Electrical Discharge Machining (EDM)

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 Contents
Introduction
History
Mechanism of EDM process
Elements of EDM machining
Process variables and process characteristics
Parametric analysis
Model for material removal
Advantages and limitations
Applications

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 Introduction
Sparking between to electrical contacts

Leads to material removal from material

Constructive use of these electric sparks

Use of dielectric: to concentrate heat energy

on small area

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Introduction
 Sometimes it is referred to as spark machining, spark eroding
 It has mainly two types die sinker and wire-EDM
 Its a manufacturing process whereby a desired shape is obtained using
electrical discharges (sparks).
 Material is removed from the workpiece by a series of rapidly recurring
current discharges between two electrodes, separated by a dielectric liquid and
subject to an electric voltage.
 One of the electrodes – ‘tool-electrode’ or ‘tool’ or ‘electrode’.
 Other electrode - workpiece-electrode or ‘workpiece’.
 As distance between the two electrodes is reduced, the current intensity
becomes greater than the strength of the dielectric (at least in some points)
causing it to break.
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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.
 New researchers entered the field and contributed many fundamental characteristics of
the machining method we know today.
 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.
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General Aspects of EDM
 EDM is a machining method primarily used for hard metals or those that
would be very difficult to machine with traditional techniques.
 EDM typically works with materials that are electrically conductive, although
methods for machining insulating ceramics with EDM have been proposed.
 EDM can cut intricate contours or cavities in hardened steel without the need
for heat treatment to soften and re-harden them.
 This method can be used with any other metal or metal alloy such as titanium,
and inconel.
 Also, applications of this process to shape polycrystalline diamond tools have
been reported.

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 Process Of EDM
Process --- step 1
 An increasing voltage is applied to the electrodes, resulting in
an increasing stress on the fluid between them until it is
ionized, and the gap becomes conductive, allowing current to
flow from one electrode to the other in the form of a spark
discharge .

Basic process 1
 Process Of EDM
Process --- step 2
 The spark channel in the first few microseconds has a very
small cross-sectional area resulting in a correspondingly high
current density calculated to be on the order of l04~l06 A /cm2.

Basic process 2
 Process Of EDM
Process --- step 3
 Because of these extreme densities, the temperature in the
channel is very high, (5,000-l0,000℃), resulting in the
melting and vaporization of a small amount of material from
the surfaces of both the electrode and the workpiece at the
points of spark contact, a rapidly expanding bubble is created
in the dielectric fluid around the spark channel.

Basic process 3
 Process Of EDM
Process --- step 4
 When the electrical pulse is terminated, both the spark channel
and the vapor bubble collapse.
 The violent inrush of cool dielectric fluid results in an explosive
expulsion of molten metal from both the electrode and
workpiece surfaces, resulting in the formation of a small crater
in the surfaces of the two conductors, solidifying hollow balls of
material, which are removed from the gap by the fluid.

Basic process 4
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Principle Of EDM
EDM – Working Principle

Electro Discharge Machining (EDM) is an electro-thermal

non-traditional machining process, where electrical energy is
used to generate electrical spark and material removal mainly
occurs due to thermal energy of the spark.
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EDM – Schematic

 Potential difference is applied

 Generally tool negative and work positive (straight polarity)
 Electric field is established
 Tool and workpiece conductor of electricity
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 EDM – Process Mechanism
Free electrons are available

If the work function is low, electrons get emitted from tool

Cold emission of electrons' and acceleration of same

Collision of electrons with dielectric molecules

Ionization of dielectric molecules- more electrons and ions

Secondary and tertiary collisions- plasma channel

“ Avalanche motion ” of electrons- spark

Impingement of workpiece by high speed electrons

High temperature on workpiece (localized melting and vaporization)

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Material removal ( craters)
EDM – Working Principle

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 PROCESS PARAMETERS IN EDM
The open circuit voltage ( Vo )

The working / Gap voltage (Vg)

The maximum current ( Ip )

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 – (δ)
The polarity [straight polarity ] tool (-ve)
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 Principle of EDM process

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 EDM : V-I waveform

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 Cathode and anode material removal

Wire
EDM Die
Sinker
EDM

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 Cathode and anode material removal
For short durations Material removal at anode will be
largest
For large durations Material removal at cathode is higher

For short duration  Electron mobility is higher 

Current is passed mainly due to electrons
For large duration  current is mainly transfer due to
positive ions
 For wire-EDM  wire –ve (cathode) and W/P (positive)

 For diesinker-EDM  W/P –ve (cathode) and tool (positive)

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EDM - Components

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EDM - Components
 The main components in EDM:
 Work piece & tool
 Dielectric medium
 Electric power supply
 Servo control unit.
 The work piece and tool are electrically connected to a DC power supply.
 The current density in the discharge of the channel is of the order of 10000
A/cm2 and power density is nearly 500 MW/cm2.
 A gap, known as SPARK GAP in the range, from 0.005 mm to 0.05 mm is
maintained between the work piece and the tool.
 Dielectric slurry is forced through this gap at a pressure of 2 kgf/cm 2 or lesser.

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Elements Of EDM

Workpiece

 Electrical conductor
 To require to erode cavity or hole
 Connected to power supply
Elements Of EDM

Tool
 An electrically conductive electrode
 Shaped to match the dimensions of the desired cavity or hole
 Connected to the pole of the supply

Typical electrode materials

- Copper
- Tungsten
- Graphite
EDM – Electrode Material
 Electrode material should be such that it would not
undergo much tool wear when it is impinged by positive
ions.
 Thus the localised temperature rise has to be less by
properly choosing its properties or even when temperature
increases, there would be less melting.
 Further, the tool should be easily workable as intricate
shaped geometric features are machined in EDM.

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EDM – Electrode Material
 Thus the basic characteristics of electrode materials are:
 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 less tool wear and thus less dimensional
loss or inaccuracy of tool
 High melting point – high melting point leads to less tool wear
due to less tool material melting for the same heat load
 Easy manufacturability
 Cost – cheap
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EDM – Electrode Material
 Graphite (most common) - has fair wear characteristics, easily
machinable.
 Small flush holes can be drilled into graphite electrodes.
 Copper has good EDM wear and better conductivity.
 It is generally used for better finishes in the range of Ra = 0.5 μm.
 Copper tungsten and silver tungsten are used for making deep slots
under poor flushing conditions especially in tungsten carbides.
 It offers high machining rates as well as low electrode wear.
 Copper graphite is good for cross-sectional electrodes.
 It has better electrical conductivity than graphite while the corner wear
is higher.
 Brass ensures stable sparking conditions and is normally used for
specialized applications such as drilling of small holes where the high
electrode wear is acceptable. 39
EDM – Electrode Wear

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EDM – Electrode Wear
 The melting point is the most important factor in determining the tool wear.
 Electrode wear ratios are expressed as end wear, side wear, corner wear, and
volume wear.
 “No wear EDM” - when the electrode-to-workpiece wear ratio is 1 % or
less.
 Electrode wear depends on a number of factors associated with the EDM,
like voltage, current, electrode material, and polarity.
 The change in shape of the tool electrode due to the electrode wear causes
defects in the workpiece shape.
 Electrode wear has even more pronounced effects when it comes to
micromachining applications.
 The corner wear ratio depends on the type of electrode.
 The low melting point of aluminum is associated with the highest wear
ratio.
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EDM – Electrode Wear

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EDM – Dielectric
 Three important functions of a dielectric medium in EDM:
1. Insulates the gap between the tool and work, thus
preventing a spark to form until the gap voltage are
correct.
2. Cools the electrode, workpiece and solidifies the molten
metal particles.
3. Flushes the metal particles out of the working gap to
maintain ideal cutting conditions, increase metal removal
rate.
 It must be filtered and circulated at constant pressure.

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EDM – Dielectric
 In EDM, material removal mainly occurs due to thermal
evaporation and melting.
 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, it should ionize when electrons collide with
its molecule.
 Moreover, during sparking it should be thermally resistant as
well.
 Generally EDM oil, kerosene and deionised water is used as
dielectric fluid in EDM. 44
Dielectric fluid
 Important properties of dielectric fluid are
 Dielectric strength
 Viscosity
 Thermal conductivity
 Thermal capacity
 Dielectric strength characterizes the fluid’s ability to
maintain high resistivity before spark discharge and
ability to recover rapidly after the discharge
 High dielectric strength leads to lower discharge
gap which in turn leads to low gap resistance.
Hence, high discharge currents may flow leading to
high MRR
Dielectric fluids
 Water is having high specific heat capacity which leads to a
better cooling effect required for wire cut operation. To
prevent chemical reactions de-ionised water is used.
Dielectric Dielectric Dynamic Thermal Sp. Heat
strength viscosity conductivity capacity
(MV/m) (g/m-s) (W/m oK) (J/Kg oK)
Kerosine 14-22 1.64 0.149 2.16

De-ionised 13 0.92 0.606 4.19

water
Air 3 0.019 0.026 1.04
EDM – Flushing
 One of the important factors in a successful EDM operation is the
removal of debris (chips) from the working gap.
 Flushing these particles out of the working gap is very important, to
prevent them from forming bridges that cause short circuits.
 EDMs have a built-in power adaptive control system that increases the
pulse spacing as soon as this happens and reduces or shuts off the
power supply.
 Flushing – process of introducing clean filtered dielectric fluid into
spark gap.
 Flushing of dielectric plays a major role in the maintenance of stable
machining and the achievement of close tolerance and high surface
quality.
 Inadequate flushing can result in arcing, decreased electrode life, and
increased production time. 47
EDM – Flushing
 Four methods:
1. Normal flow 2. Reverse flow
3. Jet flushing 4. Immersion flushing

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EDM – Flushing
 Normal flow (Majority)
 Dielectric is introduced, under pressure, through one or more passages in
the tool and is forced to flow through the gap between tool and work.
 Flushing holes are generally placed in areas where the cuts are deepest.
 Normal flow is sometimes undesirable because it produces a tapered
opening in the workpiece.
 Reverse flow
 Particularly useful in machining deep cavity dies, where the taper
produced using the normal flow mode can be reduced.
 The gap is submerged in filtered dielectric, and instead of pressure being
applied at the source a vacuum is used.
 With clean fluid flowing between the workpiece and the tool, there is no
side sparking and, therefore, no taper is produced.

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EDM – Flushing
 Jet flushing
 In many instances, the desired machining can be achieved by using a
spray or jet of fluid directed against the machining gap.
 Machining time is always longer with jet flushing than with the normal
and reverse flow modes.
 Immersion flushing
 For many shallow cuts or perforations of thin sections, simple immersion
of the discharge gap is sufficient.
 Cooling and debris removal can be enhanced during immersion cutting
by providing relative motion between the tool and workpiece.
 Vibration or cycle interruption comprises periodic reciprocation of the
tool relative to the workpiece to effect a pumping action of the dielectric.

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Generator used in EDM

The Resistance Capacitance Relaxation(RC relaxation)

circuit used in EDM
In the RC- relaxation circuit, current and gap voltage
are controlled at a pre-defined level through out the
pulse on-time but in modeling attempts in micro- EDM
based on RC pulse circuits, the current and voltage are
frequently assumed to be constant.
E=VI Duty cycle
E=½CV2
Generator used in EDM

Relaxation type pulse generator

Used in finishing and micro-machining because it is

difficult to attain short pulse duration with the constant
pulse energy using transistor type pulse generator
Generator used in EDM

Transistor type pulse generating circuit

Gap voltage and current waveforms

 Transistor type pulse generator
 Transistor is semiconductor device to amplify and switch electronic

signals. A voltage or current applied to one pair of terminals changes

the current flowing through the another pair of terminals. Output

power is more than the controlling input power.

 If one transistor switched on and discharge occurs when voltage is

20V, discharge current is 4 A in this case. Discharge current is

proportional to the no. of transistors which are switched on at the

same time.

 When transistor is switched on open voltage is applied between tool

and workpiece but discharge does not occur due to ignition delay
Transistor type pulse generator
The gate control circuit keeps the transistors on for
discharge duration ‘td’ after the dielectric breakdown,
resulting in uniform discharge. After fixed pulse off-
time transistors are again switched on and open
voltage is applied between the electrodes
Discharge energy per single pulse is given by
Q= VD * I D* td
Comparison between die sinker and wire-EDM generators

Die sinker Wire-EDM

Long pulse on-time Short pulse on-time and pulse

off time

Low current pulse Peak current pulse

High spark frequency

 Effect of servo voltage
a. Higher servo voltage b. Lower servo voltage
td - Ignition delay td - Ignition delay
time time

OV- Open OV- Open

SV- Servo SV- Servo
voltage voltage DV- Discharge
DV- Discharge voltage voltage
voltage voltage

Wire
Wire
Inter electrode Inter electrode gap
gap
Workpiece Workpiece

• Discharge gap is wide • Discharge gap is narrow

• Discharge is stable • Clogging may occur
• Low discharge frequency • High discharge frequency
• Slicing speed is low • High slicing speed

57 Fig. Effect of servo voltage on slicing speed

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Ram EDM
 In a typical ram EDM application, a graphite

electrode is machined with traditional tools. The

new specially-shaped electrode is connected to the
power source, attached to a ram, and slowly fed into
the workpiece. The entire machining operation is
usually performed while submerged in a fluid bath.
EDM – Types – Sinker EDM
 The on time setting determines the length or duration of the spark.
 Hence, a longer on time produces a deeper cavity for that spark and all
subsequent sparks for that cycle.
 This creates rougher finish on the workpiece.
 The reverse is true for a shorter on time.
 Off time is the period of time that one spark is replaced by another.
 A longer off time, for example, allows the flushing of dielectric fluid through a
nozzle to clean out the eroded debris, thereby avoiding a short circuit.
 These settings can be maintained in micro seconds.
 The typical part geometry is a complex 3D shape, often with small or odd
shaped angles.

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EDM – Types – Sinker EDM
 Sinker EDM, also called cavity type EDM or volume EDM.
 Consists of an electrode and workpiece submerged in an insulating liquid such
as oil or other dielectric fluids.
 The electrode and workpiece are connected to a suitable power supply.
 The power supply generates an electrical potential between the two parts.
 As the electrode approaches the workpiece, dielectric breakdown occurs in the
fluid, forming a plasma channel, and a small spark jumps.
 These sparks happen in huge numbers at seemingly random locations.
 As the base metal is eroded, and the spark gap subsequently increased, the
electrode is lowered automatically so that the process can continue.
 Several hundred thousand sparks occur per second, with the actual duty cycle
carefully controlled by the setup parameters.
 These controlling cycles are sometimes known as "on time" and "off time“.

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 Wire EDM
In wire EDM a very thin wire serves as the electrode.
Special brass wires are typically used; the wire is
slowly fed through the material and the electrical
discharges actually cut the workpiece. Wire EDM is
usually performed in a bath of water.
The wire itself does not actually touch the metal to be
cut; the electrical discharges actually remove small
amounts of material and allow the wire to be moved
through the workpiece.
EDM – Types – Wire EDM (WEDM)
 Also known as wire-cut EDM and wire cutting.
 A thin single-strand metal wire (usually brass) is fed through the workpiece
submerged in a tank of dielectric fluid (typically deionized water).
 Used to cut plates as thick as 300 mm and to make punches, tools, and dies
from hard metals that are difficult to machine with other methods.
 Uses water as its dielectric fluid; its resistivity and other electrical properties
are controlled with filters and de-ionizer units.
 The water flushes the cut debris away from the cutting zone.
 Flushing is an important factor in determining the maximum feed rate for a
given material thickness.
 Commonly used when low residual stresses are desired, because it does not
require high cutting forces for material removal.

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Basic elements of Wire EDM.
 Similar to EDM, any Wire EDM consists of

1. Machine.

2. Pulse generator. (Controller) &

3. Dielectric unit. (P.F. Unit)

Machine Tool
Pulse Generator
Dielectric Unit
 Additional elements of Wire EDM.
Following additional elements can also be adopted on

Wire EDM to enhance the performance.

1. Dielectric cooling unit. (Chiller). Now a days this has
become standard element of wire EDM
2. AWT (Automatic Wire Threading)
Dielectric Cooling Unit
(Chiller)
Automatic Wire Threading
EDM – Material Removal Rate

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EDM – Material Removal Rate
 In EDM, the metal is removed from both workpiece and tool electrode.
 MRR depends not only on the workpiece material but on the material of the
tool electrode and the machining variables such as pulse conditions, electrode
polarity, and the machining medium.
 In this regard a material of low melting point has a high metal removal rate
and hence a rougher surface.
 Typical removal rates range from 0.1 to 400 mm3 /min.
 MRR or volumetric removal rate (VRR), in mm3/min, was described by
Kalpakjian (1997):

where I - EDM current (A)

Tw - Melting point of the workpiece (°C).

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 Analysis of metal removal in EDM
Metal removed is analyzed in the form of crater for single pulse.
Considering the volume of crater as a part of sphere and
crater parameters given as

Tool (-ve)
hc = K1 * Wpn
Dc = K 2 *Wpn
DC VOLTAGE h c  height of crater (μm)
Dc Dc - diameter of crater ( m)
hc Where, K1and K 2constants depending electrode material and dielectric
n - constant depnding on work tool combination
Work-piece
(+ve)
So, the volume of the crater, Vc from simple geometry
 3
Figure Schematic of crater formation [3] Vc = h c ( D c 2 +h c2 )--------mm 3
6 4
 3
Vc = h c Wp3n ( K 22 +K12 ) ----mm 3
6 4
Where, values of K1 , K 2 and n are obtained from experiments
MRR = Vc * (NOP) *
No. of pulses (NOP) = t machining /(t s + t i )

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 Modeling of EDM process
Electro thermal modeling
Molten cavity

Superheated cavity
Anode
Anode
erosion (+ ve)

Compressed liquid

Plasma Channel
Energy input Plasma
formation Shockwave front

Molten cavity
Cathode
erosion Cathode
(- ve)
Superheated cavity

Figure Schematic diagram of EDM process [2]

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 Energy distributed in EDM process

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 Energy distributed in EDM
process

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 Energy distributed in EDM
process

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 EDM – Surface roughness
 Average roughness can be expressed in terms of pulse
current ip (A) and pulse duration tp (μs) by

 Surface roughness increases linearly with an increase in

MRR.

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 Effect of pulse on-time

Effect of pulse on-time (energy) on MRR & surface roughness.

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 Effect of current on crater size

Fig. Relations between crater diameter Fig. Relations between crater depth H,
DI and discharge current Ip and discharge current Ip

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 Effect of discharge duration on crater size

Fig. Relations between crater diameter Fig. Relations between crater depth
and discharge duration and discharge duration

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 EDM – Surface Integrity
 Surface consists of a multitude of overlapping craters that are
formed by the action of microsecond-duration spark discharges.
 Crater size depends on
 physical and mechanical properties of the material
 composition of the machining medium
 discharge energy and duration.
 Integral effect of thousands of discharges per second leads to
machining with a specified accuracy and surface finish.
 Depth of craters - the peak to valley (maximum) of surface
roughness Rt.
 Maximum depth of damaged layer can be taken as 2.5 times of
roughness Ra. 90
EDM – Surface Integrity
 There are several effective processes that accomplish restoration or even
enhancement of the fatigue properties.
 These methods include
 Removal of the altered layers by low-stress grinding or chemical
machining
 Addition of a metallurgical-type coating
 Re heat-treatment
 Application of shot peening.

91
 Advantages
Some of the advantages of EDM include machining of:
 Complex shapes that would otherwise be difficult to produce with
conventional cutting tools.
 Extremely hard material to very close tolerances.
 Very small work pieces where conventional cutting tools may
damage the part from excess cutting tool pressure.
 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.

92
 Disadvantages
Some of the disadvantages of EDM include:
 The slow rate of material removal.
 For economic production, the surface finish specified should not be too fine.
 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.
 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 process

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 Applications

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 Applications

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 Applications

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 Applications

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 Applications

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 Applications

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 Applications

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 Applications

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 Applications

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EDM Processes
Figure 19-23 (left) Examples of wire EDM
workpieces made on NC machine (Hatachi).

Figure 19-24 (above) SEM micrograph of EDM

surface (right) on top of a ground surface in steel. The
spherical nature of debris on the surface is in evidence
around the craters (300 x).
 Applications

104
EDM – Capabilities
 Can be used to machine any work material if it is electrically conductive.
 MRR depends on thermal properties (job) rather than its strength, hardness etc.
 The volume of the material removed per spark discharge is typically in the
range of (1/1,000,000) to (1/10,000) mm3.
 In EDM, geometry of tool - positive impression of hole or geometric feature.
 Tool wear once again depends on the thermal properties of tool material.
 Local temperature rise is rather high, but there is not enough heat diffusion
(very small pulse on time) and thus HAZ is limited to 2 – 4 μm.
 Rapid heating and cooling leads to surface hardening which may be desirable
in some applications.
 Tolerance value of + 0.05 mm could be easily achieved by EDM.
 Best surface finish that can be economically achieved on steel is 0.40 m.

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Applications
 Drilling of micro-holes, thread cutting, helical profile milling, rotary forming,
and curved hole drilling.
 Delicate work piece like copper parts can be produced by EDM.
 Can be applied to all electrically conducting metals and alloys irrespective of
their melting points, hardness, toughness, or brittleness.
 Other applications: deep, small-dia holes using tungsten wire as tool, narrow
slots, cooling holes in super alloy turbine blades, and various intricate shapes.
 EDM can be economically employed for extremely hardened work piece.
 Since there is no mechanical stress present (no physical contact), fragile and
slender work places can be machined without distortion.
 Hard and corrosion resistant surfaces, essentially needed for die making, can
be developed.

107
Applications – EDM Drilling
 Uses a tubular tool electrode where the dielectric is flushed.
 When solid rods are used; dielectric is fed to the machining zone by either
suction or injection through pre-drilled holes.
 Irregular, tapered, curved, as well as inclined holes can be produced by EDM.
 Creating cooling channels in turbine blades made of hard alloys is a typical
application of EDM drilling.
 Use of NC system enabled large numbers of holes to be accurately located.

108
Applications – EDM Sawing
 An EDM variation - Employs either a special steel band or disc.
 Cuts at a rate that is twice that of the conventional abrasive sawing method.
 Cutting of billets and bars - has a smaller kerf & free from burrs.
 Fine finish of 6.3 to 10 μm with a recast layer of 0.025 to 0.130 mm

109
Applications - Machining of spheres
 Shichun and coworkers (1995) used simple tubular electrodes in EDM
machining of spheres, to a dimensional accuracy of ±1 μm and Ra < 0.1 μm.
 Rotary EDM is used for machining of spherical shapes in conducting ceramics
using the tool and workpiece arrangement as shown below.

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Applications - Machining of dies & molds
 EDM milling uses standard cylindrical electrodes.
 Simple-shaped electrode (Fig. 1) is rotated at high speeds and follows
specified paths in the workpiece like the conventional end mills.
 Very useful and makes EDM very versatile like mechanical milling process.
 Solves the problem of manufacturing accurate and complex-shaped electrodes
for die sinking (Fig. 2) of three-dimensional cavities.

(Fig. 1) (Fig. 2)
111
Applications - Machining of dies & molds
 EDM milling enhances dielectric flushing due to high-speed electrode rotation.
 Electrode wear can be optimized due to its rotational and contouring motions.
 Main limitation in EDM milling - Complex shapes with sharp corners cannot
be machined because of the rotating tool electrode.
 EDM milling replaces conventional die making that requires variety of
machines such as milling, wire cutting, and EDM die sinking machines.

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Applications – Wire EDM
 Special form of EDM - uses a continuously moving conductive wire electrode.
 Material removal occurs as a result of spark erosion as the wire electrode is
fed, from a fresh wire spool, through the workpiece.
 Horizontal movement of the worktable (CNC) determines the path of the cut.
 Application - Machining of superhard materials like polycrystalline diamond
(PCD) and cubic boron nitride (CBN) blanks, and other composites.
 Carbon fiber composites are widely used in aerospace, nuclear, automobile,
and chemical industries, but their conventional machining is difficult.
 Kozak et al. (1995) used wire EDM for accurately shaping these materials,
without distortion or burrs.
 Recently used for machining insulating ceramics by Tani et al. (2004).

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Applications – EDM of
Insulators
 A sheet metal mesh is placed over the ceramic material.
 Spark discharges between the negative tool electrode and the metal mesh.
 These sparks are transmitted through the metal mesh to its interface with the
ceramic surface, which is then eroded.

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Applications – Texturing
 Texturing is applied to steel sheets during the final stages of cold rolling.
 Shot blasting (SB) is an inexpensive method of texturing.
 Limitations of SB include its lack of control and consistency of texturing, and
the need for protection of other parts of the equipment holding the roll.
 EDT, is a variation of EDM and proved to be the most popular.
 Texturing is achieved by producing electrical sparks across the gap between
roll (workpiece) and a tool electrode, in the presence of dielectric (paraffin).
 Each spark creates a small crater by the discharge of its energy in a local
melting and vaporization of the roll material.
 By selecting the appropriate process variables such as pulse current, on and off
time, electrode polarity, dielectric type, and the roll rotational speed, a surface
texture with a high degree of accuracy and consistency can be produced.

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EDM – Surface Integrity
 Metallurgical changes occur in the surface – Temperature 8000 to 12,000°C.
 Additionally, a thin recast layer of 1 μm to 25 μm – depending on power used.
 Delpretti (1977) and Levy and Maggi (1990) claimed that the heat-affected
zone (HAZ) adjacent to the resolidified layer reaches 25 μm.
 Some annealing can be expected in a zone just below the machined surface.
 Not all the workpiece melted by discharge is expelled into the dielectric.
 Remaining melted material is quickly chilled, primarily by heat conduction
into the bulk of the workpiece, resulting in an exceedingly hard surface.
 Depth of annealed layer is proportional to power used.
 It ranges from 50 μm for finish cutting to ~ 200 μm for high MRR.
 Annealing is usually about two points of hardness below the parent metal for
finish cutting.

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EDM – Surface Integrity
 In roughing cuts, the annealing effect is ~ five points of hardness below the
parent metal.
 Electrodes that produce more stable machining can reduce the annealing effect.
 A finish cut removes the annealed material left by the previous rough cut.
 The altered surface layer significantly lowers the fatigue strength of alloys.
 It consists of a recast layer with or without microcracks, some of which may
extend into the base metal, plus metallurgical alterations such as rehardened
and tempered layers, heat-affected zones, and inter-granular precipitates.
 During EDM roughing, the layer showing microstructural changes, including a
melted and resolidified layer, is less than 0.127 mm deep.
 During EDM finishing, it is less than 0.075 mm.
 Post-treatment to restore the fatigue strength is recommended to follow EDM
of critical or highly stressed surfaces.

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