Advances In Electric Discharge Machining (EDM)

A
Seminar Report
ON

“ADVANCES IN ELECTRIC DISCHARGE MACHINING

(EDM)”

IS SUBMITTED TO
SANT GADGE BABA AMRAVATI UNIVERSITY
IN THE PARTIAL FULFILLMENT OF THE DEGREE OF

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

SUBMITTED BY

BHAGYESH DINESH PATIL

(173839250001)
GUIDED BY

PROF. D.P.KHARAT

DEPARTMENT OF MECHANICAL ENGINEERING

PADM. DR. V. B. KOLTE COLLEGE OF ENGINEERING, MALKAPUR

SANT GADGE BABA AMRAVATI UNIVERSITY, AMRAVATI

2020-2021

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

PADM. DR. V. B. KOLTE COLLEGE OF ENGINEERING, MALKAPUR

Department of Mechanical Engineering

CERTIFICATE
This is to certify that the Seminar titled

“ADVANCES IN ELECTRIC DISCHARGE MACHINING

(EDM)”
Has been successfully completed in session 2020-2021

By

BHAGYESH DINESH PATIL

In recognition to the partial fulfillment for

The degree of Bachelor of Engineering (Mechanical Engineering),

Sant Gadge Baba Amravati University, Amravati

PROF. D.P.KHARAT PROF. S.R. SHEKOKAR

Guide H.O.D.
Guide
DR. A. W. KHARCHE
Principal

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

DECLARATION

I hereby Bhagyesh Dinesh Patil, declare that this submission is my own work except
questionnaire and that, to the best of my knowledge and belief. It contains no material
previously published or written by another person nor material that has been accepted for the
award of any other degree of the university or any other institute of higher learning, except
where due acknowledgment has been made in the text. I also declare that no copy of the work
done by me is submitted anywhere else in any other professional, technical or academic
organization and is purely submitted and developed by me as a part of the partial fulfillment
for degree of Bachelor of Engineering.

Date: Signature

(Bhagyesh Dinesh Patil)

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

RECOMMENDATION

The seminar work entitled “Advances in Electric Discharge Machining (EDM)”

submitted by Bhagyesh Dinesh Patil is a satisfactory account of bona fide work under
our supervision and is recommended towards the partial fulfillment for the award of the
“Bachelor of Engineering in Mechanical Department” from Padm. Dr.V.B. Kolte
College of Engineering, Sant Gadge Baba Amravati University, Malkapur.

PROF. D.P.KHARAT
Assistant Professor,
Department of Mechanical Engineering,
Padm. Dr.V.B. Kolte College of Engineering,
Malkapur, Dist -Buldhana (M.H)

Endorsed by

PROF. S. R. SHEKOKAR
Head of Department
Department of Mechanical Engineering,
Padm. Dr.V.B. Kolte College of Engineering,
Malkapur, Dist –Buldhana (M.H)

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

APPROVAL SHEET

The seminar work entitled “Advances in Electric Discharge Machining (EDM)”

submitted by Bhagyesh Dinesh Patil to the Padm. Dr.V.B. Kolte College of Engineering,
Malkapur. Sant Gadge Baba Amravati University, Amravati is approved as fulfillment from
the award of degree of “Bachelor of Engineering in Mechanical Department” from Padm.
Dr. V. B. Kolte College of Engineering, Malkapur. Sant Gadge Baba Amravati University,
Amravati. (M.H)

Guide: Head of Mechanical:

Name: PROF.D.P.KHARAT Name: PROF.S.R.SHEKOKAR

Date: / /2021 Date: / /2021

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

ACKNOWLEDGEMENT

I ascribe my success at this venture to Prof. D.P.KHARAT Assistant Professor

Mechanical Engineering, Padm Dr. V. B. Kolte College of Engineering, Malkapur for this
continuous encouragement and timely guidance, without his valuable suggestions it was
impossible to complete this project. His supporting & positive attitude for problem solving
commensurate towards the accomplishment of goal of the project.

I express my deep respect to Prof. S. R. SHEKOKAR Head of Department, Mechanical

Engineering, Padm Dr. V. B. Kolte College of Engineering, Malkapur, for kind support during
my B.E. (Mechanical Engineering) course at Padm Dr. V. B. Kolte College of Engineering.
He always shows me right path & guidance to complete this coursework.

I am also thankful to Dr .A. W. Kharche Principal of Padm. Dr. V. B. Kolte College of

Engineering, Malkapur (M.H), for providing me infrastructural facilities to work in, without
which this work would not have been possible.

Bhagyesh Dinesh Patil

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Content

• Abstract
• Introduction
• What Is Electric Discharge Machining (EDM)?
• Schematic Diagram of EDM Machines
• Wire Electric Discharge Machine (WEDM)
• Research Conducted in the EDM
• Various Research Areas in the EDM
• Advancement in The EDM Process
• Advance Hybrid Machining Processes With EDM
• Gallery
• Conclusion
• Reference

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

ABSTRACT

In the present manufacturing scenario, the industrial product not only requires the high precision

and quality but should be produced in the minimum time in order to sustain their position in the global

market competition. Thus, it is required to regulate the input process parameters for achieving the

desired output or the performance. EDM is the most popular machining process in the present time

among all the machining processes. EDM is the widely used non-conventional machining process that is

capable to machine the hard materials such as alloys, composite and even the ceramics also. EDM has

wide range of application in automobile, aerospace, defence and precision engineering industries. In the

past years, the many studies have been done to improve the EDM process. Every research is possible due

to the advancement of technologies and a lot of researches have been departing in all fields to reach the

market demand. In this regard various researches are going on in the development of Electrical Discharge

Machining (EDM) to achieve a stable, accurate and efficient machining. Since EDM is an assembly of

electrical, physical and mechanical process.

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

INTRODUCTION

The Erosive Erosive effect of electrical discharge 1St noted by Joseph Priestly
(1770).

Electrical Discharge Machine (EDM) is now become the most important accepted
technologies in manufacturing industries since many complex 3D shapes can be machined using a simple
shaped tool electrode. Electrical discharge machine (EDM) is an important non-traditional manufacturing
method’, developed in the late 1940s and has been accepted worldwide as a standard processing
manufacture of forming tools to produce plastics molding , die cas tings, forging dies and etc.
New developments in the field of material science have led to new engineering metallic materials,
composite materials, and high tech ceramics, having good mechanical properties and thermal
characteristics as well as sufficient electrical conductivity so that they can readily be machined by spark
erosion. At the present time, Electrical discharge machine (EDM) is a widespread technique used in industry
for high- precision machining of all types of conductive materials such as: metals, metallic alloys, graphite,
or even some ceramic materials, of whatsoever hardness. Electrical discharge machine (EDM)technology is
increasingly being used in tool, die and mould making industries, for machining of heat treated tool steels
and advanced materials (super alloys, ceramics, and metal matrix composites) requiring high precision,
complex shapes and high surface finish. Traditional machining technique is often based on the material
removal using tool material harder then the work material and is unable to machine them economically. An
electrical discharge machining (EDM) is based on the eroding effect of an electric spark on both the
electrodes used. Electrical discharge machining (EDM) actually is a process of utilizing the removal
phenomenon of electrical-discharge in dielectric. Therefore, the electrode plays an important role, which
affects the material removal rate and the tool wear rate

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

What is Elecrtic Discharge Machining(EDM)?

Electrical discharge machining is one of the most useful machinery in die and mould making
industries. The finished portions of resources of EDM have been used in aero, automotive and nuclear
industries and fine machined parts can also be applied in precise equipments of medical and surgical fields.
In the EDM process mechanical stresses ,noise and vibration are not present. The only limitation in the EDM
is that the work-piece and the tool material both should be electrically conductive.

Working principle
The general EDM consists of DC power supply, pulse generator circuit, servo control
mechanism, Electrodes and dielectric medium. EDM works on the principle of electrical erosion by which
continuous removal of material has been done in the presence of dielectric medium. The spark occurs when
the dielectric medium reaches its breakdown voltage through decomposition. A crater is formed and grown
when continuous discharges occur. There is break between the each discharge in which the dielectric regains
its original position and cools the electrodes. The dielectric medium is traditionally of kerosene. Nowadays
it has been replaced by other liquids such as de- Ionized water; distilled water etc. In Wire EDM the tool has
been substituted by a thin strand of electrically charged wire which travels through the work piece sunken.

Fig:- Working Principle of the EDM

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Schematic Diagram Of EDM Machines

Fig:- Die Sinking EDM Machine

Fig:- Wire Cut EDM Machine

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Wire Electric Discharge Machine (WEDM)

WEDM is most widely used in industries these days because of capability to generate complicated
shapes and profiles without use of pre-shaped electrode which were required in the basic EDM . The only
limitation in the WEDM is same as EDM that the tool material and work-piece both should be electrically
conductive
Wire electrical discharge machining (WEDM) was introduced because it has the ability to cut intricate
shapes and extremely tapered geometries with high performance especially in precision, efficiency, and
stability . WEDM operation has a very similar material removal mechanism as EDM process except WEDM
uses winding wire as an electrode. Micro-WEDM operation uses a very small diameter wire (Ø 20-50 μm) as
the electrode to cut a narrow width of cut in the workpiece. The wire is pulled through the workpiece from
a supply spool onto a take-up mechanism. Discharge occurs between the wire electrode and the workpiece
in the presence of a flood of dielectric fluid. The most important control parameters for this process are
discharge current, discharge capacitance, pulse duration, pulse frequency, wire speed, wire tension, voltage,
and dielectric flushing condition
Dielectric fluid is used usually hydrocarbon oil in which the workpiece and cathode are immersed.
The minute chips are produce which are wash away from piece . Wire EDM is able to cut metals as thin 0.004
in and thicker as 16 in and tolerance of +/- 0.0001 in. possible.The process is controlled by a CNC and 5-Axis
control is possible.

Fig:- The Working of Wire Cut EDM

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Research Conducted In the EDM

❖ EDM-Electric Discharge Machine

❖ WEDM-Wire Electric Discharge
Machine
❖ UEDM-Ultrasonic Vibration Electric
Discharge Machining

Various Research Areas in the EDM

Fig:- Research areas in the EDM

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Advancement In The EDM Process

Powder Mix EDM (AEDM)

As the name implies, powder of a suitable material, such as nickel, graphite, aluminium is
mixed with the dielectric fluid. The presence of this powder makes the process mechanism substantially
different from the conventional EDM process . The powder particles fill the gap between the electrode tool
and the workpiece when a voltage is applied during machining. This particle aggregation forces the electrode
tool and the workpiece to move a small distance further apart by an amount equal to the gap filled by the
powder particles. The gap between the electrode tool and the workpiece can increase by 100% to 300%
(from 25–50 um to 50–150 um) . The presence of the powder particles between the electrode tool and the
workpiece leads to earlier and faster sparking, which causes a higher erosion rate.

Micro EDM
EDM operation has already been developed in micro scale industries, as delicate micro tools
can machine workpiece surface without any deviation or breakage. Micro-EDM follows the similar principle
of conventional EDM technology. However, there are some differences between these two machining in
terms of circuitry. EDM uses resistance capacitance relaxation (RC-relaxation) circuit while micro-EDM uses
RC-pulse circuit. In RC-relaxation circuit, current and voltage are usually assumed as constant in modelling
process. However, in reality, for RC-relaxation circuit, current and voltage are controlled at a predefined level
throughout the pulse on-time. In contrast, based on the modelling process and parametric analysis, RC-pulse
generator for a single discharge shows that the current and voltage are not maintained to any predefined
level. Still, the RC-pulse generator depends on capacitor charge state at any instant. The RC-pulse circuit type
is known to have low material removal rate (MRR) since it can produce very small amount of discharge
energy. Micro-EDM is particularly developed to manufacture component of sized between 1 and 999 μm.
Hence, in order to produce high precision and high accuracy micro geometries products, micro-EDM is a
suitable type of machining.

Dry EDM (Without any Electrolyte)

In EDM process, dielectric fluid plays an important role in order to flush away the debris from
the machining gap. In addition, the dielectric fluid also helps to improve the efficiency of the machining
operation as well as improving the quality and economy of the machined parts. The commonly used
dielectric fluids are mineral oil-based liquid or hydrocarbon oils which cause fire hazard and environmental
problems. This is because dielectric wastes generated during the machining operation are very toxic and

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

non-recyclable. Besides that, during the machining operation, toxic fumes (CO and CH4) are produced
because of the high temperature chemical breakdown of mineral oils. The toxic fumes also pose a health
hazard to the machining operators. In order to avoid these problems, researchers introduce dry EDM which
includes dry WEDM, dry micro-EDM, and dry micro-WEDM.
Dry EDM is a green machining method where the electrode used is in a pipe form and gas or air flows
through the pipe instead of the liquid as a dielectric fluid which removes the debris from the gap and cools
the machining surface . The flow of gas with high pressure helps to remove the debris and also avoids
unnecessary heating of the wire and workpiece at the discharge gap. Lower tool wear, better surface quality,
lower residual stresses, thinner white layer, and higher precision in machining are the prime outcome of this
dry technique.

Fig:- Schematic diagram of dry EDM

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Advance Hybrid machining processes with EDM

Ultrasonic vibration (USM)

➢ The main advantage of ultrasonic vibration in EDM it improves the dielectric circulation which
helps to generate the large amount of pressure between the work-piece and tool material.
➢ Ultrasonic vibration it facilitates the debris removal from the work table
➢ It simplifies the equipment and reduce overall cost of equipment

Electrical discharge grinding (EDG)

➢ The hybrid grinding capable to machine extremely hard materials which such as carbides 2-3
times faster than the conventional grinding process.

➢ EDG capable to achieve high accuracy and high surface finish rates (0.2-0.3μm) than the
conventional grinding.

Laser beam machining (LBM)

➢ The hybridization of laser beam machining and EDM using in the micro-machining processes to
reduce the production time and eliminating the recast layer produced by EDM

➢ Laser beam machining is used to fabricating the desired shape from the material and EDM is used
for the final finishing

➢ Production rate, surface finish and efficiency are higher and tool wear rate is very less in the
hybridization of LAEDM as compared to conventional EDM

Electrochemical discharge machining (ECDM)

➢ Hybridization of EDM and ECM is studied since 1970 .

➢ ECDM is also known as electro-erosion dissolution machining process (EEDM).

➢ ECDM has wide variety of applications especially in non-conductive materials such as various
types of ceramics and composites

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Gallery

Some Industrial machined parts with EDM

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

Conclusion

EDM is one of the widely used unconventional machining method that is capable of producing the
complex shapes. The only limitation in the EDM is the work piece should be conductive in nature. With the
time there is lot of improvements in the EDM and its assisted processes as well as optimization techniques,
which made some new research scopes in the EDM. Some studies found that non-electrical parameters also
play an important role in the performance of the EDM. Developments in modeling techniques have made
new research scopes in the EDM and improves the performance of EDM process.
EDM has emerged as the most cost effective and high precision machining process in past years. The
machining capacity to remove hard and difficult to machine parts has made EDM as one of the most
important machining processes

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR

 Advances In Electric Discharge Machining (EDM)

REFERENCES

➢ www.google.com

➢ www.wikipedia.com

➢ www.youtube.com

➢ www.thomasnet.com

➢ www.researchgate.com

➢ www.ijist.org

➢ www.springer.com

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 Advances In Electric Discharge Machining (EDM)

Thank you

PADM DR V.B. KOLTE COLLEGE OF ENGINEERIG.MALKAPUR