BHATT DARSHILKUMAR .
M : 160670119503 DHRUVANG LAKHANI : 160670119510
CHOUBEY SAURABH .R : 160670119505
CHOUKSAY SANDEEP .P : 160670119506
DAS SANDIP .A : 160670119508
BACHELOR of ENGINEERING,
ABSTRACT
• The material removal in EDM mainly occurs
due to formation of shock waves as the
plasma channel collapse owing to
discontinuation of applied potential
difference.
• Generally the work piece is made positive
and the tool negative.
• Hence, the electrons strikes the job leading
to crater formation due to high temperature
and melting and material removal.
• Similarly, the positive ions impinge on the
tool leading to tool wear.
• The generator is used to apply voltage pulses
between the tool and job.
• A constant voltage is not applied. Only
sparking is desired rather than arcing.
• Arcing leads to localized material removal at
a particular point whereas sparks get
distributed all over the tool surface leading
to uniform material removal.
HISTORY
• In 1770, English Physicist JOSEPH
PRIESTLEY studied the erosive effect of
electrical discharges.
• Furthering Priestley's research, the EDM
process was invented by two Russian
scientists, Dr. B.R. LAZARENKO and Dr.
N.I. LAZARENKO in 1943.
• In their efforts to exploit the destructive
effects of an electrical discharge, they
developed a controlled process for
machining of metals. Their initial process
used a spark machining process, named after
the succession of sparks (electrical
discharges) that took place between two
electrical conductors immersed in a
dielectric fluid.
• The discharge generator effect used by this
machine, known as the LAZARENKO
Circuit, was used for many years in the
construction of generators for electrical
discharge.
• In 1952, the manufacturer CHARMILLES
created the first machine using the spark
machining process and was presented for the
first time at the European Machine Tool
Exhibition in 1955.
• In 1969, Agie launched the world's first
numerically controlled wire-cut EDM
machine.
• Seibu developed the first CNC wire EDM
machine in 1972 and the first system was
manufactured in Japan.
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PROF. MAYUR .N PATEL, MECHANICAL DEPARTMENT. SALITER
INTRODUCTION
• 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
• 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.
• For improving effectiveness, the w/p & tool
both are submerged in a dielectric fluid
(hydrocarbon or mineral oils).
• It has been observed that, If both the
electrodes are made of same materials, the
electrode connected to (positive) +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
(because 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 workpiece.
DIXIT DISHANT .V : 160670119511
JIYANI NIHAR .B : 160670119516
MEER GOPAL .S : 160670119521
, AHMEDABAD - 60
CONSTRUCTION TYPES OF EDM
SINKER EDM
FAST HOLE DRILLING EDM
• 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 WIRE CUT EDM
between the electrodes.
• TOOL (ELECTRODE) : The shape of the
tool should be replica of the desired product,
APPLICATION
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  It is used in the production of die for
discharge duration and control the recurring fabrication of all components.
rhythm of the discharge.  EDM can be used in manufacturing of
• DI-ELECTRIC FLUID : In EDM, the hydraulic valve spools, gear wheels, fine
dielectric fluid is flushed through the spark holes or slots in hard blade materials used in
gap. It is supplied either to a hole in the tool gas turbines, compressors, diesel engines etc.
or from external jet. This fluid works as the  It is used in fabrication, extrusion, blanking,
spark conductor. The widely used dielectric stamping and embossing dies.
fluid is kerosene; others used are deionized  It is also used for removal of drill and tapes
water, Si oils, ethylene glycol etc. The fluid from components.
must be hydrocarbon because deionization  EDM can be used to make parts with
occurs due to the involvement of hydrogen in irregular shape with precision for forging
hydrocarbon. press tool, extrusion dies, cutting tool dies
etc.
 EDM Drilling to drill very small holes and
WORKING EDM milling to machine complex shapes.
ADVANTAGES DISADVANTAGES
o Handles delicate o Excessive tool wear.
tasks.
o Hard & tough o The surface after
metals can be machining is highly
machined with better stressed.
surface finish.
• High voltage is applied between terminals
o Complex & internal o The work piece must
and it induce electrical field in spark gap.
shapes can be be electric
• Free Electrons on tool are subjected to
machined. conductor.
electrostatic force and hence they are emitted
from tool and accelerate towards work. o No effect of material o Specific power
There would be collision between electrons hardness and tool consumption is too
and molecules in dielectric. It causes further wear. high.
generation of electrons because of Ionization o Tolerance upto 0.4 μ o Machining time is
of dielectric molecules. is achieved. too long.
• This cyclic process increase concentration of o Very small kerf for o Thin, Brittle & Heat
electrons in spark gap & when potential wire EDM. affected zone
difference is sufficiently high dielectric
break down and large no. of electrons will
REFERENCES
flow from tool to job & ions from job to tool.
• This movement of electrons visually seen as  Theoretical models of the electrical discharge
Spark and electrical energy is dissipated as machining process. III. The variable mass, cylindrical
plasma model.
thermal energy of spark.  Singh, A. & Ghosh, A. A Thermo-Electric Model of
• With a very short duration of spark, Material Removal During Electric Discharge
Temperature of electrodes raised locally to Machining. International Journal of Machine Tools
more than their normal boiling point and Manufacture 39, 669-682 (1999).
 Fuzhu Han, Li Chen, Dingwen Yu and Xiaoguang
this heat of spark melt a tiny bit of metal
Zhou. Basic study on pulse generator for micro-edm.
from work. The International Journal of Advanced
• The Melted Metal Cools & Solidifies as tiny Manufacturing Technology 33, 474-479 (2007).
particles in dielectric. The metal is carried  Carlo Ferri, Atanas Ivanov and Antoine Petrelli.
away due to circulation of dielectric by Electrical measurements in μ-edm. Journal of
Micromechanics and Microengineering 18, 085007+
means of pump and the process continues.
(2008).