Pallavi Dubey

UNCONVENTIONAL MACHINING PROCESSES
Presented by : Pallavi Dubey

B.Tech Mechanical Engineering
(2107510409016)
CONTENT
• Introduction
• Classification
• Erosion Machining
– Electro Discharge Machining
I. Introduction
II. Major components of EDM
III. Principle of EDM
IV. Working
V. Summary
Advantages
Disadvantages
EDM - CHARACTERISTICS
INTRODUCTION
• Traditional machining is mostly based on removal of materials
using tools that are harder than the materials themselves.
• Traditional machining methods are often ineffective in
machining hard materials like ceramics and composites or
machining under very tight tolerances as in micromachined
components.
• The need to a avoid surface damage that often accompanies
the stresses the created by conventional machining. Eample:
areospace
CLASSIFICATION
ELECTRO DISCHARGE MACHINING
• Electro Discharge Machining (EDM) is an electro-

thermal non-traditional machining processes , where
electrical energy is used to generate electrical spark
and material removal mainly occurs due to thermal
energy of the spark.
• EDM is mainly used to machine difficult-to-materials
and high strength temperature resistant alloys.
• EDM can be used to machine difficult geometries in
small batches or even on job-shops basis.
MAJOR COMPONENTS OF EDM
The main components of EDM are:
• Electric power supply
• Work piece & tool
• Dielectric medium
• Servo control unit.
PRINCIPLE OF EDM
• Controlled metal -removal technique where
electric spark used to cut (erode) workpiece.
• Takes shape opposite to that of cutting tool
• Electrode(cutting tool) made from electrically
conductive material
• Dielectric fluid surrounds both tool and work
• Servo mechanism gives gap .005 to.001 in.
between work and tool
• Direct current of low voltage.
Electro Discharge Machine setup
WORKING
• In EDM, a potential difference is applied between the tool and
workpiece.
• Both the tool and work material are to be conductors of
electricity.
• The tool and the work material are immersed in a dielectric
medium.
• Dielectric medium-kerosene or deionised water.
• Gap is maintained between the tool and the workpiece.
• Depending upon the applied potential difference and the gap
between the tool and workpiece , an electric field would be
established.
• Tool is connected to the negative terminal of the generator and
the workpiece is connected to positive terminal.
Schematic representation of the basic working principle of EDM process
Working
• As the electric field is established between the tool and the job, the
free electrons on the tool are subjected to electrostatic forces
• “cold emission”-the work function on 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 the electrons are called or termed as cold emission.
• The “cold emitted” electrons are then accelerated towards the job
through the dielectric medium,as they gain velocity and energy,and start
moving towards the job,there would be collision between the electrons
and dielectric molecules. Such collision may result in ionization of the
dielectric molecules.
• As the electrons get accelerated, more positive ions and electrons would
get generated due to collisions.
• This cylic process would increase the concentration of electrons and ions
in the dielectric medium between the tool and job at the spark gap.
The concentration would be so high that the matter existing in that channel could be
characterized as “plasma”.
SUMMARY
• The material removal in EDM mainly occurs due to formation of shock

waves
• as the plasma channel collapse owing to discontinuation of applied
potential difference
• generally the work piece is made positive and the tool negative.
• Hence, the electrons strike the job leading to crater formation due
high temperature and melting and material removal.
• Similarly, the positive ions impinge on the tool leading to tool wear.
• The generator is use to apply voltage pulses between the tool and job.
• A constant voltage is not applied. Only sparking is desired rather than
arcing.
• Arcing leads to localized material removal rate at a particular point
wheras spark get distributed all over the tool surface leading to
uniform material removal.
ADVANTAGES
• Some of the advantages of EDM include machining of:
• Complex shapes that would otherwise be difficult to produce
with conventional cutting tools.
• Extremely hard material to very close tolerances.
• Very small work pieces where conventional cutting tools may
• damage the part from excess cutting tool pressure.
• There is no direct contact between tool and work piece.
Therefore
• delicate sections and weak materials can be machined without
any distortion.
• A good surface finish can be obtained
DISADVANTAGES
Some of the disadvantages of EDM include:
• The slow rate of material removal.
• For economic production, the surface finish specified should not be too fine.
• The additional time and cost used for creating electrodes for ram/sinker
EDM.
• Reproducing sharp corners on the workpiece is difficult due to electrode
wear.
• Power consumption is high.
• "Overcut" is formed.
• Excessive tool wear occurs during machining.
• Electrically non-conductive materials can be machined only with specific set-
up of the
process
• In EDM, geometry oftool – positive impression of hole or geometric feature.
• Tool wear once again depends on the thermal properties of tool material.
• Local temperature rise is rather high, but there is not enough heat diffusion
(very
small pulse on time) and thus HAZ is limited to 2 – 4 μm.
• Rapid heating and cooling leads to surface hardening which may be
desirable in
some applications.
• Tolerance value of + 0.05 mm could be easily achieved by EDM.
• Best surface finish that can be economically achieved on steel is 0.40 m
• Can be used to machine any work material if it is electrically conductive.
• Capacitor discharge is between 50 and 380 V
• Dielectric slurry is forced through this gap at a pressure of 2 kgf/cm2 or lesser.
• A gap, known as SPARK GAP in the range, from 0.005 mm to 0.05 mm is
maintained
between the work piece and the tool.
• The current density in the discharge of the channel is of the order of 10000
A/cm2 and
power density is nearly 500 MW/cm2.
• MRR depends on thermal properties (job) rather than its strength, hardness etc.
• The volume of the material removed per spark discharge is typically in the range
of
(1/1,000,000) to (1/10,000) mm3.

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UNCONVENTIONAL MACHINING PROCESSES

Presented by : Pallavi Dubey

• Electro Discharge Machining (EDM) is an electro-

• The material removal in EDM mainly occurs due to formation of shock

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