Electrical Discharge Machining (EDM)

Introduction
• EDM is a thermo-electric (or electro-thermal)
non-traditional machining process.
• Electrical energy is used to generate electrical
spark and material removal occurs mainly due to
thermal energy of the spark. (or spark erosion)
• EDM is mainly used to machine difficult-to-cut
materials and high strength temperature
resistant alloys.
Basic working principle of EDM
 Process description
• The tool and the w/p are immersed in a
dielectric medium. Generally, kerosene or
deionised water is used as the dielectric.
• A potential difference is applied between the
tool and the w/p. The tool is made cathode and
w/p is made anode.
• A gap is maintained between the tool and the
w/p and electric field will be generated.
• The tool and the w/p material should be
electrically conductive. (i.e., they should have
more amount of free electrons)
 Contd…
• Once the electric field is generated, the free
electrons on the tool experience electrostatic
forces.
• If the bonding energy of the electrons is less,
electrons will be emitted from the tool. Such
emission of electrons is known as “cold
emission”.
• These electrons are accelerated towards the w/p
through the dielectric medium.
• As these electrons gain velocity and start
moving towards the w/p , there will be collision
of electrons with the dielectric molecules.
 Contd…
• Thus, ionization takes place and dielectric
molecules will ionize due to the collision.
• Therefore, more amount of ions and electrons
will be generated which results in increased
concentration of ions and electrons in the
dielectric medium between the tool and w/p.
• This will result in secondary and tertiary
collisions which can be characterised as
“plasma”.
• Suddenly, large number of electrons will flow
from tool to the w/p and ions from w/p to the
tool.
 Contd…
• This is known as “avalanche motion” of
electrons resulting in spark erosion.
• Thus, high energy electrons strike the w/p
surface leading to high temperature rise and
hence localised melting on the w/p surface
resulting in material removal.
Schematic showing spark gap and ionized
column
EDM setup
 Process parameters in EDM
• The process parameters in EDM are mainly
related to the waveform characteristics-
Contd…
Characteristics of EDM
Characteristics of EDM
 Dielectric in EDM
• The dielectric fluid is a spark conductor, coolant
and also a flushing medium. The requirements
of a dielectric fluid are-
 It should have sufficient and stable dielectric
strength to serve as an insulation between the
tool and w/p till the breakdown voltage is
reached.
 It should deionize rapidly after the spark
discharge has taken place.
 It should have low viscosity.
 Contd…
 It should be chemically neutral and should have
high flash point.
 It should be economical and easily available.
 It should not emit any toxic vapors.
 Tool electrode materials
• Copper – Used for fine surface finish
• Brass – Easily available
• Graphite – Good machinability and wear
resistant.
 Advantages of EDM
• No physical contact between the tool and w/p
and hence no cutting forces act on the w/p.
• Fragile and brittle components can be
machined.
• Any complex shape molds and dies can be
easily produced to the required degree of
accuracy.
• EDM is not affected by hardness of the w/p.
• The material removal rates are almost
comparable with traditional machining
processes.
 Contd…
• Though the material is removed by the thermal
energy of spark, there is no thermal damage to
the w/p material.
• EDM is a highly automated process.
 Limitations of EDM
• Wear rate on the tool electrode is considerably
high due to striking of ions on the tool.
• W/p to be machined should be electrically
conductive.
• Energy required for the operation is more and
hence process is more expensive.