171

12 Dielectric Oil and

Flushing for Ram EDM
Dielectric Oil
Ram EDM uses oil for its dielectric fluid. Dielectric oil performs three important
functions for ram EDM. See Figure 12:1.
1. The oil forms a dielectric barrier for the spark between the workpiece and the
electrode.
2. The fluid cools the eroded particles between the workpiece and the electrode.
3. The pressurized oil flushes out the eroded gap particles and removes the
particles from the oil by causing the oil to pass through a filter system.

Incoming Dielectric Oil

Dielectric Oil Cools Electrode

Electrode and Workpiece

The oil forms a dielectric

Arc
Gap barrier between the work-
piece and the electrode.

Eroded Particles Removed

from Arc Gap.

Figure 12:1
Dielectric Oil Functions

Various manufacturers produce many types of dielectric oil. The best way to
determine the type of oil needed for a particular machine is to ask the machine
manufacturer for its recommendations. It is important to get oil which is specifically
produced for ram EDM.
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172 Compliments of www.ReliableEDM.com

Coolant System
EDM creates sparks in the gap with sufficient energy to melt the material. The
resulting heat is transferred into the oil. Oil loses its efficiency when it reaches 100°
F (38° C). Controlling this heat is essential to ensure accuracy and efficient cutting.
Therefore, it is best to have a coolant system to maintain a proper temperature.

Flash Point
Oil will ignite at certain temperatures. The ignition temperature is called “flash
point." This is especially important when doing heavy cutting, because the oil may
get so hot that it reaches its flash point. Even though some oils have a flash point of
200° F (93° C) and higher, it is unsafe to use oil over 165° F (74° C). Precautions
need to be taken to prevent the oil from reaching its flash point. Some machines are
equipped with a fire suppression system that is controlled by an infrared scanner.

Flushing
A. Proper Flushing
The most important factor in EDM is to have proper flushing. There is an old
saying among EDMers: “There are three rules for successful EDMing: flushing,
flushing, and flushing."
Flushing is important because eroded particles must be removed from the gap
for efficient cutting. Flushing also brings fresh dielectric oil into the gap and cools
the electrode and the workpiece. The deeper the cavity, the greater the difficulty
for proper flushing.
Improper flushing causes erratic cutting. This, in turn, increases machining time.
Under certain machining conditions, the eroded particles attach themselves to the
workpiece. This prevents the electrode from cutting efficiently. It is then necessary
to remove the attached particles by cleaning the workpiece.
The danger of arcing in the gap also exists when the eroded particles have not
been sufficiently removed. Arcing occurs when a portion of the cavity contains
too many eroded particles and the electric current passes through the accumulated
particles. This arcing causes an unwanted cavity or cavities which can destroy the
workpiece. Arcing is most likely to occur during the finishing operation because
of the small gap that is required for finishing. New power supplies have been
developed to reduce this danger.
B. Volume, Not Pressure
Proper flushing depends on the volume of oil being flushed into the gap, rather
than the flushing pressure. High flushing pressure can also cause excessive electrode
wear by making the eroded particles bounce around in the cavity. Generally, the
 Dielectric Oil and Flushing for Ram EDM 173

ideal flushing pressure is between 3 to 5 psi. (.2 to .33 bars).

Efficient flushing requires a balance between volume and pressure. Roughing
operations, in which there is a much larger arc gap, require high volume and low
pressure for the proper oil flow. Finishing operations, in which there is a small arc
gap, requires higher pressure to ensure proper oil flow.
Often, flushing is not a problem in a roughing cut because there is a sufficient
gap for the coolant to flow. Flushing problems usually occur during finishing
operations. The smaller gap makes it more difficult to achieve the proper oil flow
to remove the eroded particles.
C. Types of Flushing
There are four types of flushing: pressure, suction, external, and pulse flushing.
Each job needs to be evaluated to choose the best flushing method.

1. Pressure Flushing
Pressure flushing, also called injection flushing, is the most common and
preferred method for flushing. One great advantage of pressure flushing is that the
operator can see the amount of oil that is being used for flushing. With pressure
gauges, this method of flushing is simple to learn and use.

a. Pressure Flushing through Electrode

Pressure flushing may be performed in two ways: through the electrode (Figure
12:2) or through the workpiece.

Pressure Flushing

Electrode

Workpiece

Figure 12:2
Pressure Flushing through Electrode
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With pressure flushing, there is the danger of a secondary discharge. Since

electricity takes the path of least resistance, secondary discharge machining can
occur as the eroded particles pass between the walls of the electrode and the
workpiece, as presented in Figure 12:3. This secondary discharge can cause side
wall tapering. Suction flushing can prevent side wall tapering.

Pressure Flushing
Electrode
Secondary Machining

Workpiece

Figure 12:3
Pressure Flushing May Cause Secondary Machining

b. Pressure Flushing through Workpiece

Pressure flushing can also be done by forcing the dielectric fluid through a
workpiece mounted over a flushing pot. See Figure 12:4. This method eliminates
the need for holes in the electrode.

Electrode

Workpiece

Flushing Pot

Pressure Flushing

Figure 12:4
Pressure Flushing through Workpiece
 Dielectric Oil and Flushing for Ram EDM 175

2. Suction Flushing
Suction or vacuum flushing can be used to remove eroded gap particles. Suction
flushing can be done through the electrode, as in Figure 12:5, or through the
workpiece, as in Figure 12:6.

Suction Flushing

Electrode

Workpiece with Stud

Figure 12:5
Suction Flushing through Electrode

Electrode

Flushing Pot

Figure 12:6
Suction Flushing through Workpiece
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Suction flushing minimizes secondary discharge and wall tapering. Suction

flushing sucks oil from the worktank, not from the clean filtered oil as in pressure
flushing. For suction cutting, efficient cutting is best accomplished when the work
tank oil is clean.
A disadvantage of suction flushing is that there is no visible oil stream as with
pressure flushing. Also, gauge readings are not always reliable regarding the actual
flushing pressure in the gap.
A danger of suction flushing is that gases may not be sufficiently removed, this
can cause the electrode to explode. In addition, the created vacuum can be so great
that the electrode can be pulled from its mount, or the workpiece pulled from the
magnetic chuck.

3. Combined Pressure and Suction Flushing

Pressure and suction flushing can be combined. They are often used for molds
with complex shapes. This combination method allows gases and eroded particles
in convex shapes to leave the area and permit circulation for proper machining.

4. Jet Flushing
Jet or side flushing is done by tubes or flushing nozzles which direct the
dielectric fluid into the gap, as shown in Figure 12:7. Pulse flushing is usually used
along with jet flushing.

Electrode

Jet Flushing

Workpiece

Figure 12:7
Jet Flushing Using Multiple Flushing Nozzles
 Dielectric Oil and Flushing for Ram EDM 177

5. Pulse Flushing
Three types of pulse flushing are:
a. Vertical flushing: the electrode moves up and down.
b. Rotary flushing: the electrode rotates.
c. Orbiting flushing: the electrode orbits.
a. Vertical Flushing
In vertical flushing, the electrode moves up and down in the cavity. This up and
down motion causes a pumping action which draws in fresh dielectric oil. Many
machines are now equipped with jump control which causes the electrode to jump
rapidly in and out of the cavity which aids in flushing out the eroded particles. See
Figure 12:8.

Electrode moving vertically.

Dielectric oil and eroded

particles being flushed out.

Workpiece

Figure 12:8
Vertical Flushing: Electrode Moves Up and Down
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Since many of the new machines have rapid pulse, or high speed jump machining,
thin ribs can be easily EDMed, as shown in Figure 12:9.

Figure 12:9 Courtesy Makino

Pulse Machining with Thin Electrodes

b. Rotary Flushing
In rotary flushing, the electrode rotates within the cavity, as in Figure 12:10.
Rotating the electrode aids in flushing out the EDM particles from the cavity.

Rotating Electrode

Workpiece

Figure 12:10
Rotary Flushing: Electrode Rotates
 Dielectric Oil and Flushing for Ram EDM 179

For small round electrodes, manufacturers make multiple cavities in these

electrodes to aid in flushing. This is a very efficient method of producing holes
without a stud. See Figure 12:11.

Multiple Cavity Electrode

Bottom View

Figure 12:11
Electrode with Multiple Cavities for Rotary EDMing

c. Orbiting Flushing
Orbiting an electrode in a cavity allows the electrode to mechanically force the
eroded particle from the cavity, as pictured in Figure 12:12.

Orbiting Electrode

Dielectric oil and eroded particles being

flushed out due to orbiting effect.

Workpiece

Figure 12:12
Orbiting Flushing: The Electrode Orbits in Workpiece
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Orbiting flushing is the most efficient method for cutting. Furthermore, if the
orbiting is larger than the radius of the flushing holes in the electrode, it will
produce no studs.

Filtration System
In order to insure proper cutting, a filtration system needs to be maintained that
adequately removes the eroded particles from the dielectric oil. Improperly filtered
oil will send oil with eroded particles into the gap which will hinder effective
cutting.

The Challenge of New Procedures

Reducing costs should always be on the minds of manufacturers. One of the best
ways to reduce costs is to understand the process and search for new procedures.
The next chapter will examine ways to reduce costs.