Electrical Discharge Machining

is a controlled metal-removal
process that is used to remove metal
by means of electric spark erosion.
• I n this process
an electric spark is
used as the cutting
tool to cut(erode) the
work piece to produce
the finished part to
the desired shape.
• Electro discharge
machining process is a non-
conventional and non-
contact machining
operation which is used in
industry for high precision
products.
•EDM is known for
machining hard and
brittle conductive
materials since it can
melt any electrically
conductive material
regardless of its
hardness.
• EDM is mainly
used to machine
difficult-to-machine
materials and high
strength temperature
resistant alloys.
✓ EDM can be used to
machine difficult geometries
in small batches or even on
job-shop basis.
✓ Work material to be
machined by EDM has to be
electrically conductive.
CONSTRUCTION
OF EDM
2.12
Working
Principle
❑ In EDM, a potential
difference is applied between
the tool and work piece. Both
the tool and the work material
are to be conductors of
electricity.
❑ It is metal removal
❑ The tool and the work process based on
the principle of
material are immersed in material removal by
a dielectric medium.
electric spark
Generally kerosene or
between electrode
deionized water is used
as the dielectric medium.
tool and work piece.
A gap is maintained
between the tool and the work
piece. Depending upon the
applied potential difference and
the gap between the tool and
work piece, an electric field
would be established.
Generally the tool is connected
to the negative terminal of the
generator and the work piece is
connected to positive terminal.
• As the electric field
is established
between the tool
and the job, the free
electrons on the tool
are subjected to
electrostatic forces.
• If the work function or the
bonding energy of the
electrons is less, electrons
would be emitted from
the tool (assuming it to be
connected to the negative
terminal).
• Such emission of electrons

are called or termed as
cold emission.
T he “cold emitted”
electrons are accelerated
towards the workpiece
through the dielectric
A s electrons gain
medium.
velocity and energy, and

start moving towards the
workpiece, there are
collisions between the
electrons and dielectric
molecules.
• Thus, as the electrons
get accelerated, more
positive ions and electrons
would get generated due to
collisions.
This cyclic process would
increase the concentration of
electrons and ions in the
dielectric medium between the
tool and the job at the spark gap.
• The concentration would be so

high that the matter existing in that
channel could be characterized as
“plasma”. The electrical
resistance of such plasma channel
would be less.
• Thus suddenly, many electrons will flow
from the tool to the job and ions from the job
to the tool.
• This is called avalanche motion of
electrons. Such movement of electrons and
ions can be visually seen as a spark.
• The electrical
.
energy is dissipated
as the thermal energy
of the spark
• G enerally
the work piece
is made positive
and the tool
negative.
•H ence, the electrons
strike the job leading to
crater formation due to
high temperature and
melting and material
removal.
• Similarly, the positive

ions impinge on the tool
leading to tool wear.
✓I n EDM, the generator is used to
apply voltage pulses between the tool

and the job.
✓A constant voltage is not applied.

Only sparking is desired in EDM rather
than arcing.
✓Arcing leads to localized material

removal at a particular point whereas
sparks get distributed all over the tool
surface leading to uniformly distributed
material removal under the tool.
COMPONENTS
OF EDM
The main components in EDM:
• 1. Electric power generator
• 2. Dielectric fluid
• 3. Tool (Electrode)
• 4. Servo control unit
• 5. Fixture
• 6. Tank
1. POWER GENERATOR:
• In EDM Power supply converts
AC into pulsed DC, used to
produce spark between cutting
tool(electrode) and work piece.
• In EDM supply peak voltage

ranging from 40 to 400V, and
peak discharge current ranging
from 0.5 to 500 A.
- Resistance-capacitance
type (RC type)generator
• Different - Rotary impulse type
power generator
generators
are used in - Electronic pulse
EDM and generator
some are
listed below : - Hybrid EDM generator
• 2. DIELECTRIC FLUID :
• • The dielectric medium plays an important role
in the working of the EDM process. The dielectric is
usually a low viscosity hydrocarbon oil.
• • The work piece and electrode tool are

separated by the dielectric.
• • During operation the dielectric medium is

ruptured when the tool and work gap is about 0.03
mm and at about 70 V.
• • when the dielectric is ionized to form a column

or path in the tool and work gap so that a surge of
current takes place as the spark is produced.
§ Functions
of Dielectric
fluid:
1. Remain electrically non-

conductive until the
required breakdown
voltage is attained
2. When once the breakdown

voltage is reached it should
breakdown electrically instantly.
• Desirable Properties of
dielectric fluid:
a) High electric strength for
proper insulation.
b) High flash and fire point to
prevent fire hazards.
c) Low viscosity and good
wetting properties.
d) Chemically neutral to
prevent corrosion.
e) Non-toxic in nature.
f) Low decomposition rate for
long life.
g) Low cost.
h) Good quenching properties.
Functions of Dielectric fluid
(cont):
Deionize
D eionize the spark gap, i.e.,
quench the spark rapidly after the
discharge has occurred.
Carry
away
Carry away the metal particles
removed from the arc gap.
Act Act as a good cooling medium .

3. TOOL (ELECTRODE ):
• In EDM process the shape of the

tool is transferred in the cavity cut
during machining.
• Thus, the shape and accuracy of

the machined surface will depend
primarily on the shape and accuracy
of the tool electrode.
Thus the basic characteristics
of electrode materials are:
a) High electrical
conductivity
b) High thermal conductivity
c) Higher density
d) High melting point
copper
brass
graphite
• Electrodes made from brass,

copper and copper alloys, graphite,
molybdenum, silver, and tungsten
CHARACTERISTICS
OF EDM
• CHARACTERISTIC OF EDM
a) The process can be used to
machine any work material if it is
electrically conductive
b) Material removal depends on
mainly thermal properties of the
work material rather than its
strength, hardness etc.
c) In EDM there is a physical tool and

geometry of the tool is the
d) positive impression of the hole or
geometric feature machined.
e) The tool must be electrically
conductive as well. The tool wear
once again depends on the
thermal properties of the tool
material.
ADVANTAGES
AND
DISADVANTAGES
OF EDM
• • Complex shapes can be produced while it is
difficult to be
• machined by conventional Machining.
• • Extremely hard material can be cut with tight
tolerance.
• • Good surface finish can be obtained.
ADVANTAGES • • The part can be machined without perceivable

distortion, because
OF EDM • there is no direct contact between tool and work

piece.
• • Tolerances of +/- 0.005 can be achieved.
• • EDM is a no-contact and no-force process, making
it well suited
• for delicate or fragile parts that cannot take the
stress of traditional
• machining
• High power consumption.
• The removal rate of material is very slow.
• Due to electrode wear, it is difficult to

reproduce sharp corners on the work piece
• Excessive tool wear occurs during machining.
• Only able to machine conductive materials
• More expensive process than conventional

milling or turning
APPLICATIONS
OF EDM
• Drilling of
micro-holes,
thread cutting,
helical profile
milling, rotary
forming, and
curved hole
drilling.
• Delicate
work piece
like copper
parts can be
produced by
EDM.
a) Can be applied to all
electrically conducting metals
and alloys irrespective of their
melting points, hardness,
toughness, or brittleness.
b) Other applications: deep,
small-dia. holes using tungsten
wire as tool, narrow slots,
cooling holes in super alloy
turbine blades, and various
intricate shapes.
c) EDM can be economically
employed for extremely
hardened work piece.
2.2
Eqn. 2.21
Eqn. 2.22
Eqn. 2.23
Eqn. 2.24
Eqn. 2.25
Eqn. 2.26
Eqn. 2.27
Eqn. 2.28
Eqn. 2.29
Eqn. 2.210
Eqn. 2.211
Eqn. 2.212
Eqn. 2.213
Eqn. 2.214
Eqn. 2.215
Eqn. 2.216
Eqn. 2.217
Eqn. 2.218
Eqn. 2.219
Eqn. 2.220
Eqn. 2.221
Using appropriate and neat sketches, write short notes using categories 1 to 6 of
2.3 Laser beam machining,
2.4 Electro-chemical machining,
2.5 Chemical machining,
2.6 Electron beam machining.
1 Introduction
2 Working Principle
3 Components
4 Characteristics
5 Advantages and Disadvantages
6 Applications

351-Chipless machining

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2-Chipless Machining Processes:

2.1 Electro-discharge machining,

Electrical Discharge Machining

• Such emission of electrons

velocity and energy, and

• The concentration would be so

• Similarly, the positive

apply voltage pulses between the tool

✓A constant voltage is not applied.

✓Arcing leads to localized material

• In EDM supply peak voltage

• • The work piece and electrode tool are

• • During operation the dielectric medium is

• • when the dielectric is ionized to form a column

1. Remain electrically non-

2. When once the breakdown

Act Act as a good cooling medium .

• In EDM process the shape of the

• Thus, the shape and accuracy of

• Electrodes made from brass,

c) In EDM there is a physical tool and

ADVANTAGES • • The part can be machined without perceivable

OF EDM • there is no direct contact between tool and work

• The removal rate of material is very slow.

• Due to electrode wear, it is difficult to

• Excessive tool wear occurs during machining.

• Only able to machine conductive materials

• More expensive process than conventional

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