EDM Electrical Discharge

Machining.
Team members: Dan, Townsend
Today Dan and myself will cover five topics relate to EDM in hopes
that by the end you will all have a better understanding of this very
interesting nontraditional machining technology and why it is used in
many machine shops today.
We will be covering the following topics
• What is EDM?
• How does EDM work?
• What are the capabilities of EDM?
• What are the applications of EDM?
• What are the disadvantages of this process?
 Introduction to EDM and what is
it?

• A Brief history of EDM

• EDM uses electrical

discharge to “erode” the
metal

• There are two main types

of EDM, Wire EDM, and
Sinker EDM
Overview Video
 A Brief history of EDM
HISTORY - The idea for EDM came from a man watching lightning
• In the late 1700s, Sir Joseph Priestly( the father of carbonated water) discovered this
phenomenon while observing the erosive effect of electric current on metal
conductors.
• Shortly after World War II, the Lazerenko brothers of Russia announced their first
electronic erosion machine, and since then, it has been used in various industries,
especially aerospace, medical and micro engineering.
• The advent of computer-aided EDM in the early seventies helped it gain significance
in manufacturing processes.
• In 1982, it was introduced into dentistry by Gunter Rubeling to fabricate precision
attachments. Rubeling introduced the SAE Secotec Spark Erosion
technique to implant dentistry in the early nineties.
• Later, in the same year, Windeler received a patent for improving the fit of cast
restorations using EDM and since 1990 it has been used widely in implant prostheses
and is essential for preventing biologic and technical failures of implants and fixed
partial dentures. ("SPARK EROSION PROCESS: A NEW SPARK IN DENTISTRY."), (“History of EDM Machining”),
EDM uses electrical discharge to erode
the metal

Spark erosion is conducted through electrical discharge

machines (EDM). These machines use electrodes to send
low voltage/ high current electrical charge that melts the
designated piece of metal at the same time cold water
thermal shocks the molten steel and pulverizes it into
micro size pieces and flushes it away.
Interestingengineering.com “What Is Electrical Discharge Machining and How Does it Work”)
 There are two main types of EDM, Wire
EDM, and Sinker EDM

Wire EDM Sinker EDM

• Most common EDM. • Also called Ram, Plunge, spark machining, spark
eroding, burning, and die sinking.
• A manufacturing process whereby a
desired shape that is a through cut • Uses electrode some are custom made.
is obtained using electrical • Used for removing metal for cavities where there is
discharge. no through holes.
• Primarily used to cut hard metals
and other materials that would be
impossible to machine with
traditional techniques.
 How Does EDM work

Although both major types of EDM have differences they share the
basic principles of how they remove material while machining.

EDM uses an electrode that is fed extremely close to the base

material, then the machine builds an electric charge and releases an arc
between the electrode and the base material, this arc will flash with very
high heat. This will melt a small amount of base material then melted metal
is flushed away by the dielectric fluid (Dielectric fluid is generally deionized
water or a non-conductive oil).

(mscdirect.com “Beyond The CNC: What is Electrical Discharge Machining”)

(Tooling-U, SME “Intro to EDM 100”)

(Interestingengineering.com, “What Is Electrical Discharge Machining and How Does it Work”)


(Tooling-U, SME “Intro to EDM 100”)
(mscdirect.com “Beyond The CNC: What is Electrical Discharge
Machining”)
(Interestingengineering.com “ What Is Electrical Discharge
Machining and How Does it Work”)
How Does EDM work
(Cont.)
This illustration shows the components and function of
EDM as described in the previous slide
• The electrode is fed close to the part
• The spark jumps from electrode to the work piece
• The dielectric fluid flushes away the dross
NOTE
In this example we can see the dielectric fluid flowing
through a hole in the electrode, this would indicate that
this is an illustration of a sinker EDM being used for
hole drilling, in most other EMD operations the part is
submerged in the Dielectric fluid.
 Sinker EDM

As the name implies sinker EDM uses an electrode that is

“sunk” into the part, this process can be used for hole
making operations similar to a column and knee mill, or
even for making the inverse of a shape, something like a
press mold, or a cookie cuter.

Sinker EMD is very

versatile, in the work it can
do and the shape of parts it
produces. This is due to its
ability to use many different (Donaldson, Brent. "Inside the Sinker EDM Process, One Spark at a Time." Modern Machine Shop),

shape electrodes. (Tooling-U, SME “Intro to EDM 100”),

(mscdirect.com “Beyond The CNC: What is Electrical Discharge Machining”),
(Interestingengineering.com “ What Is Electrical Discharge Machining and How Does it Work”)
 Sinker EDM (Hole Drilling)
The simplest operation a sinker EDM is capable of, is hole drilling, as we previously
discussed this process sets itself apart in that, the work piece is not submerged in the
dielectric fluid, but instead it flows through the electrode itself. This process is similar to
a coolant fed mill or drill bit.
(mscdirect.com “Beyond The CNC: What is Electrical
Discharge Machining”)
 Wire EDM
Wire EDM uses a spool of electrode wire typically made of copper or brass, this wire is
continually fed from a spool through a hole in the part using the side of the wire as
the electrode face. This proses is similar to that of a band saw.
It is very accurate and uses an electrode wire as small as .0006” up to .012”. It is
easily able to hold a tolerance of .0005”.
Tooling-U, SME “Intro to EDM 100”)
(mscdirect.com “Beyond The CNC: What is Electrical
Discharge Machining”)
(Interestingengineering.com “ What Is Electrical Discharge
Machining and How Does it Work”)
 What are the
capabilities/ advantages
of EDM
• EDM can be used for any material that can
conduct electricity

• EDM is very good for very hard materials like

carbide

• EDM can hold to very tight tolerances

• EDM Does not produce cutting forces thus

making it an excellent choice for small and
fragile parts
 EDM can be used for any material that can conduct
electricity

• The list of materials that can be machined successfully with EDM

Electro discharge machining would be very extensive.
• However a simple rule is that if the material can conduct electricity
it can be machined using either wire or spark erosion.
• The only other thing to consider is – has the material or part been
coated, often a coating will impair electrical continuity.
• For EDM to be possible there needs to be sufficient uncoated areas
for continuity to be established through the part.
 EDM is very good for very hard materials like carbide

• It can be used for any hard material and even in heat treated condition.

• It is very difficult to machine carbide but by this process it can be

machined easily.

• It can also machine ceramic carbide materials and other hard materials.

• Surface finish obtained by this process is very good.

 EDM can hold to very tight tolerances

• Accuracies of +/- 0.00004” (0.001mm) are sometimes quoted for

wire EDM

• But accuracies +/- 0.0002” (0.005mm) is more widely accepted.

EDM Does not produce cutting forces thus making it
an excellent choice for small and fragile parts.

• The electrode never touches the

part so there is no pressure.

• The parts don’t need to be

clamped.
 What are the applications of EDM

Due to the EDMs advantage of being able to precisely machine hard materials. It has been used for a
very long time in the tooling and dye industry, for manufacture tooling for forging, stamping, and
casting. In these examples the EDM is being used to machine pre-hardened tool steel (on the left) and is
modifying a carbide mill (on the right).

(Tooling-U, SME “Intro to EDM 100”)

(mscdirect.com “Beyond The CNC:
What is Electrical Discharge
Machining”)
 What are the applications of EDM (cont.)
Since EDM does not generate any cutting forces, vibration, or burs, it is able to machine very thin, fragile,
or small parts. Because of this EDM is growing in popularity in many industries.
EDM is growing in industries like:
Medical and dental equipment
Precision mechanical components - Like watch parts or some applications in the aerospace industry
Or any small batches of parts that need a very high level of position

(Tooling-U, SME “Intro to EDM 100”)

(mscdirect.com “Beyond The CNC:
What is Electrical Discharge
Machining”)
What are the disadvantages of EDM

• EDM is slow

• EDM can leave behind a layer of oxide on

certain metals that will need to be cleaned off
the part

• EDM can only be used on parts that conduct

electricity
 EDM is slow

• A Wire EDM machine is limited to the amount of average current

that can be used due to the small contact area of the (Wire)
electrode.

• The first Wire EDM machines were slow by today’s standards, rated
at a mere 1-1/2 to 2 in” /hr. machining speeds. Now Manufactures
boasting 25 in”/hr.

• Unlike Die Sinkers, these early machines were extremely delicate

instruments.
 EDM can leave behind residue on certain
metals that will need to be removed
• Depending on the metal being cut, another disadvantage of wire
EDM cutting is that an oxide layer can form on the cut surface.

• This may require secondary cleaning, which adds to cost.

• There is also is a chance for pitting or cratering which can affect the
quality.
 EDM can only be used on parts that conduct
electricity

• Most composite parts cannot be cut because they do not conduct

electricity.
 Conclusion:

• How does EDM work?

EDM uses an electrode, an electrical current, and dielectric fluid to machine a base
metal.
• History? Started from seeing what lightning did. Throughout history people have
made improvements.
• What are the capabilities/ advantages? The two main types of EDM are the wire EDM
and sinker EDM. The EDM is impressive in its ability to machine hard metals and its
accuracies.
• What are the disadvantages. Very slow to machine large parts
 Conclusion: (Cont.)

The applications of EDM

• The use of EDM can and does range greatly but EDM is mostly used
for:
• High precision short run work
• Tooling and dye
• Or small precision parts