Electric Discharge Machining

11 Presented by, Uma .B. S II SEM MTech (1MS11MSC013) Department of Mechanical Engineering

Lect. Mr. Mohan Das .K. N

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Unit 2: Thermal metal removal process

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Principle of operation Uma. B. S EDM basic circuitry Gajaana Anne, Anand Babu Dielectric fluids, process parameter Mrudula Prashanth Benefits, limitations and applications - Manjunath

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Presentation Content
33

Introduction

Popularity of EDM

Basic principle of EDM

Mechanism of metal removal

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Nontraditional Machining and Thermal Cutting 44 Processes : Nontraditional machining

Material removal processelectrical or chemical energy sense mechanical, thermal, Do not use a sharp cutting tool in the conventional

Thermal cutting process : Thermal energy generally applied to a small portion of the work surface, causing removal by erosion and/or vaporization energy Thermal energy is generated by conversion of electrical
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EDM highlights
55 Energy type: Mechanics of metal removal: Energy source: Medium: Spark Gap: Maximum metal removal rate: Spark frequency: Peak voltage: Thermal Erosion and/ or vaporization Electric spark Dielectric fluid 10-125m 5*10 mm/min 200-500,000Hz 30-250 volts 5/25/12

Histo ry
EDM

6 6

In1770s,

discovered by Joseph Priestly.

In 1943 first

EDM Machine (Lazarenko & Lazarenko)

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Popularity of EDM
77

Electrically conductive materials

Physical properties of w/p not a barrier

(Hastalloys, nimonics, waspalloy) HSTR metals

No mechanical deformation

Surface produced contains multitude of small craters

(helps in oil retention)

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Thermal (Thermoelectric) EBM - electron Processes beam machining

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EDM - electrical discharge machining EDG - electrical discharge grinding cutting - electrical discharge wire

EDWC

LBM - laser beam machining PAM - plasma arc machining Ion beam machining
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Classification
EDM
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Sinking by EDM Drilli ng Die sinking

Cutting by EDM

Grinding by EDM Form Externa grindi l EDM grindin Internal ng g EDM grinding Wire cutting
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Slicing using ribbon

Slicing using ribbon

Terms in EDM
10 10

Spark

discharge conductors

The electrical between two

Spark Gap - The space

between the workpiece and the electrode at the point of discharge measurement difference between the dimensions of the cavity EDMed and the dimensions of the electrode used to cut the cavity -

Overcut

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Basic scheme of EDM

11 11

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Component of EDM system

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EDM system: A tool (electrode) Work piece A dc power supply Servomotor Dielectric fluid

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13 13

Detailed view of spark gap

Overall view of workpiece and tool

Exact Difficult Machining

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Principle of operation
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Application of an electrical potential between tool (electrode) and workpiece Creation of an ionized channel Spark Implosion of the plasma channel 5/25/12

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Mechanism of metal removal

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Diagram of electroerosive machining: (1) tool, (2) workpiece, (3) liquid dielectric, (4) 5/25/12 electric discharges

Fig A. Crater formed on the workpiece Fig B. The finished EDM workpiece 16 16 several distinct layers
1 2 3

Fig B.
1.

2.

Fig A.

3.

Layer with small globules of removed workpiece metal and electrode the white or recast layer Heat affected zone or annealed layer
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References
Advanced Machining Processes V. K Jain (Pg No.,126) Unconventional Manufacturing process M. K. Singh
17 17

(Pg No.,81)
Manufacturing science Amitabh Ghosh (Pg No.,

329)
HMT production technology

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Questions?
18 18

Thank You

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