A Novel Electrical Power Supply for Electrothermal and Electrochemical Removal Machining

Methods

David Tastekin Harry Krötz Clemens Gerlach Jörg Roth-Stielow

Institute of Power Electronics
and Electrical Drives
Universität Stuttgart
Pfaffenwaldring 47
70569 Stuttgart, Germany
tastekin@ilea.uni-stuttgart.de
Institute of Machine Tools
and Manufacturing
ETH Zürich
Tannenstrasse 3
8092 Zürich, Switzerland
harry.kroetz@eldec.de
SFL GmbH
Baumwiesenweg 6b
70569 Stuttgart, Germany
Gerlach@sfl-gmbh.de
Institute of Power Electronics
and Electrical Drives
Universität Stuttgart
Pfaffenwaldring 47
70569 Stuttgart, Germany
ilea@ilea.uni-stuttgart.de

Abstract—For electrically conductive materials Electrical
Discharge Machining (EDM), Electrochemical Machining
(ECM) and Electrochemical Discharge Machining (ECDM)
constitute a procedure to manipulate materials that are difficult
to machine using conventional machining methods. Due to their
different electrical behavior all three methods would usually
require dedicated power supplies.
This paper introduces and analyzes a novel low-loss power
supply which can be used for all methods (EDM, ECM, ECDM)
without the need for any circuit modifications. Thus it is
possible to combine the machining methods in the same
mechanical configuration. The mode of operation is explained
for EDM and ECM and it will be shown that the proposed
power supply is short- and open-circuit proof. The power
electronics topology is described in detail as well as the control
strategy. Furthermore a prototype for a micro drilling
application is shown to validate the theoretical considerations.
Index Terms—Power supply, Electrical Discharge Machining
(EDM), Electrochemical Machining (ECM), Electrochemical
Discharge Machining (ECDM), Micro drilling
I. INTRODUCTION
Electrical Discharge Machining (EDM), Electrochemical
Machining (ECM) and Electrochemical Discharge Machining
(ECDM) are removal machining methods that can be used to
machine conductive materials. The field of applications
ranges from cutting and drilling to polishing and deburring
[1]-[4]. In the past years, micro drilling became a field of
interest used for applications such as injection nozzles [2].
A general configuration for micro drilling which can be
used for all three methods (EDM, ECM and ECDM) is
depicted in Fig. 1. A tool electrode is positioned at a fixed
small distance (gap) above the workpiece and both, tool
electrode and workpiece are submerged in a fluid.
The three machining methods solely differ in the type of
fluid used. While EDM uses a dielectric fluid (deionized
water or hydrocarbon oil), ECM and ECDM use an
electrolyte (e.g. sodium nitrate). Due to the different fluids
the machining processes differ in their physical
characteristics.
EDM is an electrothermal machining method. Material
removal is based on plasma that ignites between the tool
electrode and the workpiece once the dielectric breakdown
field strength in the gap is reached.
ECM uses an electrolyte so that the process line is
conductive, i.e. after applying a voltage a current occurs and
the removal process is caused by anodic dissolution.
ECDM is a combination of ECM and EDM [4]. An
electrolyte is used, thus the process initially behaves like
ECM. Due to electrolysis during the process, bubbles form
between the electrodes. This generates a dielectric process
line and starts the formation of plasma as it occurs with EDM
methods. Hence in the following it is sufficient to investigate
EDM and ECM.
Fig. 2 (a) and (b) show the simplified electrical equivalent
circuits of EDM [5] and ECM [3]. Obviously, the electrical
power supply has to match different characteristics. As EDM
requires an ignition voltage and a discharge current, ECM
requires either a current or a voltage source, depending on
the application. A common feature is the pulsed mode
operation (up to 1 MHz for micro drilling).

Fig. 1. General configuration Fig. 2. Electrical equivalent circuits of (a) EDM and (b) ECM

978-1-4244-2893-9/09/$25.00 ©2009 IEEE 2682

 In [3], [6]-[9] several power supplies were introduced
which were developed to supply just one of these processes.
The purpose of this paper is to present a novel low-loss
power supply that is suited to feed all mentioned processes
without circuit modifications. The mode of operation is
explained with EDM and ECM as well as its power
electronics configuration. All conclusions have been proven
with an experimental setup.
II. FUNCTIONAL PRINCIPLE
In Fig. 3 (a) and (b) the specified voltage and current
waveforms for EDM and ECM are depicted.
Fig. 3. Specified waveforms for (a) EDM and (b) ECM
A power supply which is suitable to generate such
waveforms is pictured in Fig. 4. This power supply consists
of a constant current source I0 , a constant voltage source
U 0 , an ignition switch S and a decoupling diode D. The
required load waveforms can be generated by the operation
of the ignition switch S. The operation of this power supply
can be described separately for EDM and ECM in several
stages.
Fig. 4. Proposed power supply for EDM, ECM and ECDM
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A. EDM
1) Ignition Stage [ t0 , t1 ]:
This stage begins at t0 , opening the ignition switch S. As
the gap is not yet conductive, the current I0 flows through
the decoupling diode D into the constant voltage source U 0
(see Fig. 5). Thus the gap voltage E equals U 0 which can be
characterized as the ignition voltage in this stage. At t1 the
dielectric breakdown occurs and the ignition stage ends. The
ignition delay (time period between t0 and t1 ) cannot be
affected by the ignition switch S, as it depends on process
parameters. Thus the ignition delay can change.
Fig. 5. Current path (dashed line) during ignition stage
2) Discharge Stage [ t1 , t2 ]:
In this stage the ignition switch S remains open. As the
dielectric breakdown occurs at t1 , a channel of plasma is
formed between the electrodes and the current I0 flows
through the gap (see Fig. 6). So I0 equals I E which is the
discharge current during this stage. Neglecting the inductance
in Fig. 2 (a) the EDM voltage during this stage is determined
as
E = U DIS = I0 ⋅ RG + E Arc (1).
Fig. 6. Current path (dashed line) during discharge stage
3) Pause Stage [ t2 , t3 ]:
The discharge stage ends when the ignition switch S is
closed at t2 . Hence the load is short-circuited and the current
I0 flows through the ignition switch S (see Fig. 7). At t3 a
new period can be started by opening the ignition switch S
again.
 Fig. 7. Current path (dashed line) during pause stage

B. ECM
The proposed power supply (see Fig. 4) can be either used
as a current or voltage source for ECM. Neglecting the
capacitances in Fig. 2 (b) ECM can be regarded as a resistive
load. If the voltage U 0 is chosen as

(
U 0 > U ECM = I0 Rs + 2 ⋅ R p ) (2) Fig. 8. Current path (dashed line) during conduction stage (a) voltage source
(b) current source

the power supply is a current source for ECM. If the current

I0 is chosen as III. POWER ELECTRONICS CONFIGURATION
U0 Now, one has to discuss the implementation of the
I0 > I ECM = (3)
Rs + 2 ⋅ R p constant current and voltage sources needed for the power
the power supply is a voltage source for ECM. Thus two supply. One possible realization was presented in [10] (see
cases have to be described. Fig. 9). It consists of a buck converter and a boost converter
connected to the same dc link. The buck converter is used as
a constant current source by controlling the inductor current
1) Conduction Stage [ t0 , t1 ]: to a constant value. The boost converter’s capacitance can be
loaded by the buck converter’s inductor current through the
This stage begins at t0 , opening the ignition switch S. Due
decoupling diode during ignition stage (EDM) or conduction
to the electrolyte, the gap is immediately conductive. If (3) is
stage (ECM). The voltage U 0 is controlled by the boost
fulfilled the power supply operates as a voltage source, the
converter to a constant value. Thus it appears that the boost
current divides into two paths (see Fig. 8 (a)), the voltage E
converters capacitance can get its energy only from the buck
equals U 0 and the current through the ECM line is
converter.
determined as
U0
I E = I ECM = (4).
Rs + 2 ⋅ R p
If (2) is fulfilled just one current path occurs, the power
supply operates as a current source (see Fig. 8 (b)), the
current I E equals I0 and the ECM voltage is determined as

(
E = U ECM = I0 ⋅ Rs + 2 ⋅ R p ) (5).

2) Pause Stage [ t1 , t2 ]:
The conduction stage stops when closing the ignition
switch S at t1 . Hence the load is short-circuited and the
current I0 flows through the ignition switch S (see Fig. 7).
At t2 a new period can be started by opening the ignition
switch S.
It should be noted that special cases like short circuit or
open circuit can be also handled by the power supply.
Fig. 9. Circuit diagram of the power supply in [10]
Tests have shown that the voltage U 0 decreases during
EDM operation. To eliminate this problem the configuration
can be extended by a switch and a diode (see Fig. 10) so that
the boost converter changes to a two-quadrant chopper.
Accordingly, the capacitance can now be loaded via the half

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bridge, i.e. the buck converter current is no longer necessary
to load the capacitance. During ignition stage (EDM) or
conduction stage (ECM) the buck converter current
additionally loads the capacitance through the decoupling
diode. This current can be regarded as disturbance. The
voltage control of U 0 realized by the two-quadrant chopper
has to eliminate this disturbance.
Fig. 10. Circuit diagram of the proposed novel power supply
Compared to classical or alternative power supplies for
EDM [6], [9] and [11], neither resistors nor active operated
transistors are used in this topology (see Fig. 10). So the only
losses occur in the transistors (conduction and switching
losses) and the inductor’s copper resistor. These losses are
negligible compared to the losses generated in classical or
alternative power supplies, hence in Fig. 10 a low-loss power
supply is depicted.
An additional advantage of the proposed circuit (Fig. 10)
is that several of such power supplies can be connected in
parallel (see Fig. 11). This allows the generation of special
current profiles, which can be useful for some EDM
applications.
Fig. 11. Possible parallel connection
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IV. CONTROL STRATEGY
A. Buck Converter
As mentioned above, the current source is realized by the
buck converter controlling its inductor current to a constant
value. The applied direct current control method works
according to the principle of “time discrete switching state
modulation” [12]. Its basic function is shown in Fig. 12. For
the explanation of the basic controller functions the bypass
integrator will be disregarded. The Switch State Request
(SSR) results from the control deviation. A positive deviation
leads to SSR = 1 , a negative one to SSR = 0 . The actual SSR
is not directly fed forward to the buck converter, but time-
discrete sampled with the frequency f sample = 100 kHz and
thus converted into a so-called Switch State Command (SSC).
Hence the SSC remains constant at least for the duration of
one sampling period Tsample = 10 µs (see Fig. 12). The SSC is
equivalent to the buck converters switch state, the switch is
open for SSC = 0 and it is closed for SSC = 1 . Due to its
time discrete characteristic the controller described so far
shows a steady control deviation. Therefore the controller can
be equipped with a bypass integrator as shown in Fig. 12.
Fig. 12. Block diagram of the current controller
B. Two-Quadrant Chopper
Fig. 13 shows the voltage control of the two-quadrant
chopper. It’s realized as a cascaded control system. The inner
capacitance current control loop is equivalent to the direct
current control described above (see Fig. 12) with one
extension. As the two-quadrant chopper contains two
switches, two SSCs are required. The direct current control
described above generates only one SSC, the second one is
produced by negating that SSC. Thus the direct current
control shown in Fig. 12 just has to be extended by a NOT ( Tsample = 10 µs ) and to generate the switching commands for
gate. Of course a must-have is the switching lag-time the ignition switch (up to 1 MHz). The remaining functions
between SSC and SSC to prevent a shortage of the half are implemented in the dS1104 board.
bridge.
The outer loop controls U 0 by using a conventional
PI controller.

Fig. 14. System overview

Fig. 15 shows a measurement of an EDM sequence with a

100 kHz repetition rate and Fig. 16 one with a 1 MHz
repetition rate.

Fig. 13. Block diagram of the cascaded voltage control of the two-quadrant
chopper

V. EXPERIMENTAL RESULTS
A prototype has been built based on the circuit (see
Fig. 10) presented in this paper. The prototype is designed for
micro drilling applications for injection nozzles. The data of
the prototype and its components are displayed in Table 1.
Fig. 15. EDM sequence ( U 0 = 180 V , I0 = 1.5 A , 100 kHz rep.rate)
TABLE 1
POWER SUPPLY DATA

Electrical specification:
DC-link voltage 200 V
Current I0 (adjustable) 0…2.5 A
Voltage U 0 (adjustable) 5…180 V

Component data:
Inductor (buck converter) 100 mH
Inductor (two-quadrant chopper) 1.7 mH
Capacitance (two-quadrant chopper) 960 µF

In practice, the buck converter’s inductor is realized by six

single inductors connected in series. This reduces the
inductors winding capacitance and results in a better dynamic
performance concerning the pulsed mode operation of the
load. All switches are implemented with MOSFETs.
Fig. 14 shows a block diagram of the system. The control
unit consists of a rapid prototyping board dS1104 from Fig. 16. EDM sequence ( U 0 = 180 V , I0 = 1.5 A , 1 MHz rep.rate)
dSPACE and a Programmable Logic Device (PLD). The
PLD is necessary for the direct current control

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 As can be seen, the specified characteristic has been machined micro hole generated by that configuration using
achieved. The ignition, discharge and pause stage are visible. the machining conditions in Table 2.
As discussed before it can be seen that the ignition delay
varies. The oscillations occurring in voltage and current
during the discharge stage are caused by parasitic resonant
circuits that are contained due to the setup. The oscillations
don’t matter as EDM is an electrothermal machining method.
Fig. 17 and Fig. 18 show measurements of an ECM
sequence, with 100 kHz repetition rate respectively 1 MHz
repetition rate, by using the same micro drilling configuration
with a different fluid. The power supply is operated as a
voltage source.

Fig. 19. ECDM machined micro hole

TABLE 2
ECDM MACHINING CONDITIONS
Machining conditions:
Workpiece 100Cr6 (steel)
Tool electrode Wolfram rod (100 µm ∅ )

Fluid: Sodium Nitrate ( 20 mS )

Fig. 17. ECM sequence ( U 0 = 10 V , I0 = 1.0 A , 100 kHz rep.rate) cm
Power supply conditions:
Current I0 0.6 A

Voltage U 0 85 V
Repetition rate 285 kHz

Thus the range of functions of the proposed novel power

supply was verified in the experimental setup.

Fig. 18. ECM sequence ( U 0 = 10 V , I0 = 1.0 A , 1 MHz rep.rate)
The required characteristic can be seen here, too. A
measurement of an ECM sequence by operating the power
supply as a current source is omitted because it yields to the
same result as in Fig. 17 and Fig. 18.
As already mentioned, the power supply was used in a
micro drilling configuration. The requirement of this
configuration is to develop an optimal micro drilling process
for micro holes. Therefore a drilling machine “AGIE
Compact I” by the company GF AgieCharmilles was
modified for micro drilling applications and equipped with
the implemented power supply. Fig. 19 shows an ECDM
VI. CONCLUSION
A novel low-loss electrical power supply is presented in
this paper which can supply an EDM process, an ECM
process as well as all process combinations as ECDM.
Hence, one power supply can be used for all these processes
which lead to shorter developmental periods.
As necessary, the power supply is open- and short-circuit
proof. One advantage over other ECM power supplies is that
it can be either used as a current or voltage source. The
mentioned statements are confirmed by respective
measurements made on a prototype for micro drilling
applications. MOSFETs are used for the prototype but can be
replaced by IGBTs for higher power applications. As a
further option, special current profiles can be created by
connecting several of the proposed power supplies in
parallel.

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