EDM

( Electric Discharge Machining )

Prakash Mohan Singh Mech. Engg. 3rd year 2810440002

EDM - Electrical Discharge Machining is a process of metal removal

by means of energy release by repetitive spark discharges. these electrical discharges occur between an electrode (Cutting Tool) and an electro-conductive workpiece and minute particles are eroded from both electrode and workpiece.

INTRODUCTION
Electrical discharge machining die sinking has proved valuable in the machining of super tough, electrically conductive materials, such as the new space-age alloys. These metals would have been difficult to machine by conventional methods. EDM has made it relatively simple to machine intricate shapes that would be impossible to produce with conventional cutting tools. This process is continually finding more applications in the metal-cutting industry. It is used extensively in the plastics industry to produce cavities of almost any shape in the steel molds.

HISTORY OF EDM
The circuit for making metallic powder in the reference published in Germany in 1919 is indicated.
Discharge gap

Metal sticks

The metal of both ends becomes powder and precipitate

Transistorized circuit EDM

Servo mechanism

Control circuit

EDM circuit by Lazarenko (RC circuit)

Gap controller

Electrode

Workpiece

PRINCIPLE OF EDM

Electrical discharge machining is a controlled metal removal technique whereby an electric spark is used to cut (erode) the workpiece, which takes a shape opposite to that of the cutting tool or electrode.The cutting tool (electrode) is made from electrically conductive material, usually carbon. The die sinking electrode, made to the shape of the cavity required, and the workpiece are both submerged in a dielectric fluid, (a light lubricating oil). This dielectric fluid should be a nonconductor (or poor conductor) of electricity.

VARIOUS TYPES OF ELECTRIC DISCHARGE MACHINESa. Wire EDM

Electrode

Workpiece In wire EDM, the spark jumps from the wire electrode to the workpiece and erodes metal both from the wire electrode and the workpiece.

b. Ram EDM

Electrode

Workpiece

generally used to produce blind cavities

c. Small Hole EDM Drilling

Also known as fast hole EDM drilling or hole popper Uses a hollow electrode to drill holes by means of electrical discharge machining by eroding material from the workpiece

Materials that can be EDMed

Inconel Aluminum Vasconal 300

Tool Steels: 01, A2, D2, S7

Carbide Ferro-Tic CPM 10V 4130

Aluminum Bronze
Copper Brass Cold Roll Steel Hot Rolled Steel

PCD Diamond
Nitronic Beryllium Copper Hastalloy Stellite

Graphite

Stainless Steels

Titanium

SAFETY
a. Check that the workpiece has been set in a proper way.

b. Check that the electrode has been set securely.

c. Check that there is no abnormality in the discharge cable.

d. flashing

EDMing with flushing alone must be avoided

e. If a metallic injection nozzle is used, make sure that it will not come into contact with the electrode.

f. Make sure that the table travel will not cause any interference with the nozzle.

g. Check that the fluid level has been set properly. Set the dielectric fluid level at not less than 50mm above the top of the workpiece.

APPLICATION

EDM product

widely used by the mould-making tool and die industries Especially in the aerospace, automobile and electronics industries Dies for producing jewelry and badges by the coinage (stamping) process

ADVANTAGES
Complex shapes that would otherwise be difficult to produce with conventional cutting tools Extremely hard material to very close tolerances There is no direct contact between tool and work piece. Therefore delicate sections and weak materials can be machined without any distortion

DISADVANTAGES
The slow rate of material removal. The additional time and cost used for creating electrodes for ram/sinker EDM Reproducing sharp corners on the workpiece is difficult due to electrode wear Specific power consumption is very high

REFERENCES

Manufacturing technology by P.C.Sharma. Exploring advanced manufacturing technologies by By Stephen F. Krar, Arthur Gill. Manufacturing Technology by B.L.Raghuvansi.

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