IJSTE - International Journal of Science Technology & Engineering | Volume 2 | Issue 11 | May 2016

ISSN (online): 2349-784X

Optimization of Process Parameters in Die

Sinking EDM- A Review
Narinder Singh
M. Tech Scholar
Department of Mechanical Engineering
Green Hills Engineering College, Solan

Onkar Singh Bhatia

Associate Professor
Department of Mechanical Engineering
GHEC Solan

Abstract
Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM is a thermal process in
which rapid and continuous spark is discharged between electrically conductive work piece and electrode in dielectric medium. In
the EDM process both the work piece material and the electrode material must be conductors of electricity. This process becomes
cost-effective method of machining extremely tough and brittle materials. It is widely used for making moulds, dies and sections
of complex geometry and forming deep complex shaped holes, by arc erosion in all kinds of electro-conductive materials. The
input variable parameters are current, pulse on time and duty cycle. The effect of the variable parameters mentioned above upon
machining characteristics such as Material Removal Rate (MRR), Tool Wear Rate. Die sinking electrical discharge machining
(EDM) is one of the most widely used techniques for the fabrication of die and mold cavities which are finally used for mass
production of metals and polymer products by replication such as die casting, injection molding, etc. In any replication process, it
is expected that the quality mold will faithfully duplicate its shape and surface texture. Inaccurate duplications cause problems in
assemblies, operations as well as lower the aesthetic view. In die sinking EDM the electrode produces exactly its opposite shape
on the work material.
Keywords: Optimization, Process Parameters, EDM, MRR, TWR
________________________________________________________________________________________________________
I.

INTRODUCTION

Electric discharge machining is a non-conventional machining process and has found its wide application in making moulds, dies,
and in aerospace products and in surgical equipment [9]. As shown in fig.1 potential difference is applied between the tool and
work piece. Both the tool and the work material are to be conductors of electricity. The tool and the work material are immersed
in a dielectric medium. A gap is maintained between the tool and the work piece [2,3]. Depending upon the applied potential
difference and the gap between the tool and work piece, an electric field would be established. If the work fu8nction 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 [5]. 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 collisions
between the electrons and dielectric molecules. Such collision may result in ionization of the dielectric molecule depending upon
the work function or ionization energy of the dielectric molecule and the energy of the electron. 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 [30]. The
concentration would be so high that the matter existing in that channel could be characterized as plasma. The high speed electrons
then impinge on the job and ions on the tool. The kinetic energy of the electrons and ions on impact with the surface of the job and
tool respectively would be converted into thermal energy or heat flux. Such intense localized heat flux leads to extreme
instantaneous confined rise in temperature which would be in excess of 10,000 C such localized extreme rise in temperature leads
to material removal. Material removal occurs due to instant vaporization of the material as well as due to melting [28]. Thus, it is
essential to understand the influence of various factors on EDM process. Analytical and statistical methods are used to select best
combination of process parameters for an optimum machining performance. Different author use different combination of process
parameters. They analyze the experimental data by plotting Interaction graphs, Residual plots for accuracy and Response curves.
Some other methods used by different author for analysis of Taguchis DOE data related to Electrical Discharge Machining (EDM).
Most of the author used L27 Orthogonal Array. Generally the effect of Pulse ON time, Pulse OFF time, Spark gap set Voltage,
Peak current, Flushing Pressure, Work piece height, wire tension and wire feed on the material removal rate, surface roughness,
kerf and gap current is investigated

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Optimization of Process Parameters in Die Sinking EDM- A Review

(IJSTE/ Volume 2 / Issue 11 / 138)

.
Fig. 1: Schematic diagram of EDM process [25]

Components of EDM:
1)
2)
3)
4)

Work-piece-all the conductive material can be worked by EDM

Tool Electrode-The EDM electrode is the tool that determines the shape of the cavity to be produce.
Dielectric fluid- The dielectric fluid is a catalyst conductor, coolant and also a flushing medium.
Flushing method- Flushing is the process of introducing clean filtered dielectric fluid into the spark gap. There are a
number of flushing methods used to remove the metal particles efficiently such as pressure flushing, side flushing, and
suction flushing. In this experiment we are using side flushing to clean the small gap.
5) Servo system-The servo system is commanded by signals from gap voltage sensor system in the power supply and control
the feed of electrode & workpiece to precisely match the rate of material removal.
6) Power supply-The power supply is an important part of any EDM system. It transform the alternating current from the
main utility supply into the pulse direct current (DC) required to produce the spark discharge at the machining gap.
7) The DC pulse generator is responsible for supplying pulses at a certain voltage and current for specific amount of time.
Application of EDM:
1) The EDM process is most widely used by the mould-making tool and die industries, but is becoming a common method
of making prototype and production parts, especially in the aerospace, automobile and electronics industries in which
production quantities are relatively low.
2) It is used to machine extremely hard materials that are difficult to machine like alloys, tool steels, tungsten carbides etc.
3) It is used for forging, extrusion, wire drawing, thread cutting.
4) It is used for drilling of curved holes.
5) It is used for internal thread cutting and helical gear cutting.
6) It is used for machining sharp edges and corners that cannot be machined effectively by other machining processes.
7) Higher Tolerance limits can be obtained in EDM machining. Hence areas that require higher surface accuracy use the
EDM machining process.
8) Ceramic materials that are difficult to machine can be machined by the EDM machining process.
9) Electric Discharge Machining has also made its presence felt in the new fields such as sports, medical and surgical,
instruments, optical, including automotive R&D areas.
10) It is a promising technique to meet increasing demands for smaller components usually highly complicated, multifunctional parts used in the field of micro-electronics.
Advantages of EDM:
1)
2)
3)
4)

Any material that is electrically conductive can be cut using the EDM process.
Hardened workpieces can be machined eliminating the deformation caused by heat treatment.
X, Y, and Z axes movements allow for the programming of complex profiles using simple electrode.
Complex dies sections and molds can be produced accurately, faster, and at lower costs. Due to the modern NC control
systems on die sinking machines, even more complicated work pieces can be machined.
5) The high degree of automation and the use of tool and work piece changers allow the machines to work unattended for
overnight or during the weekends
6) Forces are produced by the EDM-process and that, as already mentioned, flushing and hydraulic forces may become large
for some work piece geometry. The large cutting forces of the mechanical materials removal processes, however, remain
absent.
7) Thin fragile sections such as webs or fins can be easily machined without deforming the part.

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Optimization of Process Parameters in Die Sinking EDM- A Review

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Limitation of EDM:
1) Both the material the tool and work piece material has to be electrical conductivity property. Because of this property
creation of electric discharges is possible.
2) Sometimes the wear rate on the electrode or tool is higher which requires use of more than one tool to finish the machining
on the work piece.
3) Sometimes the measurement of thin gap between the tool and work piece is not easily predictable especially in case of
complex geometries which demands the flushing method to be differ from the simple one.
4) Optimum machining settings of the EDM process largely are influenced by on the grouping of the tool and work piece.
EDM manufacturers only fund these settings of the required material combination. Therefore skill personnel required to
develop his own technology.
5) In case of die sinking EDM the cavity formed on the work piece with low metal removal rate. In case of wire-cut EDM
only outline of the required shape on the work piece has to be machined. Therefore EDM is limited to small production
applications.
II. SOME MACHINING PARAMETERS OF EDM
Parameters of Dry EDM mainly classified into two categories: process parameters & performance Parameters.
Process Parameters:
The process parameters in EDM are used to control the performance measures of the machining process.
Spark On-Time (Pulse Time or Ton):
It is the duration of time expressed in micro seconds in whom the peak current is ready to flow in every cycle. This is the time in
which energy removes the metallic particles from the work piece. This energy is really controlled by the peak current and the
length of the on-time.
Spark Off-Time (Pause Time or Toff):
It is the period of time expressed in micro seconds between the two pulses on time. This time permits the melted particle to
coagulate on to the work piece and to be wash away by flushing method of the arc gap.
Arc Gap:
It is gap between the electrode and work piece in which the spark generate for eroding the metal from the work piece. It is very
thin gap in the range of 10 125 m.
Discharge Current (IP):
Current is measured in ampere (A). Discharge current is responsible directly for material removal. It contains energy for melting
and evaporation.
Duty Cycle ():
It is a percentage of the on-time relative to the total cycle time. This parameter is calculated by dividing the on-time by the total
cycle time (on-time pulse off-time).
Voltage (V):
It is a potential that can be measure by volt it is also effect to the materialremoval rate and allowed to per cycle. Voltage is given
by in this experiment is 50 V.
Diameter of Electrode (D):
It is the diameter of electrode or tool material. Diameter of tool is one factor considered on machining. This experiment 10 mm
tool diameter is utilized.
Over Cut:
It is a clearance per side between the electrode and the workpiece after the marching operation.
Performance Parameters:
These parameters measure the various process performances of EDM results.
Material Removal Rate (MRR):
MRR is a performance measure for the erosion rate of the workpiece and is typically used to quantify the speed at which machining
is carried out. It is expressed as the volumetric amount of workpiece material removed per unit time.
Tool Wear Rate (TWR):
TWR is a performance measure for the erosion rate of the tool electrode and is a factor commonly taken into account when
considering the geometrical accuracy of the machined feature. It is expressed as the volumetric amount of tool electrode material
Removed per unit time.
Surface Quality (SQ):
Surface quality is a broad performance measure used to describe the condition of the machined surface. It comprises components
such as surface roughness (SR), extent of heat affected zone (HAZ), recast layer thickness and micro-crack density.

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III. AIMS AND OBJECTIVES OF WORK

The main objective of present work is to investigate of the influence of input EDM ( Electro Discharge Machining) parameters
on machining characteristics like cutting speed and surface roughness and the effects of various EDM process parameters such as
pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process response
parameters such as material removal rate (MRR), surface roughness (Ra), Kerf (width of Cut), wire wear ratio(WWR)and surface
integrity factors. In this paper few selected research paper related to Die-sinker EDM with effect of MRR, TWR, surface roughness
(SR) and work piece material have been discussed.
IV. LITERATURE REVIEW
EDM is an essential manufacturing process in some industries, which gives importance to variety, precision and accuracy. Since
the inception of the EDM process in late 1960s to till date, a lot of research works have been done by several researchers. The
amount of research work can be divided into two major areas namely EDM process optimization and process monitoring and
control. Several researchers have attempted to improve the performance characteristics namely the surface roughness, cutting
speed, dimensional accuracy and material removal rate, in EDM process. Some of the work related to the present study is discussed
in the following paragraphs.
The EDM process bases on a complex electro-thermal principle that depends very significantly on environmental circumstances.
Especially in the area where a discharge takes place between workpiece and tool electrode, influences like contamination,
temperature and ionization of the dielectric fluid have a massive impact on the resulting material removal, tool wear, etc. Process
control strategies have been developed to counteract these impacts based on detailed process monitoring. The feed rate of sinking
EDM processes results from a controlled gap width with the help of electric signals. [9] Addresses certain aspects of common
process control mechanisms, e.g. gap width control by the ignition delay time or voltage levels as well as self-optimizing
algorithms. [7], [8] and [10] introduce into threshold based spark characterization and advanced threshold based process controls
including experimental investigations and spark characterization to develop technologies.
[1], [3] the effects of operating parameters of tungsten carbide on the machining characteristics such as surface quality, material
removal rate and electrode wear rate was studied. The study was carried out on the basis of the parameters such as pulse on time
and pulse off time peak current, power supply voltage,. The investigated of surface quality was in this carried out by using
perthometer machine. Material removal rate (MRR) and electrode wear (EW) in this experiment was calculated by using
mathematical method.
The Influence of Input Parameters such as pulse on-time and pulse current on the EDM Process. The studied process
characteristics included machining features, embracing material removal rate, tool wear ratio, and arithmetical mean roughness, as
well surface integrity characteristics comprised of the thickness of white layer and the depth of heat affected zone of AISI H13
tool steel as work piece [4,5].The effects of process parameters i.e. discharge current, pulse on and off times, and capacitance on
process outputs i.e. material removal rate and electrode wear rate which was determined on the bases of minimum number of
experiments. For the prediction, mathematical modeling of process has been done using response surface methodology. In their
results a developed model can achieve reliable prediction of experimental results within acceptable accuracy the research is oriented
on newer aspects of wire EDM in the field of analysis and optimization. The mathematical models have been developed to predict
material removal rate and surface finish while machining AISID2 tool steel at different machining conditions. A neural network
model and simulated annealing algorithm have been formulated in order to predict and optimize the surface roughness and cutting
velocity of the WEDM process in machining of SUS 304 stainless steel materials. The cutting speed and surface roughness of
EDM process have been modeled through the response surface methodology and artificial neural networks (ANNs) [10]. [12] The
improvement of machining characteristics of die-sinking EDM such as Material Removal Rate, Surface Roughness and Tool Wear
Ratio. He reviewed various techniques which is reported by EDM researchers for improving the machining characteristics have
been categorized as process parameters optimization, multi spark technique, powder mixed EDM, servo control system and pulse
discriminating. He results out that flexible machine controller is suggested for Die Sinking EDM to enhance the machining
characteristics and to achieve high-level automation.
[23] The Mathematical Modeling of Process Parameters on Material Removal Rate in EDM of EN31 Steel Using RSM
Approach. The effect of process parameters namely peak current, pulse on time, duty factor and supply voltage on material removal
rate during electrical discharge machining process using response surface methodology. It is found that peak current, pulse on time,
duty factor and supply voltage and few of their interactions have significant effect on material removal rate. The adequacy of the
model is satisfactory as R is 98.17% and R (adj) is 97.59%. If the threshold is set too high, too many good discharges are cut off.
If it is set too low, too many discharges with a low discharge voltage occur. In both cases productivity can drop and relative wear
can rise; also surface defects are a product of occurring discharges with a too low discharge voltage. Consequently an optimum of
the discharge voltage respectively of the threshold can be estimated for every application [7]. Newest investigations have shown
that the voltage signal can be used to distinguish between lateral and frontal sparks. Lateral sparks have a higher voltage level as
high speed camera images could prove, which were correlated to the voltage signal of a sinking EDM process [11].

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V. DISCUSSION
The ultimate goal of the EDM process is to achieve an accurate and efficiency machining operation without compromising the
machining performance. This is mainly carried out by understanding the inter-relationship between the various factors affecting
the process and identifying the optimal machining condition from the infinite number of combinations. The adaptive monitoring
and control systems have also been extensively implemented to tame the transient EDM behavior without the risk of wire
breakages. Moreover, several monitoring and control algorithms based on the explicit mathematical models, experts knowledge
or intelligent systems have been reported to reduce the inaccuracy caused by the vibration behavior and static deflection of the
wire. With the continuous trend towards unattended machining operation and automation, the EDM process has to be constantly
improved to maintain as a competitive and economical machining operation in the modern tool-room manufacturing arena. EDM
process due to its ability to efficiently machine parts with difficult-to-machine materials and geometries has its own application
area unmatched by other manufacturing processes.
VI. CONCLUSIONS & FUTURE SCOPE OF EDM
Electrical discharge machining is one of the most Emerging non-conventional manufacturing processes for machining hard to
machine materials and intricate shapes, which are not possible with conventional machining methods. This is more efficient and
economical for machining hard to machine materials. The effect of various parameters and Setting of various parameters at their
optimal levels is very much required for manufacturers. From the literature, the parameters and their effects observed are given as
under:
The effect of discharge current and pulse duration has been taken into consideration in various research works but
variation in pulse interval has not been investigated or it has been taken into consideration in conjunction with pulse
duration by way of duty factor.
Most of the available research works on powder-mixed dielectric have studied the impact of such machining on MRR,
surface roughness and TWR etc. with normal polarity.
The study of the impact of this method on surface modification has been taken up by very few researchers.
Less work has been reported using powders of important alloying elements such as manganese, chromium, molybdenum
and vanadium in the dielectric medium. Likewise, some of the important die steel materials such as OHNS die steel,
molybdenum high speed tool steels and water-hardening die steels (W-series) have not been tried as work materials.
Hollow tube and eccentric drilled holes type electrodes are reported to have a positive impact on MRR due to improved
flushing conditions. Such designs need investigations for more work materials to evaluate their case to case effects.
Copper electrode has frequently been used as electrode material in ultrasonic vibration assisted EDM. Other electrode
materials need to be investigated thoroughly.
There is negligible published work available on comparative analysis of various EDM techniques of MRR improvement
with same/different work materials in EDM.
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