J. T. Mahajan Polytechnic, Faizpur.

Seminar report on
ELECTRIC DISCHARGE MACHINING
(EDM)
Guided By
S.S.Jain Sir

Submitted By:
Shubham Nandkishor Sharma.
 CONTENTS
. INTRODUCTION
. PRINCIPLE
. CONSTRUCTION
. TOOL MATERIAL
. FLUID PROPERTIES
. WORKING
. EFFECTS OF EDM ON METAL SURFACE
. ADVANTAGES
. DISADVANTAGES
. APPLICATIONS
• EDM is a machining method typically used for hard metals which are
electrically conductive.
• It makes possible to work with metals for which traditional
machining techniques are ineffective.
• The use of a thermoelectric source of energy in developing the
nontraditional techniques has greatly helped in achieving an
economic machining of the extremely low machinability materials
and difficult jobs.
• The process of material removal by a controlled erosion through a
series of electric sparks, commonly known as EDM, was first started
in the USSR around 1943. Then onwards, research and development
have brought this process to its present level.
PRINCIPLE

Fig :Principle Diagram of EDM

• The principle of EDM is also called electro discharge or spark
erosion or electro erosion, is based on erosion of metals by
spark discharges.
• Since, when two current carrying conductors/wires are allowed
to touch each other, an arc is produced. If we look closely at the
point of contact b/w the two wires, we note that a small portion
of metal has been eroded away, leaving a small crater.
• In EDM,when a discharge takes place b/w two points of the
anode and the cathode, the intense heat generated near the zone
melts & evaporates the materials in the sparking zone.
• It has been observed that, If both the electrodes are made of
same materials, the electrode connected to +ve terminal
generally erodes at faster rate. For this reason, the w/p is
normally made the anode.
• . A suitable gap, known as the spark gap, is maintained b/w
the tool & the w/p surfaces.
• . The sparks are made to discharge at a high frequency with
a suitable source.
• . Since the spark occurs at the spot where the tool & the w/p
surfaces are the closest and since the spot changes after each
spark(bcoz of material removal after each spark), the spark
travels all over the surface.
• . This results in a uniform material removal all over the
surface, and finally the work face confirms to the tool
surface.
• . Thus, the tool produces the required impression in the work
piece.
The main components of EDM are-
• Power Supply
• Tool (Electrode)
• Spark Generator
• Di-electric fluid

Power Supply:
Power supply converts AC into pulsed DC, used to
produce spark b/w tool and w/p. This high power pulsed output
responsible for generating spark between the electrodes.*
 *
• TOOL (ELECTRODE) : The shape of the tool should be
replica of the desired product, except that an allowance is made
for side clearance, over cuts for broaching small holes.
• Solid tool(rod) may be used but for larger ones hollow tools
are used.
• If object have geometrical shape having symmetry about some
axis, tool symmetric to only a part of the object will be
sufficient for complete machining of the object.
• SPARK GENERATOR : The spark generator performs the
important function of supplying sufficient voltage to initiate &
maintain the discharge.
• It also absorbs the supply of varying current intensity and the
discharge duration and controll the recurring rhythmof the
discharge.
DI-ELECTRIC FLUID : In EDM, the dielectric fluid is
flushed through the spark gap.
• It is supplied either to a hole in the tool or from external jet.
• This fluid works aas the spark conductor.
• The widely used dielectric fluid is kerosene; others used are
deionized water, Si oils, ethylene glycol etc.
• The fluid must be hydrocarbon becoz deionization occurs due
to the involvment of hydrogen in hydrocarbon.
It consist of a table with x,y axis and z axis is vertical.
A NC system, a tank in which there is dielectric fluid.
 TYPES OF EDM
• The selection for tool material is depends upon various factors.
The main factor is, the tool should have electrical conductive.
• Other factors are, volume of material to be removed, required
surface finish, desired tolerance, wear ratio & many more.
• The various materials which can be used for making tool may
be of bross, copper, graphite.
• The dielectric fluid used in EDM should have following
properties-
• It should have sufficient dielectric strength.
• It should have low viscosity & good wetting capacity.
• It shoud be chemically neutral.
• It should not evolve toxic vapors during entire operation
range.
• The flash point should be high.
• It should provide sufficient cooling medium.
• It should be less costly & easily available.
• It should flush the debris produced during opration.
• The EDM system consist of a shaped tool(electrode) & w/p,
which are connected to the dc power supply and placed in
electrically non conducting dielectric fluid.
• When a voltage is applied to the tool, a magnetic field causes
suspended particles in the dielectric fluid to concentrate,
eventually forming a bridge for current to flow to the w/p.
• An intense arc is then generated, causing sufficient heating to
melt a portion of w/p & usually some of the tooling material
also.
• In addition, the dielectric fluid heated rapidly, causing
evaporation of the fluid in the arc gap; this evaporation
increases resistance of interface until the arc can no longer
maintained.
• Once arc is interrupted, heat is removed from the gas bubble by
surrounding dielectric fluid, and the bubbles collapses
(cavitates).
• The gap b/w the tool & w/p called overcut is critical; thus the
downward feed of the tool is controlled by a servomechanism,
which automatically maintains a constant gap.
• Hence, the machining of material is done by EDM technique.
• Hard & tough metals can be machined with better surface
finish.
• Complex & internal shapes can be machined.
• No cutting force due to no contact b/w metal and w/p.
• The surface finish is non-directional.
• No effects of material hardness and tool wear.
• Tolerance upto 0.4 micro meter is achieved.
• Secondary finishing operation can be neglect.
• No need of Heat treatment before machining.
• Low MRR.
• The w/p must be electric conductor.
• The surface after machining is highly stressed.
• Machining time is too long.
• Specific power consumption is too high.
• Excessive tool wear.
• It is used in the production of die for fabrication of all
components.
• EDM can be used in manufacturing of hydraulic valve
spools, gear wheels, fine holes or slots in hard blade
materials used in gas turbines, compressors, diesel engines
etc.
• It is used in fabrication, extrusion, blanking, stamping and
embossing dies.
• It is also used for removal of drill and tapes from
components.