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electro Discharge Machine

Instructive Objective
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Non _Traditional Machine

Broad classification of NTM

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non-convient

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Broad classification of NTM

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Non _Traditional Machine

non-convient

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Electro Discharge Machine (EDM)

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electro Discharge Machine

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Mechanism MRR process

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Both the tool and the work material are to be conductors of electricity. A gap is maintained between the tool and the workpiece. As the electric field is established between the tool and the job, the free electrons on the tool are subjected to electrostatic forces  Such emission of electrons are called or termed as cold emission. The cold emitted electrons are then accelerated electro Discharge Machine 12/01/2012 towards the job through the dielectric medium.

Mechanism MRR process

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As they gain velocity and energy, and start moving towards the job, there would be collisions between the electrons and dielectric molecules. Such collision may result in ionization the dielectric molecule depending upon the work function or ionization energy of the dielectric molecule and the energy of the electron.

electro Discharge Machine

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Mechanism MRR process.

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increase the concentration of electrons and ions in the dielectric medium between the tool and the job at the spark gap. so that the matter existing channel plasma.
a large number of electrons will flow from the tool to the job and ions from the job to the tool. This is called avalanche motion

electro Discharge Machine

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Standard Wave form

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electro Discharge Machine

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process of parameter
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The open circuit voltage - Vo The working voltage - Vw The maximum current - Io The pulse on time the duration for which the voltage pulse is applied - ton The pulse off time - toff The gap between the workpiece and the tool spark gap The polarity straight polarity tool (-ve) The dielectric medium External flushing through the spark gap.
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Characteristics of EDM
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a) The process can be used to machine any

work material if it is electrically conductive (b) Material removal depends on mainly thermal properties of the work material rather than its strength, hardness etc (c) In EDM there is a physical tool and geometry of the tool is the positive impression of the hole or geometric feature machined
electro Discharge Machine 12/01/2012

Characteristics of EDM
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(d) The tool has to be electrically conductive as well. -The tool wear once again depends on the thermal properties of the tool material (e)Though the local temperature rise is rather high, still due to very small pulse on time, there is not enough time for the heat to diffuse and thus almost no increase in bulk temperature takes place.  Thus the heat affected zone is limited to 2 4 m of the spark crater.
electro Discharge Machine 12/01/2012

Characteristics of EDM
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(F) However rapid heating and cooling and local high temperature leads to surface hardening which may be desirable in some applications (g)Though there is a possibility of taper cut and overcut in EDM, they can be controlled and compensated.

electro Discharge Machine

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Dielectric
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material removal mainly occurs due to thermal evaporation and melting. As thermal processing is required to be carried out in absence of oxygen so that the process can be controlled and oxidation avoided. Oxidation often leads to poor surface conductivity (electrical) of the work piece hindering further machining.

electro Discharge Machine

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Dielectric
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dielectric fluid should provide an oxygen free machining environment. Further it should have enough strong dielectric resistance so that it does not breakdown electrically too easily but at the same time ionize when electrons collide with its molecule. sparking it should be thermally resistant as well. Generally kerosene and ionised water is used as dielectric fluid in EDM. Tap water cannot be used as it ionizes too easy and thus breakdown due to presence of salts as impurities occur. Dielectric medium is generally flushed around the spark zone.
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Tool Characteristics
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High electrical conductivity electrons are cold emitted more easily and there is less bulk electrical heating High thermal conductivity for the same heat load, the local temperature rise would be less due to faster heat conducted to the bulk of the tool and thus less tool wear Higher density for the same heat load and same tool wear by weight there would be less volume removal or tool wear and thus less dimensional loss or inaccuracy High melting point high melting point leads to less tool wear due to less tool material melting for the same heat load Easy manufacturability
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Tool materials
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Graphite Electrolytic oxygen free copper Tellurium copper 99% Cu + 0.5% tellurium Brass

electro Discharge Machine

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Modeling of Material Removal and Product Quality

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electro Discharge Machine

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Quality Issue
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electro Discharge Machine

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Quality Issue
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electro Discharge Machine

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EDM equipment
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electro Discharge Machine

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Power generator of EDM

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electro Discharge Machine

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Power generator of EDM

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electro Discharge Machine

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Power generator of EDM

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electro Discharge Machine

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Power generator of EDM

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electro Discharge Machine

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Power generator of EDM

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Where

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Time cycle and frequency

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ES

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problems
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electro Discharge Machine

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problems
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problems
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electro Discharge Machine

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