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Corresponding Author:
Ade Erawan Minhat,
Department of Electronic and Computer Engineering,
Faculty of Electrical Engineering,UniversitiTeknologi Malaysia,
81310, Johor Bahru, Johor.
Email: adeerawan@gmail.com
1. INTRODUCTION
Electrical Discharge Machining (EDM) is a machining process that enables noncontact drill via
electrochemical effects irrespective of the hardness of the workpiece (see Figure 1). In EDM process, pulse
power generator is required in order to obtain the discharge spark. The efficiency of production is depending
on the performance of the pulse power generator. Control servo is used to control the space gap between
electrode and workpiece. In creating the spark discharge, a current flow from the electrode through a
dielectric fluid due to the gap distance between electrode and workpiece is reduced to a very small clearance
approximately 10 to 50 microns [1, 2]. Electrical energy from the spark is converted into heat energy, then
builds up the workpiece temperature and melts the area on its surface. The working pulse power generator is
an important role in affecting the material removal rate (MRR) and the properties of the machined surface [3,
4]. The filtration system is used to maintain the dielectric fluid and flush out the eroded gap particles. This
article presents the pulse phase in the EDM process due to improve in machining parameter. In order to prove
the theoretical more clearly is determine by performing the simulation and experimental studies.
Pulse generator is divided into two types. There are relaxation (resistance-capacitance) generator
and transistor pulse generator. The relaxation circuit type of EDM pulse power generator create pulses
through the capacitor charge and discharge behavior. Discharge energy is determined by the used capacitance
and by the stray capacitance that exists between electrode and workpiece. The electrical sparks are created
from the released charges of capacitor.
The transistor pulse generator is widely used in conventional EDM and provides a higher MRR due
to its high discharge energy [9]-[11]. Moreover, the pulse duration and discharge current can be arbitrarily
changed depending on the required machining characteristics. The transistor pulse generator generates a
rectangular pulse discharges by controlling the current or voltage source. By changing the duty cycle, pulse
width modulation is used to control the transistor states. To ensure a constant processing, the MOSFET
transistor is used as a switch to control the output pulse power as shown in Figure 3.
Model of Pulsed Electrical Discharge Machining (EDM) using RL Circ (Ade Erawan Minhat)
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By applying Kirchhoff’s voltage law. The voltage gap is in open circuit voltage state can be
expressed as follows.
(1)
(2)
When the circuit is not formed in a closed-loop network, then no current through in the circuit.
0 (3)
(4)
When i is zero, current gap during ignition phase can be expressed as follows,
(5)
According to Figure 5, thecircuit is formed in a closed-loop network. The gap voltage is the
difference between V and voltage across R . By applying Kirchhoff’s voltage law, gap voltage can be
expressed as follows,
(6)
(7)
(8)
From Equation (8), the gap voltage can be express as the voltage divider ruleduring the ignition
phase,
(9)
Figure 6. The circuit in discharge phase condition which is switch (S1) and switch (S2) is turn ON
(10)
0 (11)
Model of Pulsed Electrical Discharge Machining (EDM) using RL Circ (Ade Erawan Minhat)
256 ISSN: 2088-8694
(12)
After adjusted,
(13)
(14)
(15)
By using assumption,
(16)
(17)
(18)
(19)
(20)
ln (21)
ln (22)
ln (23)
ln ln (24)
ln (25)
(26)
(27)
1 (28)
(29)
1 (30)
1 (31)
(32)
(33)
As illustrated in Figure 7, the three phases of EDM pulses has been shown in details. based on the
time duration in one period, the initial phase from 0 until t1, followed by the ignition phase of the t1 to t2 and
the next phase of the discharge of the t2 to t3.
Figure 7. The profile of EDM pulse which is consists switch (S1), switch (S2), gap voltage (Vgap) and current
gap (Igap) versus of time
Model of Pulsed Electrical Discharge Machining (EDM) using RL Circ (Ade Erawan Minhat)
258 ISSN: 2088-8694
PWM
Pulse
Generator
R_shunt
+Vin i_gap
+
Vin v
-
Vgap
-Vin1
Mosfet
g
S
D
Electrical Model of EDM waveform
Scope
1
+Vin i_gap
i
1 + -
i gap1
PWM1
R6 >=
1 s
+ + v Relational
D
g
PWM -
- Operator
C VS V1
Mosfet1
R_ignition C1
S
Diode
0.6
Constant
R1
L1
-Vin1
Figure 8. The electrical model of EDM pulse power generator and the configuration of EDM pulses inside
the block diagram
(a) (b)
Figure 9. (a)The simulation results show the pulse width modulation, voltage and current in the gap. (b)The
gap waveform displayed from the experiment (Ch1: Gap Voltage, Ch2: Gap Current)
Figure 10. (a) Spark discharge phase; (b) Holes fabricated by the transistor pulse generator; (c) Zooming into
the hole surface at 100X magnification
5. CONCLUSION
In conclusion, a new mathematical model of EDM pulses has been presented and implemented
successfully. Based on current and voltage gap, there are three mathematical models has been developed such
as initial, ignition and discharge phase. Referring to the equations described above, Equation (2) and
Equation (3) can be used in an initial phase conditions while Equation (5) and Equation (9) on the ignition
phase and Equation (31) and Equation (33) for discharge phase. Mathematical model of EDM pulses as the
objective of this study has been achieved. The model has been validated by simulation and experimental
Spark
result. The performance of the simulation design has been tested and give a good result compared with the
theoretical pulse shape.Comparing simulation and experimental result, this mathematical model is applicable
to other simulation studies relating to the EDM pulses. This is great theoretical and practical importance for
EDM process.
ACKNOWLEDGMENTS
The authors would like to thank the Universiti Teknologi Malaysia (UTM) and Ministry of
Education (MoE) Malaysia for financial support through Research University Grant (GUP) with Vote
No.05H41.
REFERENCES
[1] A Yahya, et al. Communication within hardware of Electrical Discharge Machining (EDM) system. Jurnal
Teknologi (Special Edition) Sciences & Engineering. 2011; 55(1): 201-212.
[2] A Yahya. Digital control of an electro discharge machining (EDM) system. Ph.D Thesis, Loughborough University,
2005.
[3] AE Minhat, et al. Power Generator of Electrical Discharge Machining (EDM) System. Applied Mechanics and
Materials. 2014; 554: 638-642.
[4] Y Tsai, C Lu. Influence of current impulse on machining characteristics in EDM. Journal of Mechanical Science
and Technology. 2007; 21: 1617-1621.
[5] AE Minhat, et al. Model of Pulse Power Generator in Electrical Discharge Machining (EDM) System. Applied
Mechanics and Materials. 2014; 554: 613-617.
[6] A Yahya, et al. Comparison Studies of Electrical Discharge Machining (EDM) Process Model for Low Gap Current.
Advanced Materials Research Journal. 2012; 133-440: 650-654.
[7] Y Yang, et al. Design of pulse power for EDM based on DDS chip AD9851. Mechanic Automation and Control
Engineering (MACE), 2010 International Conference on. 2010: 3302-3304.
[8] AE Minhat, et al. Control Strategy for Electrical Discharge Machining (EDM) Pulse Power Generator. Applied
Mechanics and Materials. 2014; 554: 643-647.
[9] T Andromeda, et al. Predicting material removal rate of Electrical Discharge Machining (EDM) using artificial
neural network for high Igap current. Kuantan, 2011.
[10] N Mahmud, et al. Pulse Power Generator Design for Machining Micro-pits on Hip Implant. Jurnal Teknologi
(Sciences & Engineering). 2013; 61: 33-38.
[11] M Rahman. A comparative study of transistor and RC pulse generators for micro-EDM of tungsten carbide.
International Journal of Precision Engineering and Manufacturing. 2008; 9: 3-10.
[12] W Mysinski. Power supply unit for an electric discharge machine. Power Electronics and Motion Control
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Model of Pulsed Electrical Discharge Machining (EDM) using RL Circ (Ade Erawan Minhat)
260 ISSN: 2088-8694
BIOGRAPHIES OF AUTHORS
Ade Erawan is a Ph.D. candidate in the Electronic and Computer Engineering Department,
Faculty of Electrical Engineering, Universiti Teknologi Malaysia, Skudai, Johor. He obtained his
bachelor and master’s degrees from Universiti Teknologi Malaysia in 2007 and 2011
respectively. His recent research is about pulse power generator for Electrical Discharge
Machining (EDM) system. He is interested in Switch Mode Power Supply, Analog/Digital
Circuit, MATLABSimulink and PSoC (Programmable System-on-Chip) microcontroller.
Dr. Nor Hisham Haji Khamis is a senior lecturer in the Radio Communication Engineering
Department (RaCED), Faculty of Electrical Engineering Department, Universiti Teknologi
Malaysia, Skudai, Johor. He received his B.Sc.E.E. from the University of Evansville, Indiana,
USA in 1988, M.E.Sc.E.E. from the University of New South Wales, Australia in 1992, and PhD
from UTM in 2005. He joined UTM in 1989 and currently is the Head of Radar Laboratory. He
is also the subject coordinator for the Microwave Engineering, RF Microwave Circuit Design,
and Radar courses at the faculty. He also leads the Sonar and Marine Instrumentation Research
Group (STAR). His research interest includes antenna design especially microstrip antenna,
microwave components, wireless transmission, and propagation studies. He is a member of Eta
Kappa Nu (Electrical Engineering Honor Society, USA) and IEEE.
Azli Yahya is a senior lecturer at the Faculty of Electrical Engineering, UTM and attached to the
Faculty of Health Science and Biomedical Engineering, UTM. In faculty, he is a Head of
Department for Postgraduate Studies. He got his B.Eng (Hons) degree in Electro-Mechanical
Power System and M.Sc. degree in Electronic Production from University of Glamorgan, Wales-
UK. In 2006, he obtained his PhD degree in Electronic/Electrical Engineering from University of
Loughborough, UK. His research areas cover Electrical Discharge Machining System, Analog /
Digital Circuit, Microcontroller, PSPICE, MATLAB, Switch Mode Power Supply, Biomedical
instrumentation.