EDM Machine and its types full brief descriptions and details

1. 1
An investigation of the effect of pulse off
time on TWR in Additive mixed EDM.
Submitted By:
Adeel Ahmad 15S-BSMT-151149
Tariq Jamil 15S-BSMT-151154
M. Rehman 15F-BSMT-121058
Supervisor Engr. Noman Asif
DEPARTMENT OF TECHNOLOGY
GLOBAL INSTITUTE LAHORE

2. 2
An investigation of the effect of pulse off
time on TWR in Additive mixed EDM.
This project is submitted to Global Institute Lahore in partial fulfillment of the
requirement for awarding the degree of
Bachelor of Science
in
Mechanical Technology
________________ _________________
Internal Examiner External Examiner
(Engr. Noman Asif)
DEPARTMENT OF TECHNOLOGY
GLOBAL INSTITUTE LAHORE

3. 3
DEDICATION
This work was carried out at the Department of Technology, The Global Institute
of Lahore Pakistan, under the kind supervision of Engr. Noman Asif, to whom we
are very grateful for his guidance and support.
We would like to thank our respectable teachers and supervisor and the university
for creating a pleasant and productive environment. Special thanks to Mr. Noman
Asif and management staff for interesting discussions and fruitful collaborations.
We would like to thank the staff and Head of Department of Technology for
providing us opportunity to dream out our visions.
Thanks

4. 4
Acknowledgement
We are dedicating this project to the dearest figures in our lives:
Most of all ,Allah, the almighty name above all names. Oh Allah we can do nothing or be
nothing without your grace. You have always been by our side guiding us all the way to
this destiny. You gave us ours parents, brought us into this world, born us as a child. You
continued to guide us every day.
Our dearest parents, we are going to dedicate this project to you. May you live long by
the blessing of Allah with a lot of happiness and pleasures, May Allah forgive all your
sins.
AMEEN

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Contents
DEDICATION.......................................................................................................................................3
Acknowledgement .................................................................................................................................4
Table of Figures.....................................................................................................................................6
List of Tables .........................................................................................................................................7
Abstract .................................................................................................................................................8
Chapter 1 ...............................................................................................................................................9
Introduction & Types of EDM..............................................................................................................9
1.1: Introduction:...........................................................................................................................9
1.2: Working Principle: .................................................................................................................9
1.3: Classification of EDM:..........................................................................................................10
1.4: Components EDM: of...........................................................................................................15
1.5: Parameters of EDM:.............................................................................................................19
1.6: Applications of EDM:...........................................................................................................20
1.7: Advantages of EDM:.............................................................................................................21
1.8: Dis-advantages of EDM:.......................................................................................................21
Chapter 2 .............................................................................................................................................22
Literature Review................................................................................................................................22
Chapter No 3 .......................................................................................................................................23
Project Review.....................................................................................................................................23
3.1: Problem Statement ...................................................................................................................23
3.2: Objectives of the research ........................................................................................................23
3.3: Literature Survey .....................................................................................................................23
3.4: Methodology .............................................................................................................................24
3.4.1: Brief description of how project is completed...................................................................24
3.4.2: Experimentation ................................................................................................................25
3.4.3: Experimental set up ...........................................................................................................26
3.4.4: Utilization of research & results........................................................................................27
Chapter No 4 .......................................................................................................................................30
Conclusion ...........................................................................................................................................30
References: ..........................................................................................................................................31

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Table of Figures
Figure 1-Working principle......................................................................................................9
Figure 2 Ram EDM.................................................................................................................11
Figure 3 Wire EDM ................................................................................................................13
Figure 4 Drilling EDM ........................................................................................................14
Figure 5 Types of Work pieces ...............................................................................................15
Figure 6 Function of Dielectric Fluid. ....................................................................................17
Figure 7 Flushing Methods in EDM.......................................................................................18
Figure 8 Copper tool Measurement with Weight Scale.........................................................25
Figure 9 Experimental set up.................................................................................................27
Figure 10 Become Experiments Tool & Work piece Condition ............................................28
Figure 11 After Experiments Tool & Work piece Condition ................................................29

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List of Tables
Table 1 Common Dielectric Fluids:........................................................................................18
Table 2 Constant Parameters:................................................................................................25
Table 3 Experimentation parameters.....................................................................................26
Table 4Following response parameters (Table) are selected.................................................26

8. 8
Abstract
Electrical discharge machining is a non-traditional machining process that is used for cutting the
hard materials just like. Tool steel, Titanium and other hard materials that can’t be proceed or cut
easily. Spark is produced in EDM that melts the metal in the EDM cutting procedure. Dielectric
is used to flush away the debris of cutting wastage during EDM procedure. Original tank of
EDM machine has capacity of some 300 to 400 liters for Dielectric.
In order to perform EDM machining with additives of different kind cost is so high which limits
is application. So, a separate tank has been designed to reduce this consumption of Additive and
Dielectric. In order to ensure proper mixing of additives a stirrer has also been used. We use D2
(Tool Steel) material as a work piece it has good mechanical properties and harder material and
Copper or Brass material as a Tool or Electrode and Chemical Tween-60 is add in kerosene oil
as a dielectric fluid to Improve MRR and Reduce TWR.

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Chapter 1
Introduction & Types of EDM
1.1: Introduction:
Electrical discharge machining is a non-conventional cutting process. Electrical discharge
machining is a machine that is complete its operations with removing the material by local
melting or vaporizing small areas at the surface of work piece. This process is also known as
thermal material removal process. Were move the material from the surface of work piece by
electric spark that is generated between work piece and tool submerged in a dielectric medium.
EDM is also used for machining of hard metals which cannot be machined easily by
conventional metal cutting processes. The products include dies, tools made of tungsten,
carbide,& brass etc.
1.2: Working Principle:
EDM works on the principle of removing the material by sparking that is generated
between the work piece and the tool with the voltage sparking in dielectric fluid. The working
system is shown in (Fig. 1.1). The work piece and tool are connected by D.C voltage generator.
Positive charge is on electrode and negative charge on work piece. When electrode & work piece
are connected with each other spark is generated and cutting process is performed according to
requirements. Electrode is designed according to shape that is required on the work piece.
Figure 1-Working principle

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1.3: Classification of EDM:
There are three main types of EDM;
1: Ram EDM
2: Wire-cut EDM
3: Drilling EDM
1.3.1: RAM EDM:
In ram EDM, the electrode/tool is attached to the ram and the ram is connected with the
positive pole, of a pulsed power supply. The work piece is connected to the negative pole. When
the work piece is on its position so that there is a gap between it and the electrode. The gap is
required to flow the die electric fluid. Once the power supply is turned on, thousands of direct
currents, or DC, impulses per second cross the gap in the beginning of erosion process. The
temperature of generated spark range is from 14,000° to 21,000° Fahrenheit. As the erosion
continues, the electrode working efficiency increase into the work while maintaining a constant
gap dimension.
The finished EDM's work piece can produced several distinct layers. The surface layer will have
small globules of removed work piece metal and electrode particles are also attached with it,
which are easily removed with hands. The second layer is called the “white” or “recast” layer
where EDM effected the surface of this layer structure of the work piece. The third layer is the
heat-affected zone or “annealed” layer. This layer has been heated but not melted.
All of these surface conditions are affected by:
• The EDM cycles of on- and off-time
• The duty cycle, this is the ratio of on-time relative to total cycle time.
• The gap distance between the work piece and the electrode.
Ram EDM machines are also known as Diesinkers or vertical EDMs. They range in size from
tabletop models to large CNC units. Ram EDMs have four sub-systems:
• A DC power supply to provide the electrical discharges, with controls for voltage, current,
duration, duty cycle, frequency, and polarity

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• A dielectric system to introduce fluid into the voltage area/discharge zone and flush away work
and electrode debris, this fluid is usually a hydrocarbon or silicone based oil
• A consumable electrode, usually made of copper or graphite
• A servo system to control in feed of the electrode and provide gap maintenance CNC Ram
EDM machines have automatic tool change capability allowing long unattended running times,
use of multiple electrodes for rough and fine metal removal, orbiting controls for cavity
enlargement, and contouring capability.
Figure 2 Ram EDM

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1.3.2: Wire EDM:
The wire EDM process uses a consumable, electrically charged wire to get very effective
and fully furnished cuts. The process is usually used to cutting fine details in pre-hardened
stamping and blanking dies. The wire is continuously flow in the circle and a fresh wire is
produced for cutting every time. Typical wire diameters range from 0.002 - 0.013 of an inch, or
0.05 - 0.33 of a millimeter. These wires will produce a kerf slightly larger than their own
diameter. A 0.012 inch/0.3-millimeter wire will create a 0.015 inch/0.4-millimeter kerf. Wire
EDM’s can run for long periods without operator attention.
Four basic wire EDM subsystems include:
• The DC power supply
• The dielectric system
• The wire feeding system
• The work positioning system
The wire system principle of operation is the same as the ram type, using a series of DC
discharges between the wire and work piece. As with ram EDMs, flushing with dielectric fluid is
critically important. In some cases, both wire and work are completely submerged. However, this
may cause electrolytic corrosion on some work piece materials. Since the wire electrode is very
thin, power used is limited and removal rates are slow. The actual removal rate is calculated in
square inches per hour.
A two-axis wire EDM can only make cuts at right-angles to the work table, while a CNC
positioning system with a two-axis table can perform a wide variety of angled cuts. Independent
multi-axis machines can cut tapered angles and make cuts that result in different top and bottom
profiles. This capability is needed in making items such as extrusion dies and flow valves. The
wire never touches the work during cuts. The wire control servo system is able to maintain a
wire-to-work distance of approximately .001 inch. The wire cuts along a programmed path
starting at either an edge or in a predrilled hole. Parts to be cut can be stacked for production
quantities.

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Figure 3 Wire EDM

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1.3.3: Drilling EDM:
A third type of EDM is designed for drilling small, but very deep holes. These holes may
have a depth-to diameter ratio up to 100 to 1. Tubular electrodes up to a foot long are rotated at
speeds of about 100 RPM while drilling. As the electrical discharges occur, this rotation aids in
flushing and provides for uniform electrode wear.
Some of the hazards in EDM machining include the chance of flash fire in the dielectric fluid if
the level falls too low. Smoke can be irritating to the eyes and lungs and but can be controlled
with exhaust and smoke eating devices. The dielectric fluid can be irritating to the skin as well.
Figure 4 Drilling EDM

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1.4: Components EDM: of
There are some main components of EDM.
1.4.1: Work Piece:
Work piece must be conductive like polycrystalline, titanium, high temperature alloys.
Figure 5 Types of Work pieces

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1.4.2: Electrode:
Electrode selection is important factor in Ram EDM.
Functions of electrode:
 The purpose of electrode is to transfer the electric charge and to erode the work piece to a
desire shape. Different electrode materials greatly effect on Machining. Some will
remove metal efficiently but have great removal, and some material of electrode slight
wear but remove metal slowly.
Electrode Selection:
There are some main factors that are evaluate during selecting an electrode for machining
process.
 Cost of electrode material
 Easy or difficult to making an electrode.
 Type of finish desired.
 Amount of electrode wear.
 No of electrode required during complete the job.
 Material of electrode that is suitable for work piece.
Materials of Electrode:
There are some material that is used to making an electrode. All materials have its own
properties & Temperature to wear.
 Zinc
 Brass
 Cooper
 Graphite
 Tungsten
Properties of Electrode:
 High material removal rate.
 Low wear rate of electrode.
 High degree of electric efficiency.

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1.4.3: Dielectric:
The dielectric is usually allowing viscosity hydrocarbon oil. The work-piece and
electrode tool are separated by the dielectric. The dielectrics very important for working
of the EDM. When the tool and work gap is about 0.03 mm and at about 70 V, the
dielectric is ionized to form a column or path in the tool and work gap so that a surge of
current takes place as the spark is produced. The spark discharge will be in a micro small
area at around 10,000°C and thousands of atmospheric pressures and takes place in less
than a micro second for each spark. A tiny part of work material is vaporized due to the
arcing The tiny metal particles are cooled into small spheres and are swept from the area
by the flow of dielectric fluid
Functions of Dielectric fluid:
There are some main functions of dielectric fluid used in EDM process are:
 Dielectric must be electrically non-conductive.
 When the breakdown voltage is reached it should breakdown electrically instantly.
 Remove all metal parts(carbon) from the arc gap.
 Good cooling media.
Figure 6 Function of Dielectric Fluid.
Properties of dielectric:
According to requirement of EDM process dielectric has following properties.
 High electric strength for proper insulation.
 High flash & fire point to prevent fire hazards.
 Low viscosity.
 Low decomposition rate for long life.
 Low cost.
 Good quenching properties.

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Common Dielectric Fluids:
The different fluids used are:
 Kerosene
 Paraffin oil
 Transformer oil
 Lubricating oil, etc
SR # Dielectric fluid
Material removal
rate cm / amp
Wear ratio-work material
/ tool material
1. Kerosene 40.0 2.8
2. Distilled water 54.5 2.7
3. Glycol 103.0 6.8
Table 1 Common Dielectric Fluids:
Dielectric flushing in EDM:
The different methods of circulation of dielectric fluid for flushing in EDM are:
 Pressure dielectric flow
 Reverse dielectric flow
 Vacuum dielectric flow
 Vibration flush cut
Figure 7 Flushing Methods in EDM

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1.4.4: Circulation system:
Circulation system of EDM is used to circulate dielectric medium with the help ofPipes,
Pump & strainer. Circulation system plays an important role in EDM.
1.4.5: Machining Tank:
Machining tank is also known as the upper tank of EDM. Work piece is hold on Die in
machining tank. The size of work piece is decided according to the capacity of machining
tank.
1.4.6: Storage tank:
Storage tank is commonly used for storage of the dielectric fluid. Pump throws fluid from
storage tank to machining tank for machining process. After machining process dielectric
fluid goes back to storage tank with piping system.
1.5: Parameters of EDM:
There are some main Parameters of EDM.
1.5.1: Peak current:
The peak current is the maximum amount of current which an output is capable of
sourcing for brief periods of time. The difference between the steady state value & the
peak current is what is referred to as the inrush current. The peak current should be
within limits and only last for a short duration to avoid stressing the components or
causing excessive heating or damage.
1.5.2: Voltage:
The lighting spark occurs at very long distance from the cloud to the ground, & the
voltage reaches millions volts. In EDM, the voltage supplied is approximately 50 to 300
volts because higher is not suitable for high precision machining. Therefore, EDM
discharge gap is about 0.005 – 1.0 mm.

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1.5.3: Pulse on time:
Pulse on time mean that time when an EDM’s electrode performs cutting operation with
the dielectric medium.
1.5.4: Pulse off time:
Pulse off time means time when an EMD’s electrode cannot perform cutting process.
This time also called non-cutting time.
1.6: Applications of EDM:
There are some main applications of Electric discharge machine.
1. Dies, fixtures, gauges
2. Cutting tools
3. Press tools, extrusion dies
4. Die molds for plastics
5. Die-casting dies, mold inserts
6. Re-machining, repairing of worn dies for hot and cold forging.
7. Making forging dies like connecting rod forging dies, etc.
8. Sintering dies
9. Calibrating tools
10.Shaping carbide tools, templates.

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1.7: Advantages of EDM:
There are some advantages of EDM.
1. It can make complex shapes that would otherwise be difficult to produce with
conventional cutting tools.
2. Hard materials can also be machined.
3. Vary small work piece can also be machined.
4. The fact that the process takes place in a fluid improves the removal of metal chips from
the cutting area and enhances cooling characteristics of the tool and work piece.
5. The process allows for “Heavy” duty operation in higher frequency & current (A) values
which result in increased process efficiency.
6. Easy to increase productivity.
7. It can help to improve quality.
1.8: Dis-advantages of EDM:
There are some dis-advantages of EDM.
1. Applying the EDM method for turning & grinding is not easy.
2. More expensive process than conventional milling & turning.
3. Only able to machined conductive materials.

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Chapter 2
Literature Review
1. Many peoples are researched on the EDM parameters but the sturdy of the effect of tool
electrode on EDM performance of Tie Ti-6Al-4V by Rahul1 · Dileep Kumar Mishra2 ·
Saurav Datta2 · Manoj Masanta2 is compared the normal Copper electrode, use of
cryogenically treated Copper electrode has offered increased MRR, improved surface
finish and reduced tool wear while executing EDM operation on Ti-6Al-4V.
2. The murahali kolli and kumar adepu are researched on Influence of Span 20 Surfactant
and Graphite Powder Added in Dielectric Fluid on EDM of Titanium Alloy their research
are depends on these main Keywords- 1-Span20surfactant, 2-Graphite Powder, 3-EDM,
4-Titanium Alloy because with the use of graphite powder added in dielectric in the
duration of experimentation it decrease the TWR and with the help of Titanium alloy it
enabled us to improve the MRR and surface roughness.
3. According to Md. Ashikur Rahman Khan1 & M.M. Rahman who is research on Surface
characteristics of Ti-5Al-2.5Sn in electrical discharge machining using negative polarity
of electrode manuscript presents the surface characteristics of the machined surface in
EDM on Ti-5Al-2.5Sn titanium alloy. The surface roughness and the microstructure of
the machined surface are explored for different EDM parameters and electrode materials.
Experimentation was accomplished using negative polarity of copper, copper-tungsten
and graphite electrode. In this study, peak current, pulse-on time, pulse-off time and
servo-voltage are taken into consideration as process variables. The surface roughness is
greatly influenced by peak current and pulse-on time among the selected electrical
parameters. Among the three electrodes, the copper electrode produces the lowest surface
roughness whilst graphite electrode gives the highest surface roughness.
4. According to M.Schward who is search on Material Removal rate & Electrode wear in
Die Sinking during using of Graphite electrode. He says Graphite is a handsome
electrode that is used in EDM & more profitable than Cooper electrode.
5. Electrode is an important component of EDM. Electrodes design with different materials
that are suitable according to work piece. The purpose of electrode is to transmit the
electric charge and make the work piece desired to a shape.

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Chapter No 3
Project Review
3.1: Problem Statement
Tool wear problem is very important issue in EDM machining operations’ because due to this
problem we face different type of losses that given blow,
i. This issue direct impact the final shape of die cavity.
ii. Increase the tool cost of manufacturing operations.
iii. Increase the machining time.
3.2: Objectives of the research
The main objective of the research is given blow:
In this sturdy we gain variations in tool wear characteristics that we present them namely, Tool
wear rate surface roughness after all for solution of these problems we investigate them with
varying machining parameters because,
whenever we use the Electric Discharge Machine for our working purpose we need maximum
material removal rate and minimum Tool wear rate with high definition accuracy to archive this
goal we just want to take some experiments on EDM to enhance the MRR and decrease TWR.
3.3: Literature Survey
Electric Discharge Machining (EDM) is a nontraditional machining method that we used to
produce die cavities with high accuracy via erosive effect of electrical discharge. First of all we
use electrically conductive tool means electrode that is the male shape of die cavity, this tool is
prepared to machine the die cavity. This method is especially used to machining hard die steels,
complex cavities and small work pieces. Die casting, forging, injection molding, upset forging,
extrusion, and powder compaction dies manufacturers are used the EDM Technology.

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3.4: Methodology
Methodology is the method that completely explain the our EDM project therefore
it consists of four points,
3.4.1:Brief description of how project is completed.
3.4.2: Experimentation.
3.4.3: Experimental set up.
3.4.4: Utilization of research results.
3.4.1: Brief description of how project is completed.
First of all it declared that the material is purchased from the market just like,
1) copper tool material with dimensions of (50 X 15Ø)mm
2) D2 Material work piece with dimensions of (95mm x 40mm x 7mm)mm
3) Kerosene oil
4) Tween 60
5) 0.001 Gram least count Weight Scale etc.
After collection of required material we are getting ready for experiments on our specific
parameters.

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Figure 8 Copper tool Measurement with Weight Scale
3.4.2: Experimentation
 Constant Parameters:
Table 2 Constant Parameters:
Sr. No Name of Parameter Value
1 Peak Current 8A
2 Voltage 120V
3 Machining Time 5min
4 Electrode Copper
5 Electrode Diameter 15mm’
6 Work piece Dimension 95mm x 40mm x 7mm

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 Experimentation parameters.
Sr. No Input Parameter (Variables) Level 1 Level 2 Level 3
1 Dielectric type K K+T60 K+T60
2 Work piece Material D2 D2 D2
3 Pulse Off Time (Poff) 12 25 50
4 Electrode Material Copper Copper Copper
5 Polarity Positive Negative -
Table 3 Experimentation parameters.
 Following response parameters (Table) are selected.
Sr. No Response parameters
1. TWR (Tool Wear Rate)
Table 4Following response parameters (Table) are selected.
Machining will be performed for one set of parameters and then work piece and tool electrode
will be weighted again to calculate MRR and TWR respectively. After this surface roughness
will be measured and recorded.
3.4.3: Experimental set up
Specially designed Separate circulation system with storage tank will be used for
dielectric circulation in EDM Die Sinker. Chapter No: 03 will explain construction of this
circulation system. Small size machining tank will also be fabricated. This will reduce the
dielectric quantity for machining resulting in reduced machining cost. Another thing that is
important to discus is the material of tool and work piece of our experiment, now we used the D2
material as a work piece. It has good mechanical properties and maintains its hardness at high
temperature and good physical properties like thermal conductivity, melting point and electric
resistivity. Electrode material usually steel copper and brass. But we use copper material for our
experiments to get someone special results of our experiments. Now we setup the process
parameters that show performance parameters mainly surface roughness. The EDM machining

27. 27
parameters are divided into two groups Non Electrical parameters and Electrical parameters.
These parameters are normal and stable machining are set throughout the experiments. We setup
the EDM machine parameters with respect to (Table # 01). Then we will be move on next setup
to utilization of our research results.
Figure 9 Experimental set up
3.4.4: Utilization of research & results.
Electric Discharge Machine is a slow process. Various combinations of parameters are checked
to decrease the Tool Wear Rate. Brass & Copper Tool and positive polarity have decrease the
Tool Wear Rate in presence of Dielectric Kerosene oil and mixed additive like chemical Tween-
60. These parameters give us the amazing Tool Wear Rate decrease results on lowest rate of
pulls off time.

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Results:
Title: An investigation of the effect of pulse off time on TWR in Additive mixed EDM.
Results:
Tool Material Used:
1. Copper Electrode (Diameter 15mm, Length 100mm,)
2. Brass Electrode (Diameter 15mm, Length 100mm)
Input Parameters:
Electrode Material:
TWR = W1 – W2 / time*density
Above formula has been used for TWR calculation.
It is found that TWR is decreased when copper Electrode is used for cutting D2 Material with
tween-60 and kerosene oil.
Polarity:
Less TWR is observed with Negative polarity of Tool Electrode.
 Become Experiments Tool & Work piece Condition
Figure 10 Become Experiments Tool & Work piece Condition
Sr. NO Parameters Values
1 Tool Material Brass Copper
2 Polarity Positive Negative

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 After Experiments Tool & Work piece Condition
Figure 11 After Experiments Tool & Work piece Condition

30. 30
Chapter No 4
Conclusion
Electrical discharge machining is a non-traditional machining process that is used for cutting the
hard materials just like. Tool steel, Titanium and other hard materials that can’t be proceed or cut
easily. Spark is produced in EDM that melts the metal in the EDM cutting procedure.
In this research D2 (Tool Steel) material was used as a work piece due to its good mechanical
properties and high strength. Tool Electrode was Copper and Brass. In kerosene Dielectric
Chemical Tween-60 is added to study tool wear rate in the presence of surfactant. Results have
shown an increased MRR and Reduced Tool wear with the addition of Surfactant. Tool wear rate
of Copper electrode was less than brass in the presence of Tween 60 surfactant.

31. 31
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2. Liu X, Chu PK, Din C (2004) Surface modification of titanium,
titanium alloys, and related materials for biomedical applications
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Wang ZM (1997) Titanium alloys and their machinability—a review.
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EDM parameters on machining Ti–6Al–4 V with multiple quality
characteristics. Int J Adv Manuf Technol. doi: 10.1007/s00170-009-2208-35.
Ho KH, Newman ST (2003) State of the art electrical discharge
machining (EDM). Int J Mach Tools Manuf 43:1287–1300
6. Raghav G, Kadam BS, Kumar M (2013) Optimization of material
removal rate in electric discharge machining using mild steel.
International Journal of Emerging Science and Engineering 1(7):2319–6378
7. Daneshmand S, Kahrizi EF, Neyestanak AAL, Monfared V (2014)
Optimization of electrical discharge machining parameters for Niti
shape memory alloy by using the Taguchi method. J Mar Sci Technol.
doi: 10.6119/JMST-013-0624-18. Hascalık A, Caydas U (2007)
Electrical discharge machining of titanium alloy (Ti–6Al–4V).
Appl Surf Sci 253(22):9007–9016