(1) ELECTRICAL DISCHARGE MACHINING(EDM)

WORKING

Electric discharge machining is a thermo-electric non-traditional machining

process. Material is removed from the work piece through localized melting and
vaporization of material. Electric sparks are generated between two electrodes
when the electrodes are held at a small distance from each other in a dielectric
medium and a high potential difference is applied across them. Localized regions
of high temperatures are formed due to the sparks occurring between the two
electrode surfaces. Work piece material in this localized zone melts and vaporizes.
Most of the molten and vaporized material is carried away from the inter-
electrode gap by the dielectric flow in the form of debris particles. To prevent
excessive heating, electric power is supplied in the form of short pulses. Spark
occurs wherever the gap between the tool and the work piece surface is smallest.
After material is removed due to a spark, this gap increases and the location of
the next spark shifts to a different point on the work piece surface. In this way
several sparks occur at various locations over the entire surface of the work piece
corresponding to the work piece-tool gap. Because of the material removal due to
sparks, after some time a uniform gap distance is formed throughout the gap
between the tool and the work piece. Thus, a replica of the tool surface shape is
formed on the work piece as shown in figure 1.2.1. If the tool is held stationary,
machining would stop at this stage. However if the tool is fed continuously
towards the work piece then the process is repeated and more material is
removed.

 Electrode and workpiece must have electrical conductivity

 Dielectric act as spark conductor(concentrate energy to a narrow region)
 Used for hard metals and alloys
 Better surface finish
 E-EDM (ecofriendly,dielectric replaced by ionized oxygen

APPLICATION

 Prototype production
 Coinage die making
 Small hole deilling

ADVANTAGES

 Complex shapes
 Extremely hard material to very close tolerances
 Very small work
 There is no direct contact between tool and work piece. Therefore
delicate sections and weak materials can be machined without any
distortion.
 A good surface finish can be obtained.
 Very fine holes can be easily drilled.

DISADVATAGES

 The slow rate of material removal.

 The additional time and cost used for creating electrodes
 Reproducing sharp corners on the workpiece is difficult due to
electrode wear.
 Power consumption is high.
 "Overcut" is formed.
 Excessive tool wear occurs during machining.
 Electrically non-conductive materials can be machined only with
specific set-up of the proces

2.WIRE EDM

WORKING
single-strand metal wire (usually brass) in conjunction with de-ionized water (used to
conduct electricity) allows the wire to cut through metal by the use of heat from
electrical sparks.

 Easily machine complex parts

 More precise
 Wire of 0.1 to 0.3 mm dia.

3.ELECTRO CHEMICAL MACHINING

WORKING

Electrochemical machining is a process of a selective dissolution of the

anodically connected work piece material submerged in an electrolyte
together with an anodically connected tool.

Principally electrochemical machining is similar to Electropolishing where

the work piece surface roughness decreases due to the conversion of the
atoms into ions and their removal from the surface as a result of a
passage of an electric current.
Electrochemical machining is generally opposite to electroplating where
the metallic ions traveling through the electrolyte solution deposit on the
surface of the cathodically connected work piece.

At anode

Fe = Fe2+ + 2e-

At cathode

H2O + 2e- = H2 + 2OH-

At electrolyte

Fe2+ + 2OH- = Fe(OH)2

insoluble hydroxide precipitates at the tank bottom forming the sludge

Electrolyte used in ECM

 Nacl

 Hcl

 NaOH etc
ADVANTAGES OF ECM

 The rate of machining does not depend on the hardness of

the work piece material.
 The tool does not wear. Soft materials (e.g., copper) may be
used for tool fabrication.
 No stresses are produced on the work piece surface.
 No burrs form in the machining operation.
 High surface quality may be achieved.
 High accuracy of the machining operation.

DISADVANTAGES OF ECM

 Higher cost.
 Electrolyte may cause corrosion of the equipment.
 Large production floor is required.
 Only electrically conductive materials may be machined.
 Not environmentally friendly process.

APPLICATION

 It can be used for Die-Sinking operations.

 Drilling a jet engine turbine blade.
 Multiple Hole drilling.
 Steam turbine blades can be machined within close limits.

Similarities b/w ECM and EDM

1. Tool and workpieceare separated bya small gap

2.Both are conductors of electricity
3.High capital investment
4.Consume lot of power
5.Fluid is used

(4)LASER BEAM MACHINING(LBM)

WORKING
A coiled xenon flash tube is placed around the ruby rod and the
internal surface of the container wall is made highly reflecting
so that maximum light falls on the ruby rod for the pumping
operation. The capacitor is charged and a very high voltage is
applied to the triggering electrode to initiate the flash. A lens
towards the work piece surface focuses the emitted laser
beam. At the spot where the beam strikes the surface a small
portion of the material is vaporized and ablated at high speed.
The laser emitting system requires proper cooling.

 Efficiency of LBM is quite low about 0.3 – 0.5 %.

 used to drill micro holes and cutting very narrow slots.

I z = I o e -z
Iz - light intensity at depth z
 - absorption coefficient.

ADVANTAGES
 No limit to cutting path
  Stressless process
 Applicable to very hard and abrasive material
 Cost effective
 More accurate
 No tool wear
 No lubrication needed

DISADVANTAGES
 Uneconomical at high volume
 High capitalcost
 High maintenance cost
 Assit or cover gas required