1

Indian Institute of Technology Delhi

ELECTRO-DISCHARGE MACHINING
 2
Indian Institute of Technology Delhi
Instructional Objective
• Identify electro-discharge machining (EDM) as a
particular type of non-tradition processes
• Describe the basic working principle of EDM
process
• Draw schematically the basics of EDM
• Describe spark initiation in EDM
• Describe material removal mechanism in EDM
• Draw the basic electrical waveform used in EDM
• Identify the process parameters in EDM
• Describe the characteristics of EDM
• Identify the purpose of dielectric fluid in EDM
• List two common dielectric fluid
 3
Indian Institute of Technology Delhi
Instructional Objective
• Analyse the required properties of EDM tool
• List four common tool material for EDM
• Develop models for MRR in EDM
• Identify machining characteristics in EDM
• Analyse effect of process variables on roughness
• Analyse taper cut and over cut in EDM
• Identify different modules of EDM system
• Draw schematic representation of different
electrical generators used in EDM
• Analyse working principle of RC type EDM
generator
 4
Indian Institute of Technology Delhi
Electro-discharge Machining – Process
 5
Indian Institute of Technology Delhi
Standard Wave Form in EDM
 6
Indian Institute of Technology Delhi
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.
 7
Indian Institute of Technology Delhi
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
 8
Indian Institute of Technology Delhi
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
 9
Indian Institute of Technology Delhi
Taper Cut and Over Cut

• Though there is a
possibility of taper cut
and over cut in EDM, they
can be controlled and
compensated.
 10
Indian Institute of Technology Delhi
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 conductivity
(electrical) 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.
 11
Indian Institute of Technology Delhi
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
 12
Indian Institute of Technology Delhi
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.
 13
Indian Institute of Technology Delhi
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
 14
Indian Institute of Technology Delhi
Tool Material

• Graphite
• Electrolytic oxygen free copper
• Tellurium copper – 99% Cu + 0.5%
tellurium
• Brass
 15
Indian Institute of Technology Delhi
Modelling of MRR in EDM
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 
 16
Indian Institute of Technology Delhi
Product Quality Issues in EDM
• Surface finish
• Over cut
• Taper cut
 17
Indian Institute of Technology Delhi
Modelling of Surface Finish in EDM

2 3
hm  r and s  r
3

1/ 3
3 
 r  hm   s 
2 
s  gEs  gVIton
 hm   s    VIton 
1/ 3 1/ 3 1/ 3
 Es
 18
Indian Institute of Technology Delhi
EDM – Equipment
• Dielectric reservoir,
pump & circulation
system
• Power generator &
control unit
• Working tank with work
holding device
• X-Y table
accommodating the
working table
• Tool holder
• Servo system to feed the
tool
 19
Indian Institute of Technology Delhi
Types of EDM Generators

• Resistance-capacitance type (RC type)

Relaxation generator
• Rotary impulse type generator
• Electronic pulse generator
• Hybrid EDM generator
 20
Indian Institute of Technology Delhi
RC type EDM Generator

-
 21
Indian Institute of Technology Delhi
RC type EDM Generator – Charging
dV 1
 dt
Vo  Vc CRc
Vc *
iC id dVc 1 tc
   dt
0 Vo  Vc CRc 0

  c 
t tc Vc *

Vc  Vc *  Vo 1  e RcC    ln  Vo  Vc 
 Rc o
 
t
 
t  t
RcC 
Vo  Vo  1  e c 
R C
Vo e RcC
Vo  Vc 


 ic   io .e
ic   Rc
Rc Rc
 22
Indian Institute of Technology Delhi
RC type EDM Generator – Discharging

Vc dVc Vd*
dVc 1 td
id   C    dt
Rm dt V*
c
Vc CRm 0
* * td
td Vd Vc 
   ln *  Vd*
 .e RmC
CRm Vc Rm

* t
Vd Vc
RmC
id   .e
Rm Rm
 23
Indian Institute of Technology Delhi
EDM Wave Form for RC Generator
Vo
Vc *
V
Vd*
t
tc td

iC

id

t
 Indian Institute of Technology Delhi
Cycle Time & Frequency

Vc* = 0.716 Vo for maximum power output

 Vc*   Vd 
tc   RCC ln  1   td   RmC ln  * 
 V V
 c   c 

1 1
f  
tc  td  Vc*   Vd 
RCC ln  1    RmC ln  * 
 Vc   Vc 
 25
Indian Institute of Technology Delhi
Spark Energy
*2 2t
td td
Vc 
RmC
Es   id2Rm dt   2 m R e dt
0 0 Rm
td
2t *2 2t
*2 td  
Vc RmC VcRmC RmC
 e dt  . e
Rm o Rm 2t
0
  d 
2t
1 *2  RmC 
 CVc 1  e  1 *2
2   Es  CVc
2
 26
Indian Institute of Technology Delhi
Summary
• Basic mechanism of material removal in EDM
• Process parameters of EDM & effects on MRR
• Different Quality Parameters and their control
• Mathematical model relating MRR and surface
roughness with EDM parameters
• Major components of EDM equipment
• Different types of EDM generator
• Analysis of RC type generator
 27
Indian Institute of Technology Delhi
Quiz
1. Which of the following material cannot be
machined by EDM
– steel
– WC
– Titanium
– Glass
2. Which of the following is used as dielectric
medium in EDM
– tap water
– kerosene
– NaCL solution
– KOH solution
 28
Indian Institute of Technology Delhi
Quiz
3. EDM tool should not have
– high machinability
– low thermal conductivity
– high melting point
– high specific heat

4. EDM tool material should be

– electrical insulator
– electrically conductive
– very hard
– thermal insulators
 29
Indian Institute of Technology Delhi
Solved Problem – 1
1. In a RC type generator, the maximum charging
voltage is 80 V and the charging capacitor is
100 F. Determine spark energy
 30
Indian Institute of Technology Delhi
Solved Problem – 2
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
 31
Indian Institute of Technology Delhi
Solved Problem – 3
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
 32
Indian Institute of Technology Delhi
Solved Problem – 4
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 .