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Electrical discharge machining [EDM]

Introduction of Electrical discharge machining [EDM]

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Electrical discharge machining [EDM]

  1. 1. Subject – Production Technology Topic - Electrical Discharge Machining [EDM] Presented By :- Dhruv Shah
  2. 2. Electrical Discharge Machining [EDM] Electrical discharge machining process is also known as thermal erosion, electro erosion or spark erosion machining. EDM is one of the most widely used unconventional machining process. The main attraction of EDM is that this technique utilizes thermoelectric process to erode undesirable materials from the w/p by a series of discrete electrical sparks between the w/p and the electrode.
  3. 3. Figure of Electrical Discharge Machining [EDM]
  4. 4. The EDM system consider tool as negative terminal (Cathode) and w/p as positive terminal (Anode) are connected to DC power supply to create a potential difference between the w/p and the tool. The tool and w/p are separated by gap, is called spark gap. This gap is filled by dielectric fluid. This process incerse the concentration of electrons and ions in dielectric medium between the tool and the w/p at the spark gap.  Working principle of EDM :-
  5. 5. The electrical energy dissipated at the thermal energy of the spark. When the electrons and the ions reach the anode and cathode, they give up their kinetic energy in the form of heat. With a very short duration spark (2 to 2000 micro- second), The tempture of the electrodes can be raised more than their normal boiling point, abpout 10,000 C. A servo controlled electrode feeding mechanism is used to control gap between electrode and w/p. The spark gap used in EDM is about 0.0125 to 0.125 mm. There are two types of servo controlled system as electrical servo control and hydraulic servo system.
  6. 6.  Electrodes :- It should have good electrical conductivity and thermal conductivity. It should be easy to fabricate in any required shape. It should have high melting point. It should have low erosion rate.  Characteristics of Dielectric Fluid :- The function of dielectric Fluid is to act as a flushing medium for the removal of the chips and to provide a cooling medium. It should have good cooling ability and low viscosity of dielectric produces smooth surfaces. It should be chemically neutral otherwise it reacts with electrode, w/p and container. It should not produce any toxic vapors during the process.
  7. 7.  Applications of EDM :- EDM can be used make parts with complex, Precise and irregular shapes for forging, press tools, extrusion dies, cutting tool dies and mould. EDM for create accurate dimension holes, deep small diameter holes, narrow slots in turbine blades, difficult to internal shape. EDM can also used in aerospace and medical application.
  8. 8.  Advantages of EDM :- EDM Drilling to create very small holes. EDM Milling to machine complex shape with simple cylindrical electrodes. EDM process has abiity to machine hard, difficult to machine materials. Thin and brittle components can be machined without distortion because there is no direct contact between the tool and w/p. No burrs are left in machined surface.
  9. 9.  Limitations of EDM :- This process can only be employed in electrically conductive materials. Material removal rate is low and the process overall is slow compared to conventional machining process. Energy required for the operation is more than that of conventional machining. Rough surface finish when at high rates of material removal .Finishing cuts are needed at low MRR. Profile machining is complex contours is not possible at required tolerance. Produces slightly tapered holes, especially if blind.

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Introduction of Electrical discharge machining [EDM]

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