Effect of Current On Electrical Discharge Machining (Edm) : Supervise by DR: Shukry H. Aghdeab 2010 - 2011

REPUBLIC OF IRAQ.
MINISTRY OF HIGHER EDUCATION &

SCIENTIFIC RESEARCH.
UNIVERSITY OF TECHNOLOGY
PRODUCTION & METALLURGY ENG. DEP.
CONSIDERATION OF GRADUATION
EFFECT OF CURRENT ON
ELECTRICAL DISCHARGE
MACHINING ( EDM )
This project submitted to the production and metallurgy

engineering department of university of technology as a partial
fulfillment of the requirement for the degree of Bachelor of
Science (B.Sc) in production engineering
Prepared by
EDREES ABD ALI KHUDHAIR MUSTAFA MOHSEN KHUDER
Supervise by
Dr : Shukry H. Aghdeab
2010 - 2011
FOR IRAQ.
TO WHOM LEAD US TO THE TRUTH WAY.
TO OUR PARENTS , BROTHERS , SISTERS ,
LOVES & FRIENDS .
EDREES & MUSTAFA

Acknowledgement
We would like to express our sincere gratitude and

appreciation to our supervisor, Dr. Shukry H. Aghdeab for his
guidance, advice, effort and cooperation throughout the stages
of this study,
Special thanks go to anyone who supported, encouraged and

helped us.
Edrees abd ali khudair

Mustafa muhsen khuder
2011
Supervisor certificate
We certify that the preparation of this project entitled

"Effect of current on electric discharge machining" was made
under my supervision in the production and metallurgy
engineering department in the university of technology as a
partial fulfillment of the requirement for the degree of Bachelor
of Science (B.Sc) in production engineering
Supervisor
Dr . Shukry H. Aghdeab
2011
‫ﺑﺴﻢ اﷲ اﻟﺮﺣﻤﻦ اﻟﺮﺣﯿﻢ‬
‫ﺇﻥ ﺍﻟﺬﻳﻦ ﺍﻣﻨﻮﺍ ﻭﻋﻤﻠﻮﺍ‬
‫ﺍﻟﺼﺎﳊﺎﺕ ﺳﻴﺠﻌﻞ‬
‫ﳍﻢ ﺍﻟﺮﲪﻦ ﻭﺩﺍ‬
‫ﺻﺪق اﷲ اﻟﻌﻠﻲ اﻟﻌﻈﯿﻢ‬

‫ﺳﻮرة ﻣﺮﯾﻢ اﻵﯾﺔ ‪96‬‬
abstract
Electric discharge machining one of the most extensively used non-
conventional material removal processes. The principle of electric spark is used
in this thesis to generate high electrical discharge at high currents.
The machine in the experimental work for EDM (electrical discharge machining)
system has been built to cutting conductivity metals and using power supply (RC
type) ,capacitor and dielectric solution , the work piece and electrode are
conductivity metals like (copper ) .
Electric current was passed (DC pulse type) from the power supply to the
capacitor then to the electrode and work piece, the electric discharge machining
process are created bubbles within the small gap between the work piece and
electrode .Increase in the number of bubbles and their growth in size, at later
stages; generates a single bubble which makes a bridge between the electrodes
create plasma formation. This plasma is a heat source column in the center of
enveloping vapor bridge, the ends of which are touching the electrodes.
The experimental work in this research to know effect the electrical on electric
discharge machining (EDM ) and conclusion this effect on the metal removal rate
(MRR) , relative wear (RW) and machining time.
i
Overviews
Through the complementary chapters, this research will show in detail the
main subjects related to the research and thoroughly the basic concept, theoretical
and experimental analysis methods that have been applied in this field. The
research consists of the following chapters:
- Chapter one contains the introduction and literature survey.

- Chapter two includes the EDM machining process.
- Chapter three contains experimental work and results
- Chapter four is contains the discussion and conclusions and recommendation for
future work.
ii
Table of contents
Subject Page No.
Abstract i
Table of Contents iii
CHAPTER ONE : INTRODUCTION AND LITERATURE SURVEY
Subject Page No.

1-1 Introduction 1
1-2 Literature Survey 5
CHAPTER TWO : EDM MACHINING PROCESS
Subject Page No.

2-1 Introduction 6
2-2 Mechanism of Material Removal 7
2-3 The Machining System 12
2-4 Material Removal Rates 13
2-5 EDM Electrodes 15
2-5-1 Materials 15
2-5-2 Polarity 16
2-5-3 Electrode wear 16
2-6 Dielectric Solutions 18
CHAPTER THREE : EXPERMENTAL WORK and RESULTS
Subject Page No.

3–1 Introduction 19
3–2 Experimental work 19
3–2–1 Mechanism 19
3–2–2 Power supply 20
3–2–3 Dielectric solution 21
3–2–4 Work piece 22
3–2–5 Electrode 23
3–3 Practical experimental 24
3–3–1 First experimental 26
3–3–2 Second experimental 26
3–3–3 Third experimental 28
iii
3–3–4 Fourth experimental 30
3–3–5 Fifth experimental 32
3–4 Extra experimental (micro hole machining) 34
3–4–1 First extra experimental 34
3–4–2 Second extra experimental 36
3–5 Developed the mechanism 38
3–6 The computa ons 39
3–6–1 the machining time 39
3–6–2 computing the material removal rate (MRR) 40
3–6–3 computing the electrode wear (EW) 41
CHAPTER FOUR : DISCUSSION AND CONCLUSIONS AND

RECOMMENDATION FOR FUTURE WORK
Subject Page No.
4 – 1 Discussion 42
4 – 2 Conclusions 42
4 – 3 Recommendation for future work 42
References
References 43
iv
CHAPTER ONE
INTRODUCTION AND LITERATURE SURVEY
1-1 Introduction
Electrical Discharge Machining (EDM) is a thermal erosion process in which
an electrically generated spark vaporizes electrically conductive material as shown
in Fig. (1-1) [1].
Fig. (1-1) EDM spark .
EDM is one of the most extensively used non-conventional material removal

processes [2]. Both electrode (tool) and workpiece must be electrically conductive
[3]. The spark occurs in a gap filled with dielectric solution between the tool and
workpiece. The process removes metal via electrical and thermal energy, having
no mechanical contact with the workpiece [4]. Its unique feature of using thermal
energy is to machine electrically conductive parts regardless of their hardness; its
distinctive advantage is in the manufacture of mould, die, automotive, aerospace
and other applications. In addition, EDM does not make direct contact between
the electrode and the workpiece, eliminating mechanical stresses, chatter and
vibration problems during machining [2].
Today, an electrode as small as 0.1mm can be used to make hole into curved
surfaces at steep angles without drill [2]. The spark is generated due to a gap
between the work piece and a tool. The smaller the gap the better the accuracy and
the slower the MRR (material removal rate) [1]. Fig. (1-2) shows the classification
of the spark erosion machining processes [5].
EDM
Sinking by EDM Cutting by EDM Grinding by EDM
Drilling Die Slicing Slicing Wire External Internal Form

by sinking by by cutting EDM EDM grinding
EDM by EDM EDM EDM by grinding grinding by
using a using a EDM EDM
rotary ribbon
Fig. (1-2) Classification of the spark erosion machining processes [5].
The basis of EDM can be traced as far back as 1770, when English chemist
Joseph Priestly discovered the erosive effect of electrical discharges or sparks [2].
The spark generator used in 1943, known as the Lazarenko circuit, has been
employed over many years in power supplies for EDM machines and proved to be
used in many current applications [5]. The Lazarenko EDM system uses
resistance-capacitance type of power supply, which was widely used at the EDM
machine in the 1950's and later served as the model for successive development in
EDM [2]. Further developments in the 1960's of pulse and solid state generators
reduced previous problems with weak electrode as well as the inventions of
orbiting systems. In the 1970's the number of electrodes is reduced to create
cavities. Finally, in the 1980's a computer numerical controlled (CNC) EDM was
introduced in USA.
The EDM process can be compared with the conventional machining
processes like milling and turning as shown in Table (1-1), except that in this
case, a suitably shaped tool electrode, with a precision controlled feed
movement is employed in place of the cutting tool, and the cutting energy is
provided by means of short duration electrical impulses.
Table (1-1) EDM compared to conventional machining [7].
Characteristics Milling/ Turning EDM
Contact between workpiece and Yes No

cutting tool
Force Yes No
Tool/ Workpiece Rotation Yes Not Normal
Tool/ Workpiece Conductive Not required Required
Material Removal Method Shear Melt/ Vaporize

EDM has found ready application in the hard metals or alloys, which
cannot be machined easily by conventional methods. It thus plays a major role in
the machining of dies, tools, etc., made of tungsten carbides and hard steels.
The advantages of EDM process are [5]:
(i) The process can be readily applied to electrically conductive materials. Physical
and metallurgical properties of the work material, such as strength, toughness,
microstructure, etc., are no barrier to its application.
(ii) During machining, the workpiece is not subjected to mechanical deformation as
there is no physical contact between the tool and workpiece. This makes the
process more versatile. As a result, slender and fragile jobs can be machined
conveniently.
(iii) Although the metal removal is due to thermal effects, there is no heating in the
bulk of the material.
(iv) Complicated die contours in hard materials can be produced to a high degree of
accuracy and surface finish.
(v) The overall production rate compares well with the conventional processes
because it does not need operations like grinding, etc.
(vi) The surface produced by EDM consists of a multitude of small craters. This may
help in oil retention and better lubrication, especially for components where
lubrication is a problem. The random distribution of the craters does not result in
an appreciable reduction in fatigue strength of the components.
(vii) The process can be automated easily requiring very little attention from the
machine operator.
(viii) No cutting force is generated [1].
1-2 Literature Survey
Ho and Newman (2003) [2] studied the research work carried out from the
inception to the development of die-sinking EDM. They reported on the EDM
research related to improving performance measures, optimizing the process
variables, monitoring and control the sparking process, simplifying the
electrode design and manufacture. Fig. (1-3), presents the classification of the
various research areas and possible future research directions.
Margaret (2004) [4] showed the analysis of the various inputs into EDM and
the resulting outputs into the environment. A simplified model is used to analyze
the process; the main categories of flow in the model are material and energy
flow. It was concluded that the materials which were machined by EDM have no
effect on the environment.
EDM Research
Areas
Optimizing the Monitoring and Improving the EDM

Process Variables Control the Process Performance Developments
Measures
Electrical Electrode Material Tool Surface

and Non- Design and Removal Wear Quality
Electrical Manufacture
Parameters
Pulse/ Fuzzy Radio EDM Hybrid

Logic Frequency Applications Machining
Time Processes
Fig. (1-3) Classification of major EDM research areas [2].

CHAPTER TWO
EDM MACHINING PROCESS
2-1 Introduction
EDM is a non-conventional manufacturing process. In this process, the

material is removed by erosive action of electric discharges occurring between a
tool electrode and workpiece based on the fact that no tool force is generated
during machining. Both workpiece and tool electrode are submerged in a solution
called dielectric as shown in Fig. (2-1). The mechanical characteristics of
workpiece and electrode are not a concern because the electrical energy is
converted into thermal energy causing melting of the material. EDM process
allows the machining of hard materials and more complex shapes which cannot be
processed by other conventional methods. The EDM process is normally applied
to mould and die making. Compared to conventional machining method, the
material removal rate of this machining remains rather low [12, 14].
Fig. (2-1) Spark gap and material removal due to one pulse in EDM process [12,
14].
EDM is a process of removing material in a closely controlled manner from an

electrically conductive material immersed in a liquid dielectric by a series of
randomly distributed discrete electrical sparks or discharges. Non-conducting
materials cannot act directly on electrode to achieve EDM. In order to machine
these materials with EDM, the conditions that electrical discharges can be
produced on their surface must be created [8].
2-2 Mechanism of Material Removal
In EDM, The removal of material is based upon the electro-discharge erosion

(EDE) effect of electric sparks occurring between two electrodes that are
separated by a dielectric liquid as shown in Fig. (2-2). Metal removal takes place
as a result of the generation of extremely high temperatures generated by the high-
intensity discharges that melt and evaporate the two electrodes [6].
Fig. (2-2) EDM components [6].
Direct-current power is supplied to the circuit in pulses that can be

approximated by a square wave. Ideally, each pulse creates a spark. Each spark
occurs where the resistance is smallest, usually near the last spark. The erosion
occurs over the surface of the electrode and workpiece interface. The square wave
and plotting current against time are the basic common terminology of the EDM
power supply. The variables are on-time, off-time, and peak current as shown in
Fig. (2-3) [3]. A series of voltage pulses of magnitude about 20 to 120 V and
frequency on the order of 50kHz is applied between the two electrodes, which are
separated by a small gap, typically 0.01 to 0.5mm. When using RC generators, the
voltage pulses, shown in Fig. (2-4) are responsible for material removal [6].
Fig. (2-3) Typical EDM pulse current train for controlled pulse generator [3, 6].
Fig. (2-4) Variation in voltage with time using an RC generator [6].
The selection of supply voltage is a compromise between several

factors, for example, size of equipment, safety of operation, etc. The D.C. supply
voltage used in EDM machines ranges between 30 to 200V [5]. Power supplies
are rated in amperes and range from 10 to 1000A [3]. A pulsed D.C. supply was
used to test the effect of high-frequency pulsed current [1-27].
To find experimentally the amount of operational energy used to record the

current between the anode and the cathode during operation. Ohm's law state is
used [4, 5]:
V = I R …………………………………………………………….… (1)
where V voltage is in Volts, current I is in Amps, and resistance R is in Ohms.

The resistance between the anode and cathode was measured at approximately
200 ohms. As the different variables were changed, data were recorded for the
corresponding current changes. Again applying Ohm's law [4]:
P = V I ………………………………………………………………. … (2)
where P is power in Watts. Substituting equation (1) into (2) yields [4]:
P = I2 R ………………………………………………………………… (3)
And current density law states that [5]:
I
…………………………………………………………………….… (4)
S=
A
where S is current density in A/ mm2 and A is area of machining (mm2).
When the electrons and the positive ions reach the anode and cathode, they
give up their kinetic energy in the form of heat. Temperature of about 8000 to
12,000°C [2, 5, 6] or as high as 20,000°C [2, 7, 18, 26] and heat fluxes up to 1017
W/m2 [6, 26] are reached when the pulsating direct current supply occurs at the
rate of approximately 20,000-30,000Hz [2]. With a very short time spark of
typically between 0.1 to 2000μs the temperature of the electrodes can be raised
locally to more than their normal boiling points. Owing to the evaporation of the
dielectric, the pressure on the plasma channel rises rapidly to values as high as
200 atmospheres. Such great pressures prevent the evaporation of the superheated
metal [6].
EDM consists of generating spark discharge between the tool and the
workpiece immersed in a dielectric liquid. At the early stages of process, due to
very low electrical current of electrons passing through the liquid dielectric from
the negative electrode towards the positive pole, very small bubbles are created
within the gap between the closest opposing peaks of roughness of the electrodes.
Increase in the number of bubbles and their growth in size, at later stages;
generates a single bubble which makes a bridge between the electrodes, as shown
in Fig. (2-5). Due to collision of accelerated electrons with the gas or vapour
molecules within the vapour bridge, ionization of molecules is initiated which
later ends to full ionization and plasma formation. This plasma is a heat source
column in the center of enveloping vapour bridge, the ends of which are touching
the electrodes. By generation of heat within the plasma channel the vapour bubble
grows. When the electrical current is interrupted by the power source, the plasma
is put off. But the vapour bubble continues to grow until it finally collapses to
small bubbles. The continuous enlargement of the gas bubble during the electrical
discharge leads to drop of pressure within the bubble. This, in turn, promotes the
expelling of the gas dissolved in the molten material on the contact face of plasma
on the two electrodes, in other words, boiling within the whole volume of the
heated crater. At the end of the discharge, when the plasma is put off, the heat
generation stops and the pressure falls rapidly. Therefore, the
superheated material boils violently; molten droplets and vapourized materials are
ejected into the dielectric, where they are condensed into particles [25], as shown
in Fig. (2-6).
(a) (b) (c)
Fig. (2-5) Diagram of the EDM physical process from (a-c) [13].
Fig. (2-6) EDM process step by step [7].
At the end of the pulse, the pressure drops suddenly and the superheated
metal evaporates explosively. Metal is thus removed from the electrodes as shown
in Fig. (2-7).
Fig. (2-7) EDM spark description [6].
The relation between the amount of material removed from the anode and cathode
depends on the respective contribution of the electrons and positive ions to the
total current flow. Consequently the erosion of the anode workpiece should be
greater than that of the cathode. At the end of the EDM action, the plasma channel
increases in width, and the current density across the inter electrode gap decreases.
EDM performance measures such as material removal rate, electrode tool wear,
and surface finish, for the same energy, depend on the shape of the current pulses.
Open gap voltages that occur when the distance between both electrodes is too
large obviously do not contribute to any material removal or electrode tool wear
[6].
2-3 The Machining System [6]
Figs. (2-8) and (2-9) show the main components of the EDM system.
Fig. (2-8) EDM schematic [6].
Fig. (2-9) EDM system components [6].
These components include the tool feed servo-controlled unit, which

maintains a constant machining gap that ensures the occurrence of active
discharges between the two electrodes. The power supply is responsible for
supplying pulses at a certain voltage, current, on time, and off time. The dielectric
circulation unit flushes the dielectric fluid to the interelectrode gap after being
filtered from the machining debris.
2-4 Material Removal Rates
In EDM the metal is removed from both the workpiece and the tool
electrode. As can be seen from Fig. (2-10), the material removal rate depends not
only on the workpiece material but also on the material of the tool electrode and
the machining variables such as plus conditions, electrode polarity, and the
machining medium. In this regard a material of low melting point has a high metal
removal rate and hence a rougher surface [6]. The volume of material removed per
discharge is typically in the range of 10-6-10-4mm3 [2] and the MRR is usually
between 0.1 to 400 mm3/min depending on specific application [2, 6].
Fig. (2-10) Parameters affecting EDM performance [6].
Fig. (2-11) EDM removal rates and roughness for different materials [6].
The results in Fig. (2-11) show the machining rates and surface roughness for
different materials. Figs. (15) and (16) explain the effect of pulse energy (current)
and duration on the crater size and hence the
removal rate. By increasing the current and machining time the material removal
rate is increased. The volumetric removal rate (VRR), in mm 3/min, can be
expressed by the following formula [6]:
VRR= (4*104) I Tw-1.23 ……………………………...………..… (5)
where I is the EDM current (A) and Tw is the melting point of the workpiece
material (°C).
Or material removal rate (MRR), in mm 3/min is defined in Eqs. (6) [16, 20, 22-
24].
MRR = Vw.p/t …………………………………………………..……..… (6)
where: Vwp = volume of material removed from workpiece (mm3).
t = time of machining (min).
Fig. (2-12) Effect of pulse current (energy) on removal rate [6].
Fig. (2-13) Effect of pulse on-time (energy) on removal rate and surface
roughness
2-5 EDM Electrodes
2-5-1 Materials
Four main factors determine the suitability of a material for use as an

electrode. These are [5]:
(i) The maximum possible metal removal rate.

(ii) Wear ratio.
(iii) Ease with which it can be shaped to the desired shape.
(iv) Cost.
Metals with a high melting point and electrical conductivity are usually
chosen as tool materials for EDM [6]. Graphite is the most common electrode
material because of its good machinability, EDM wear characteristics and small
flush holes can be drilled. Copper has good EDM wear and better conductivity
and is economical. It is generally used for better finishes in the range of 0.5μm Ra.
Copper tungsten and silver tungsten are used for making deep slots under poor
flushing conditions especially in tungsten carbides [3]. It offers high machining
rates as well as low electrode wear [6]. Copper graphite is good for thin cross-
sectional electrodes. Electrical conductivity is greatly improved, but corner wear
is not as good as it is for the same grade of pure graphite. Brass is inexpensive and
easy to machine, but does not wear well. Steel is used to match the parting planes
of molds. Tungsten is used to make small holes (<0.2mm) [3].
2-5-2 Polarity
Electrode polarity depends on both the workpiece and electrode materials [6].
Table (2-1) shows the possible electrode polarity for different workpiece and tool
combinations, some power supplies insert an opposite polarity at fixed intervals to
try to prevent arcing [3].
Table (2-1) Electrode Polarities for Different Workpiece Materials [3, 6].
WORK MATERIAL
Electrode Tungsten Ni – base
Steel Copper Aluminum
material carbide alloy
Graphite + , ‫ــ‬ ‫ــ‬ ‫ــ‬ + + , ‫ــ‬
Copper + + , ‫ــ‬ ‫ــ‬ + +
Cu – W + + , ‫ــ‬ ‫ــ‬ + +
Steel + , ‫ــ‬ + ‫ــ‬ ‫ــ‬ ‫ــ‬
Brass + ‫ــ‬ ‫ــ‬ + ‫ــ‬
2-5-3 Electrode Wear
The melting point is the most important factor in determining the tool wear.
Electrode wear ratios are expressed as end wear, side wear, corner wear, and
volume wear as shown in Fig. (2-14). The term no wear EDM is
generally applied to cases in which the electrode-to-workpiece wear ratio is 1% or

less [3, 6]. Wear first appears on corners. Thus, corner wear is most likely to
determine when an electrode must be redressed [3].
Fig. (2-14) Types of electrode wear in EDM [3, 6].

Electrode wear depends on a number of factors associated with the EDM, like
voltage, current, electrode material, and polarity [6], a large pulse current increase
electrode wear [3]. As can be seen from Fig. (2-15) the corner ratio depends on
the type of electrode. The low melting point of aluminum is associated with the
highest wear ratio and silver-tungsten has shown a low wear ratio [6].
Fig. (2-15) Corner wear ratios for different electrode materials [6].
The wear rate of the electrode tool material Wt and the wear ratio RW [6] is
represented as follows:
Wt = (11* 103) I Tt-2.38 ……………………………………………... (7)
Rw = 2.25 Tr-2.3 …………………………………………….… (8)
where: Wt= wear rate of the tool, mm3/min
I = EDM current, A.
Tt= melting point of the tool electrode, °C.
Rw= wear ratio.
Tr= ratio of the workpiece to tool electrode melting points.
The following equation is used for finding relative percentage wear of electrode
(EW) [17, 20, 22, and 23]:
EW = VE / V w.p ………………………………………………..(9)
where: EW = volumetric electrode wear, %.
Ve = volume of material removed from electrode (mm3).
Vwp= volume of material removed from part (mm3).
2-6 Dielectric Solutions
The dielectric solution performs several functions:
1- It is a spark conductor that must ionize under an applied voltage.

2- It is a coolant for workpiece and electrode.
3- It is a flushing medium that carries away the EDM chips resulting from the
process.
Desirable properties are low viscosity, high flash point, and low cost. Because of
small working gaps at finish spark settings, a low-viscosity dielectric is especially
important. Low viscosity also helps in setting of the EDM chips, thus keeping the
dielectric solution clean. The most common dielectric fluid is petroleum-base oil.
Also used are kerosene, silicone oils, and water-base dielectrics. Demonized water
has fire safety, low cost, low viscosity, and absence of carbon to react with the
work. On balance, however, the petroleum-base oils give better control of the
spark gap and are the most-used dielectric [3]. For most EDM operations kerosene
is used with certain additives that prevent gas bubbles. Other dielectric solutions
with a varying degree of success include aqueous solutions of ethylene glycol,
water in emulsions, and distilled water [6].
Flushing is defined as the correct circulation of dielectric solution between

the electrodes and workpiece. Suitable flushing conditions are essential to obtain
the highest machining efficiency [5].
CHAPTER THREE
EXPERMENTAL WORK AND RESULTS
3 – 1 : Introduction
In this chapter the experimental work and testing procedures will be
shown, it includes the specification of machine tool, power supply,
mechanical properties of workpiece material, electrode tools and the
dielectric solution; in addition it will show the process mechanics.
3 – 2 : Experimental Work
3 – 2 – 1 : Mechanism
Mechanism was used in this work ( local made)which include :
1. Base made of ( low carbon steel) 300*350 mm .as shown in
fig.(3 – 1).
2. Guide ( cylindrical shape with Ф 10 * 50 mm ) welding on the
base .
3. Tool holder ( aluminum bar Ф 12 * 120 two no. ) the relative
motion of this tool holder are sliding on the guide and locked
by bolt to insure the vertical motion.
4. Work piece holder ,as shown in fig. ( 3 - 2).
Fig. (3 – 1) the mechanism Fig. (3 – 2) work piece holder

3 – 2 – 2 : Power supply
The source of power for the experimental work is the generator
power supply. The EDM power supply unit also operates with manual
control. Manual control is more or less a feedback loop, as information is
fed to the controller from the workpiece; the controller is able to change
its inputs thus affecting the workpiece [28].
Fig. (3 - 3)Power supply model (Cebora MMA 4040)
The unit used AC 380V input voltage contains (three phase), and output
voltage 70V (two phase), but are available with other currents like 10 -
200A. A generator for the experimental work unit used is available in
welding machine (50/60HZ) type MMA 4040/ T- cell (Cebora-Italian).
Generator current range is (10-400A) depending on industrial application,
as shown in fig. (3 - 3).
3 – 2 – 3 : Dielectric solution
Dielectric solution is the distilled water is water that has many of
its impurities removed through distillation involves boiling the water and
then condensing the steam into a clean container. distilled water can
transport the high spark current between the tool-electrode and workpiece
for conducting the sparks by breaking down at the appropriate applied
voltage. Secondly, the dielectric solution flushes out the chips from the
machined area, and finally, the dielectric reduces temperature of the
workpiece. Electrode Instrument Meter is used in measurements of PH
(Hydrogen Power)= 7.0 ph , the device model HI 9811 (Hanna Portable
Instruction Manual), as shown in fig. (3 – 4) and fig. (3 – 5) as shown the
Pyrex container .
Fig. (3- 4) PH measurements

model HI 9811 (Hanna
Portable Instruction Manual)
Fig. (3- 5 ) Pyrex used as

container 5 liter.
3 – 2 – 4 : Work piece
The workpiece used was made of copper with constant thicknesses
(1.45 mm). as shown in table (3 - 1). general Properties of work material.
Table (3 - 1) the general Properties of work material
1 Name, symbol, number Copper ,Cu, 29

2 Element category Transition metal
3 Phase Solid
4 Density 8.94 g.cm-3
5 Liquid density atm. p. 8.02 g.cm-3
6 Melting point 1357.77 K, 1084.62 оC , 1984.32 оF
7 Boiling point 28335 K, 2562 оC , 4643 оF
8 Heat of vaporization 300.4 KJ.mol-1
9 Oxidation states +1, +2, +3, +4 (mildly basic oxide)
10 Electro negativity 1.90 (Pauling scale)
1st : 745.5 KJ.mol-1
11 Ionization energies (more) 2nd : 1957.9 KJ.mol-1
3rd : 3555 KJ.mol-1
12 Atomic radius 128 pm
13 Covalent radius 132 ±4 pm
14 Crystal structure face centered cubic
15 Magnetic ordering Diamagnetic
16 Electrical resistivity (20 C) 16.78 nΩ.m
17 Thermal conductivity (300 K) 401 W.m-1. K-1
18 Thermal expansion (25 C) 16.5 µm.m-1 .K-1
19 Young's modulus 110 – 128 Gpa
20 Shear modulus 48 Gpa
21 Bulk modulus 140 Gpa
22 Poisson ratio 0.34
23 Mohs hardness 3.0
24 Vickers hardness 369 MPa
The chemical composition to the workpiece.
95 % Cu
3 % Zn
2 % Fe
3 – 2 – 5 : Tool-Electrode
The tool used was made of copper with constant diameter(Ф 3.5 mm).
and have the same properties of workpiece, see Table(3 - 1)and the
mechanical composition of workpiece as shown in fig.(3 – 6) and fig.(3 – 7).
Fig. (3 – 6) the gap between the electrode & the workpiece.
Fig. (3 – 7) the electrode after machining process.

3 – 3 : Practical experimental
3 – 3 – 1 : first experimental as shown in table (3 – 2) and fig.(3 – 8).
Table (3 - 2) show the results of 1stexperimental
Working Parameters Description
Workpiece Copper (1.45 mm thickness)
Tool-electrode material Copper (Ф3.5 mm diameter)
Shape of tool-electrode Cylindrical bar (conical)
Tool-electrode polarity Negative (-)
Work piece polarity Positive (+)
Dielectric Distiller water
Input voltage 380V (three phase)
Output voltage 70V (two phase)
Type of current D.C Pulse current
Current (10) A
Machining time 33 min.
Weight of electrode(before machining) 11.5371 gm
Weight of electrode(after machining) 11.5365 gm
Weight of workpiece(before machining) 44.0760 gm
Weight of workpiece (after machining) 43.8598 gm
Diameter of the result hole 4.65 mm
Means the fixed machining condition.

Means the result of machining.
Fig. (3 - 8) the first experimental.
3 – 3 – 2 :Second experimental as shown in table (3 – 3) and fig.(3 – 9).
Table (3 - 3) show the results of 2nd experimental.
Tool-electrode material Copper (Ф 3.5 mm diameter)
Current (50) A
Machining time 27min.
Weight of electrode (before machining) 16.5177 gm
Weight of electrode (after machining) 16.5173 gm

Fig. (3 - 9) the second experimental.
3 – 3 – 3 : Third experimental as shown in table (3 – 4) and fig.(3 – 10).
Table (3 - 4) show the results of 3rd experimental.
Current (100) A

3 – 3 – 3 : third experimental
Table (3 - 4) show the results of 3rdexperimental
Tool-electrode material Copper (3.5 mm diameter)
Current (100) A
Weight (before machining)
Weight (after machining)
Diameter of the result hole

Fig. (3 - 10) the third experimental.

3 – 3 – 4 : fourth experimental as shown in table (3 – 5)and fig.(3 – 11).
Table (3 -5 ) show the results of 4th experimental
Current (150) A

Fig. (3 - 11) the fourth experimental.
3 – 3 – 5 : fifth experimental as shown in table (3 – 6) and fig.(3 – 12).
Table (3 - 6 ) show the results of 5thexperimental
Current (200) A

Fig. (3 - 12) the fifth experimental.
3 – 4 : extra experimental (micro hole machining)
3 – 4 – 1 :1st extra experimental as shown in table (3 – 7) and fig.(3 – 13).
Table (3 - 7 ) show the results of 1st extra experimental.
Tool-electrode material Stainless steel (Ф 0.4 mm diameter)
Dielectric tap water
Current (200) A
Diameter of the result hole 0.421

3 – 4 – 2 : 2nd Fig. - 13) the 1st extra experimental.
extra(3experimental
3 – 4 –2 :2nd t extra experimental as shown in table (3 – 8) and fig.(3– 14).
Table (3 - 8 ) show the results of 2nd extra experimental.
Workpiece Copper ( 0.62 mm thickness)
Tool-electrode material Stainless steel (Ф 0.3 mm diameter)
Dielectric tap water
Current (10) A
Machining time 30 min.

Fig. (3 - 14) the 2nd extra experimental.
3 – 5 : Developed the mechanism
After 5th experimental work we are limitation the error which meet us and
possibility to avoid it , we were designed and manufactured anew
mechanism which include:
1- Base ( 35*40 mm made of wood)

2- Guide (cylindrical shape with Ф 12 * 50 mm two no. made of M.S)
fastening on the base by nuts.
3- Tool holder ( aluminum bar Ф 12.5 * 150 two no. ) the relative
motion of this tool holder are sliding on the guide and locked by
bolt to insure the vertical motion.
4- Bolt and spring arrangement to keep the constant gap.
as shown in the fig.( 3 – 15).
Fig. (3 - 15) anew design for the mechanism.

3 – 6 : The computations
3 – 6 – 1 : the machining time.
From the experimental work results we can draw the relationship

between the machining time and the current as shown in table (3 – 9)and
fig.(3 – 16)
Table (3 – 9) the machining time with current.
Exp.( 1 ) Exp.( 2 ) Exp.( 3 ) Exp. ( 4 ) Exp.( 5 )

Current 10 A 50 A 100 A 150 A 200 A
Machining
33 min. 27 min. 23 min. 19 min. 15 min.
time
35
30
machining time (min)
25
20
15
10
0
0 50 100 150 200 250
current (A)
Fig. ( 3 - 16 ) Effect of machining time on the current.

3 – 6 – 2 : computing the material removal rate (MRR):
We can calculating the material removal rate by using the equation

(10) which equal the volume of removal metal from workpiece over the
machining time , with constant thickness of workpiece (1.45 mm) and
variety current (10,50,100,150 and 200 A) as shown in table (3 – 10) and
fig(3 – 17).
MRR = volume of removal metal / machining time ……………....(10)
Table (3 – 10) computing the material removal rate

Current Diameter Volume of Machini MRR
of hole metal removal ng time
Exp. (1) 10 4.65 mm 24.6118 mm3 33 min 0.74581 mm3/min
Exp.(4) 150 4.54 mm 23.46115 mm3 19 min 1.23479 mm3/min
1.8
1.6
1.4
MRR (mm³/min)
1.2
1
0.8
0.6
0.4
0.2
0
0 50 100 150 200 250
Current (A)
Fig. ( 3 – 17 ) Effect of MRR on the current.

3 – 6 – 3 : computing the electrode wear (EW):
We can calculating the electrode wear by using the equation (11)

which equal the current value multiply the melting point over (- 2.38)
multiply the constant 11000 , with variety current (10,50,100,150 and 200
A) as shown in table (3 – 11) and fig(3 – 18).
Wear of electrode = 11000 * I * Tt -2.38 ……………………………(11)
Table (3 – 11) computing the electrode wear (EW)
current Melting point Wear of electrode

for electrode
Exp. (1) 10 A 1084.62 ◦C 0.006567
Exp. (2) 50 A 1084.62 ◦C 0.032839
Exp. (3) 100 A 1084.62 ◦C 0.065679
Exp.(4) 150 A 1084.62 ◦C 0.098519
Exp. (5) 200 A 1084.62 ◦C 0.131354
0.14
0.12
0.1
0.08
EW
0.06
0.04
0.02
0
0 50 100 150 200 250
current (A)
Fig. (3 - 18 ) Effect of EW on the current.

CHAPTER FOUR
DISCUSSION AND CONCLUSIONS AND RECOMMENDATION
FOR FUTURE WORK
4 – 1 : Discussion
In this chapter , the discussion of results obtained from experimental
work. This discussion concentrates mainly on the effect of machining
time on the current, as shown in fig. (3 –16) at copper workpiece
thickness (1.45 mm) with varying currents (10,50,100,150 and 200 A).
Fig. (3 – 16) show that the machining time decreases with increases the
current due to increases the spark number and material removal rate
increases with increases the current resulting in greater amount of spark
generation in the sparking zone , which in turn increases the material
removal and electrode wear as shown in fig. (3 – 17) and fig.(3 – 18)
respectively.
4 – 2 : conclusions
The main conclusion which can be deduced from the experimental

work can be summarized as follows:
1. EDM system has been built for this purpose .

2. The results for the MRR in this method are about (0.74581 -
1.53663 mm3/min).
3. The results for the wear of electrode between (0.006567 -
0.131354).
4. the material removal and electrode wear increases in current.
4 – 3 : Recommendation for future work
The following research points maybe suggested for future work:
1. Studying the effect of cutting other materials like Al and steel.

2. Using other dielectric solution such as oil.
3. Using other tool electrode materials such as steel and carbon.
4. Studying the surface roughness in the current of EDM.
REFERENCES
1- Lotfi, K., G., Electrical Discharge Machining (EDM), the American

University in Cairo, Department of Mechanical Engineering, Vol. 202,
2003.
2- Ho, K., H., and Newman, S., T., State of the art electrical discharge
machining (EDM), International Journal of Machine Tools and
Manufacture, Vol. 43, pp. 1287-1300, 2003.
3- John, E., F., Electrical discharge machining, Rockwell International,
ASM Metals Handbook, Vol. 16 Machining, pp. 557-564, 1997.
4- Margaret, H., C., Environmental Constituents of Electrical Discharge
Machining, thesis Submitted to the Department of Mechanical
Engineering, Massachuse s Ins tute of Technology, 2004.
5- Pandey, P., C., and Shan, H., S., Modern machining processes,
University of Roorkee, New Delhe, Chapter 4, pp.84-113, 1980.
6- Hassan, El-Hoﬀy, Advanced Machining Processes, Chapter 5, pp.115-
140, by McGraw-Hill Company, 2005.
7- Gisbert, L., Advantages of the New EDM and HSM Technology, Agie
Chamilles Group, pp. 1-34, 2005.
8- Liu, Y., et al, Study on hole machining of non-conducting ceramics by
gas-filled electrodischarge and electrochemical compound machining,
Journal of Materials Processing, Vol. 69, pp. 198-202, 1997.
9- Bhattacharyya, B., et al, Experimental investigations into
electrochemical discharge machining (ECDM) of non-conductive ceramic
materials, Journal of Materials Processing, Vol. 95,pp. 145-154, 1999.
10- Wuthrich, R., and Fascio, V., Machining of non-conducting materials
using electrochemical discharge phenomenon-an overview,
Interna onal Journal of Machine Tools and Manufacture, Vol.45, pp.
1095-1108, 2005.
11- Tsuneo, K., and Mitsuro, H., A study of EDM and ECM/ECM- lapping
complex machining technology, International Journal of Machine Tools
and Manufacture, Vol. 46, pp. 1804-1810, 2006.
12- Hoang, V., S., et al, A study of method to control EDM process,
Mechanical Engineering faculty, Department of Industrial Automation,
Hanoi University of Technology, pp. 1-5, 2003.
13- Puertas, I., and Luis, C., J., A study on the machining parameters
optimization of electrical discharge machining, Journal of Materials
Processing Technology, Vol. 143-144, pp. 521-526, 2003.
14- Hoang, V., S., A method to reduce the relative wear in EDM die
sinking processes by reversed pulse, Hanoi University of Technology, ,
pp. 1-3, Email: hvsinh@mail.hut.edu.vn, 2004.
15- Amorim, F., L., and Weingaertner, W., L., Die-sinking electrical
discharge machining of a high-strength copper-based alloy for injection
molds, J. of the Braz. Soc. of Mech. Sci. and Eng., Vol. XXVI, No. 2, pp.
137-144, April-June 2004.
16- Mahdavinejad, R., A., and Mahdavinejad, A., ED machining of WC-
CO, Journal of Materials Processing Technology, Vol. 162-163, pp. 637-
643, 2005.
17- Luis, C., J., et al, Material removal rate and electrode wear study on
the EDM of silicon carbide, Journal of Materials Processing Technology,
Vol. 164-165, pp. 889-896, 2005.
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discharge machining, International Journal of Machine Tools and
19- Jain, V., K., et al, On the analysis of the electrochemical spark
machining process, International Journal of Machine Tools and
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in a computer numerical controlled electro-discharge machining process,
Wear, Vol. 236, pp. 350-354, 1999.
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performance of die-sinking EDM by using self-adjusting fuzzy control,
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contours using plate tools, Journal of Materials Processing Technology,
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surface quality, MRR and EW of WC-CO, Journal of Materials Processing
Technology, Vol. 153-154, pp. 1026-1032, 2004.
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white layer thickness and 3D surface texture parameters in the die
sinking EDM process, Precision Engineering, Vol. 29, pp. 479-490, 2005.
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electrical discharge generated bubble in EDM, Engineering Analysis with
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University of Technology- Iraq, Chaps. 1 and 4, 2008.

Effect of Current On Electrical Discharge Machining (Edm) : Supervise by DR: Shukry H. Aghdeab 2010 - 2011

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REPUBLIC OF IRAQ.

MINISTRY OF HIGHER EDUCATION &

This project submitted to the production and metallurgy

TO WHOM LEAD US TO THE TRUTH WAY.

TO OUR PARENTS , BROTHERS , SISTERS ,

LOVES & FRIENDS .

EDREES & MUSTAFA

We would like to express our sincere gratitude and

Special thanks go to anyone who supported, encouraged and

Edrees abd ali khudair

We certify that the preparation of this project entitled

‫ﺇﻥ ﺍﻟﺬﻳﻦ ﺍﻣﻨﻮﺍ ﻭﻋﻤﻠﻮﺍ‬

‫ﳍﻢ ﺍﻟﺮﲪﻦ ﻭﺩﺍ‬

‫ﺻﺪق اﷲ اﻟﻌﻠﻲ اﻟﻌﻈﯿﻢ‬

- Chapter one contains the introduction and literature survey.

CHAPTER ONE : INTRODUCTION AND LITERATURE SURVEY

Subject Page No.

CHAPTER TWO : EDM MACHINING PROCESS

Subject Page No.

CHAPTER THREE : EXPERMENTAL WORK and RESULTS

Subject Page No.

CHAPTER FOUR : DISCUSSION AND CONCLUSIONS AND

Fig. (1-1) EDM spark .

EDM is one of the most extensively used non-conventional material removal

Sinking by EDM Cutting by EDM Grinding by EDM

Drilling Die Slicing Slicing Wire External Internal Form

Fig. (1-2) Classification of the spark erosion machining processes [5].

Table (1-1) EDM compared to conventional machining [7].

Characteristics Milling/ Turning EDM

Contact between workpiece and Yes No

Tool/ Workpiece Rotation Yes Not Normal

Tool/ Workpiece Conductive Not required Required

Material Removal Method Shear Melt/ Vaporize

The advantages of EDM process are [5]:

Optimizing the Monitoring and Improving the EDM

Electrical Electrode Material Tool Surface

Pulse/ Fuzzy Radio EDM Hybrid

Fig. (1-3) Classification of major EDM research areas [2].

EDM MACHINING PROCESS

EDM is a non-conventional manufacturing process. In this process, the

EDM is a process of removing material in a closely controlled manner from an

2-2 Mechanism of Material Removal

In EDM, The removal of material is based upon the electro-discharge erosion

Fig. (2-2) EDM components [6].

Direct-current power is supplied to the circuit in pulses that can be

Fig. (2-4) Variation in voltage with time using an RC generator [6].

The selection of supply voltage is a compromise between several

To find experimentally the amount of operational energy used to record the

where V voltage is in Volts, current I is in Amps, and resistance R is in Ohms.

And current density law states that [5]:

where S is current density in A/ mm2 and A is area of machining (mm2).

(a) (b) (c)

Fig. (2-7) EDM spark description [6].

Fig. (2-8) EDM schematic [6].

Fig. (2-9) EDM system components [6].

These components include the tool feed servo-controlled unit, which

Fig. (2-10) Parameters affecting EDM performance [6].

MRR = Vw.p/t …………………………………………………..……..… (6)

where: Vwp = volume of material removed from workpiece (mm3).

t = time of machining (min).

Fig. (2-12) Effect of pulse current (energy) on removal rate [6].

Four main factors determine the suitability of a material for use as an

(i) The maximum possible metal removal rate.