Table of Contents

1.1 PROBLEM STATEMENT.....................................................................................................................2

1.2 OBJECTIVE........................................................................................................................................2
1.3 DIAGRAM.........................................................................................................................................2
1.4 THEORY............................................................................................................................................2
1.4.1 NON-CONVENTIONAL MACHINING.........................................................................................................2
1.4.2 TYPES OF EDM MACHINES...................................................................................................................2
1.4.3 PRINCIPLE..........................................................................................................................................4
1.4.4 MACHINING PARAMETERS....................................................................................................................5
1.4.5 APPLICATIONS....................................................................................................................................6
1.4.6 MATERIAL REMOVAL RATE (MRR).........................................................................................................6
1.4.7 SURFACE ROUGHNESS..........................................................................................................................7
1.4.8 ELECTRODE WEAR RATIO.......................................................................................................................7
1.5 SPECIFICATIONS................................................................................................................................7
1.6 DEFECTS............................................................................................................................................7
1.7 SAFETY PRECAUTIONS......................................................................................................................8
1.8 QUESTIONS.......................................................................................................................................8
1.8.1 WHAT ARE LIMITATION OF EDM DIE SINKER?.........................................................................................8
1.8.2 LIST DOWN WORKPIECE MATERIALS WHICH CAN BE MACHINED THROUGH EDM?............................................9
1.8.3 WHAT ARE DIFFERENT TOOL MATERIALS?................................................................................................9
1.8.4 WHAT IS THE DIE? WHY IT IS USED?.......................................................................................................9
1.8.5 WHAT ARE THE ADVANTAGES AND DISADVANTAGES OF EDM PROCESS?.......................................................9
1.9 REFERENCES...................................................................................................................................10
 Experiment No:1
1.1 Problem Statement
Electric discharge machining is widely used process to machine variety of conductive
materials to achieve simple to complex machining profiles with good surface finish. Although
this process can machine difficult to cut materials such as titanium alloys, nickel alloys etc. but
simultaneously it offers low material removal rates. Material removal rates and surface finish
depend on number of machining parameters. In order to achieve high MRR with good surface
finish there is always a need to control the machining parameters for each material under study.
[1]

1.2 Objective
To understand the working principle and basic operating parameters of Electric Discharge
Machining (Die Sinker).

1.3 Diagram

Figure 1 EDM Die Sinking [2]

1.4 Theory
1.4.1 Non-conventional Machining
An unconventional machining process (or non-traditional machining process) is a special type
of machining process in which there is no direct contact between the tool and the workpiece. In
unconventional machining, a form of energy is used to remove unwanted material from a given
workpiece.
1.4.2 Types of EDM Machines

1. Die Sinker or “Ram” EDM

2. Wire or “Cheese Cutter” EDM

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 3. Hole Drilling or “Hole Popper” EDM

Electrical discharge machining (EDM) is a manufacturing process whereby a desired shape is

obtained using electrical discharges (sparks). Electrical discharge machining is a machining
method primarily used for hard metals or those that would be very difficult to machine with
traditional techniques. EDM typically works with materials that are electrically conductive. It is
a controlled metal remove technique whereby an electric spark is used to cut (erode) the work
piece, which takes a shape opposite to that of the cutting tool or electrode. The electrode is made
from electrically conductive material, usually carbon. The die sinking electrode, made to the
shape of the cavity required, and the work piece are both submerged in dielectric fluid light
lubricating oil). This dielectric fluid should be a non-conductor (or poor conductor) of electricity.

A direct current of low voltage and high amperage is delivered to the electrode at the rate of
approximately 20000 hertz (Hz). These electrical energy impulses vaporize the oil at this point.
This permits the spark to jump the gap between the electrode and the work piece through the
dielectric fluid. Intense heat is created in the localized area of the spark impact; the metal is
expelled from the surface of the work piece. The dielectric fluid, which is constantly being
circulated carries away the eroded particles of metal during the off-cycle of the pulse and assists
in dissipating the heat caused by the spark. [2]

Figure 2 Die Sinking inner view [3]

Known by many other names, including spark machining, arc machining and (inaccurately)
burning, the EDM process is conceptually very simple: an electrical current passes between an
electrode and a workpiece which are separated by a dielectric liquid. The dielectric fluid acts as
an electrical insulator unless enough voltage is applied to bring it to its ionization point, when it

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becomes an electrical conductor. The resulting spark discharge erodes the workpiece to form a
desired final shape.

Figure 3 Electrode Workpiece Contact [4]

1.4.3 Principle
The sinker EDM machining (Electrical Discharge Machining) process uses an electrically
charged electrode that is configured to a specific geometry to burn the geometry of the electrode
into a metal component. The sinker EDM process is commonly used in the production of dies
and molds.
Generally, the workpiece is made positive and the tool negative. Hence, the electrons strike the
job leading to crater formation due to high temperature and melting and material removal.
Similarly, the positive ions impinge on the tool leading to tool wear. In EDM, the generator is
used 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 at a particular
point whereas sparks get distributed all over the tool surface leading to uniform material
removal. [3]

Figure 4 Workpiece and Electrode Contact [4]

EDM consists of the following components,

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  Power supply Unit – Used to provide the Direct Current to produce spark between the
tool and workpiece.
 Dielectric fluid reservoir, pumps, filters and control valve – Used to supply dielectric to
the tool and workpiece. The tool and workpiece are immersed in dielectric fluid.
 Workpiece holder, Tool holder and table – Used to hold tool and workpiece firmly so that
the vibrations are reduced.
 Servo control Mechanism – Used to provide a constant gap between tool and workpiece.

1.4.4 Machining Parameters

Unconventional Machining Process depends upon the number of process parameters.

1. Electrical Parameters

 Discharge Voltage
It is a voltage which is produced in between the Workpiece and Tool when DC power
supply is given to the circuit.
 Peak Current
Peak Current is the most influencing factor in EDM. It is nothing but the amount of power used
in EDM.
 Average Current
It is a maximum current available for each pulse from the power supply.
Average current (A) = Duty Factor (%) x Peak Current
 Pulse On
It is the duration of time for which current is allowed to flow per cycle.
 Pulse Off
It is the duration of time between each spark.
 Polarity
Polarity may be positive or negative. MRR is higher when tool is connected to positive polarity.
 Electrode Gap (Spark Gap)
It is the distance between the Tool and Workpiece during the process of EDM. Servo Mechanism
is used to provide a constant gap between the gaps.
 Gap Voltage
Gap voltage is classified into open gap and working gap voltage. Open gap voltage can be
measured at the gap before the spark current discharge begins to flow and working gap voltage
can also be measured at the gap during spark current discharge. [5]

2. Non Electrical Parameters

 Workpiece Material
Workpiece material is one of the non-electrical parameters which influence the performance
characteristics of EDM. There are many materials such as die materials, alloys, super alloys and
titanium alloys which are very hard to cut.
 Electrode Shape
The performance characteristics mainly depend upon the tool shape. Many shapes in electrode
such as Rectangular, Square, Cylindrical, Hexagonal and Circular are used.

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  Rotation of Tool Electrode
The rotational movement of electrode is used to increase the Metal Removal Rate in EDM due to
the centrifugal force on workpiece.
 Flushing System and Pressure
The dielectric fluid must be circulated freely between Tool and Work Material. Eroded particles
should be flushed out at the earliest. There are many methods of flushing. They are, Pressure
Flushing, Suction Flushing and Side Flushing.
 Electrode Material
Electrode material should be such that it would not undergo much tool wear when it is impinged
by positive ions. Thus the localized temperature rise has to be less by 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. [5]
Thus the basic characteristics of electrode materials are
1. High electrical conductivity – electrons are cold emitted more easily and there is less bulk
electrical heating.
2. High thermal conductivity – for the same heat load, the local temperature rise would be
less due to faster heat conducted to the bulk of the tool and thus less tool wear.
3. Higher density – for less tool wear and thus less dimensional loss or inaccuracy of tool
4. High melting point – high melting point leads to less tool wear due to less tool material
melting for the same heat load
5. Easy manufacturability
6. Cost – cheap

1.4.5 Applications

 Drilling of micro-holes, thread cutting, helical profile milling, rotary forming, and curved
hole drilling. Delicate work piece like copper parts can be produced by EDM.
 Can be applied to all electrically conducting metals and alloys irrespective of their melting
points, hardness, toughness, or brittleness.
 Other applications: deep, small-dia holes using tungsten wire as tool, narrow slots, cooling
holes in super alloy turbine blades, and various intricate shapes.
 EDM can be economically employed for extremely hardened work piece.
 Since there is no mechanical stress present (no physical contact), fragile and slender work
places can be machined without distortion.
 Hard and corrosion resistant surfaces, essentially needed for die making, can be developed.

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 Figure 5 Application of EDM [5]
1.4.6 Material removal rate (MRR)
The MRR of the workpiece was measured by dividing the machined volume of the workpiece by
the machining time that was achieved. After completion of each machining process, the
workpiece was cleaned thoroughly by compressed air using air gun to ensure freedom from
debris and dielectric fluid.

Figure 6 Flash View [6]

1.4.7 Surface roughness

There are various methods available for measuring SR of the workpiece. The arithmetic surface
roughness value (Ra) was adopted and measured. The SR was measured by TR200 Hand-Held
Roughness tester through measuring the workpiece five times and calculating the average for
each experiment. The surface roughness measurements were made at different positions on the
machined surface for each EDM condition.
1.4.8 Electrode wear ratio
The electrode wear rate (EWR) of the electrode was measured by dividing the machined volume
of the electrode by the machining time that was achieved. After completion of each machining
process, the electrode was cleaned thoroughly by compressed air using air gun to ensure freedom
from debris and dielectric fluid. In addition to that the graphite was roasted after each process by
placing it in the oven at 180C0 to ensure no dielectric fluid were present. The weight of the
electrode was measured using a precise balance. And then the EWR% was measured by dividing
the EWR by the MRR that have been previously measured. [6]

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1.5 Specifications

Parameters Range
Incoming voltage (220-380) V
Maximum Avg. output current (30-200) A
No load output voltage 100 s
On time setting range (1-9999) s
Off time setting range (1-9999) s
Electro spark frequency 500Hz-500 KHz

1.6 Defects

There are only few limitations of this process which is as following:

 This process can only be employed in electrically conductive materials.

 Material removal rate is low and the process overall is slow compared to conventional
machining processes.
 Unwanted erosion and over cutting of material can occur.
 Rough surface finish when at high rates of material removal.
 Not uniform surface finish throughout the cut.

1.7 Safety Precautions

You may not be surprised to learn that electrical discharge machining presents a hazard of
electrical shock. As an EDM operator, there are certain things you can do to minimize this risk.
[7]

 Never touch the electrode while the machine is in operation.

 Make sure that your work area is grounded.
 Make sure that the area around the machine is dry.
 Do not wear conductive clothing or accessories such as jewellery.
 Wear appropriate eyewear, and never look directly at the spark.
 Wear closed toe, non-slip shoes with rubber soles. Shoes should be comfortable as well,
since you may be standing for extended periods of time.
 Operators and workers have to be properly trained to work with electrical discharge
machining
 Make sure that fire protection measures are installed and regularly maintained.
 Keep an eye on the fluid: The level of the dielectric fluid is of utmost importance. The
liquid prevents the discharge from crossing to conductive materials other than the
workpiece.
 Proper ventilation can clean the air of gases that might be produced in the fluid due to
chemical reactions accompanying the discharge.
 You have to monitor the dielectric fluid when it is circulating to ensure it retains its non-
conductive characteristics.

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  Keep your machine well-maintained. Your machine should clean and lubricated. When it
needs maintenance, make sure the work is done by a well-qualified professional.
 Know your machine. One of the best ways to prevent accidents is to not do anything
whose consequences you are not well aware of.
 machine free of flammable materials.
 Stay alert and give your undivided attention to machining. Intoxication on the job should
be avoided.

1.8 Questions

1.8.1 What are limitation of EDM Die Sinker?

Followings are limitations of EDM Die Sinker:

 Difficulty finding expert machinists.

 The slow rate of material removal.
 Potential fire hazard associated with use of combustible oil based dielectrics.
 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.
 Specific power consumption is very high.
 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.
1.8.2 List down workpiece materials which can be machined through EDM?

In general, every conductive material can be machined with electrical discharge machining.
Common materials include

 Metals
 metal alloys such as hardened steel, titanium, and composites.

1.8.3 What are different tool materials?

Copper and graphite are commonly used as die sinking tool materials because of the high
electrical conductivity and high melting temperature and the ease of being fabricated into
complicated shapes. Wire electrode usually made of copper, brass and molybdenum. Stratified
copper wire coated with zinc brass is often used. [8]
 Graphite - has fair wear characteristics, easily machinable. Small flush holes can be
drilled into graphite electrodes.

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  Steel
 Aluminium
 Electrolytic oxygen free copper
 Tellurium copper – 99% Cu + 0.5% tellurium
 Brass - ensures stable sparking conditions and is normally used for specialized
applications such as drilling of small holes where the high electrode wear is acceptable.
 Copper tungsten and silver tungsten - are used for making deep slots under poor flushing
conditions especially in tungsten carbides. It offers high machining rates as well as low
electrode wear.
 Copper graphite - is good for cross-sectional electrodes. It has better electrical
conductivity than graphite while the corner wear is higher.

1.8.4 What is the die? Why it is used?

A dielectric is an electrical insulator that can be polarized by an applied electric field. When a

dielectric material is placed in an electric field, electric charges do not flow through the material
as they do in an electrical conductor but only slightly shift from their average equilibrium
positions causing dielectric polarization.

EDM dielectric fluid serves three main purposes. First, it acts as a semiconductor between the
electrode and workpiece to facilitate a stable and controlled spark gap ionization condition.
Second, it also acts as a flushing agent to wash and remove the eroded debris from the spark gap
area. It cools down the heated surfaces of the electrodes and workpiece. Third, it can be chilled
to keep the workpiece, worktable and fixtures at a steady temperature. This limits the thermal
growth of the workpiece and machine in order to hold tight tolerances

1.8.5 What are the advantages and disadvantages of EDM process?

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 perceivable distortion.
 A good surface finish can be obtained; a very good surface may be obtained by redundant
finishing paths.
 Very fine holes can be attained.
 Tapered holes may be produced.

Disadvantages of EDM include:

 The slow rate of material removal.

 Difficulty finding expert machinists.

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 Potential fire hazard associated with use of combustible oil based dielectrics.
 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.
 Specific power consumption is very high.
 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. [8]

1.9 References

1. https://en.wikipedia.org/wiki/Electrical_discharge_machining
2. http://eprints.utem.edu.my/2904/1/Analysis_Of_EDM_Parameters_During_The_Micro_Hole_M
achining_Of_Tungsten_Carbide_-_24_pages.pdf
3. https://www.google.com/search?
q=applications+of+edm+die+sinking+ppt&source=lmns&bih=569&biw=1276&hl=en&ved=2
ahUK
4. ^ Microwave Engineering – R. S. Rao (Prof.). Retrieved 2013-11-08.
5. ^ Kao, Kwan Chi (2004). Dielectric Phenomena in Solids. London: Elsevier Academic Press.
pp. 92–93. ISBN 978-0-12-396561-5.
6. ^ Debye, P. (1913), Ver. Deut. Phys. Gesell. 15, 777; reprinted 1954 in collected papers of Peter
J.W. Debye. Interscience, New York
7. ^  Chiang, Y. et al. (1997)  Physical Ceramics,  John Wiley & Sons, New York
8. http://www.engineeringarticles.org/electrical-discharge-machine-edm-types-advantages-and-
disadvantages/

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