Electrical discharge machining (EDM) has been recognized as an efficient production method for precision machining of electrically conducting hardened materials. EDM in gaseous media is one of the fastest growing branches among institutions involved in the research and development of EDM as green manufacturing process Dry EDM is an environmental friendly machining process were liquid dielectric fluid is replaced by gaseous dielectric fluids. Present & past performance of dry EDM process using various types of gases & their mixtures as dielectric medium. The main objective is to study the effect of pulse-on time, pulse-off time, gap voltage, open voltage, servo voltage, discharge current; polarity, pulse width, duty factor, gas or air pressure, electrode rotation speed on Material removal Rate (MRR), Surface Roughness (Ra) and Tool Wear Rate (TWR) also discussed resulting finding condition for machining of material depends on the optimization techniques or criteria. Development of Dry EDM Technology enhance the performance parameters such as material removal rate (MRR), Low tool wear rate (TWR), thin recast layer.

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Current Research development in Dry Electric Discharge
Machining (DEDM): Review Paper
Sushil Kumar Choudhary1,
R. S Jadoun2
1
Research Scholar, 2
Professor, Department of Industrial & Production Engineering, College of Technology, G. B. Pant
University of Agriculture & Technology Pantnagar, Uttarakhand., India.
Abstract--Electrical discharge machining (EDM) has been
recognized as an efficient production method for precision
machining of electrically conducting hardened materials.
EDM in gaseous media is one of the fastest growing branches
among institutions involved in the research and development
of EDM as green manufacturing process Dry EDM is an
environmental friendly machining process were liquid
dielectric fluid is replaced by gaseous dielectric fluids. Present
& past performance of dry EDM process using various types
of gases & their mixtures as dielectric medium. The main
objective is to study the effect of pulse-on time, pulse-off time,
gap voltage, open voltage, servo voltage, discharge current;
polarity, pulse width, duty factor, gas or air pressure,
electrode rotation speed on Material removal Rate (MRR),
Surface Roughness (Ra) and Tool Wear Rate (TWR) also
discussed resulting finding condition for machining of
material depends on the optimization techniques or criteria.
Development of Dry EDM Technology enhance the
performance parameters such as material removal rate
(MRR), Low tool wear rate (TWR), thin recast layer.
Keyword-- EDM, DEDM, MRR, TWR, EWR
I. INTRODUCTION
1.1 Introduction of EDM
Electrical Discharge Machining (EDM) is non
traditional, no physical cutting forces between the tool and
the workpiece, high precision metal removal process using
thermal energy by generating a spark to erode the
workpiece. The workpiece must be a conductive electricity
material which is submerged into the dielectric fluid for
better erosion. EDM machine has wide application in
production of die cavity with large components, deep small
diameter whole and various intricate holes and other
precision part. A picture of EDM machine in operation is
shown in Figure 1.
Fig. 1 Schematic of EDM process [Choudhary & Jadoun (2014)]
1.2 Dry Electrical Discharge Machining (DEDM)
Dry EDM, which applies high flow rate gaseous
dielectric fluid, tends to alleviate the environmental
problem resulted from the liquid and powder mixed
dielectrics and also enhance the machining performance.
Using inert gas to drill small holes (NASA, 1985) is the
first dry EDM attempt. Electric discharge machining
Technique in which the liquid dielectric is replaced by a
gaseous dielectric. Gas at high pressure as used as the
dielectric medium. In dry EDM, tool electrode is formed to
be thin walled pipe. The flow of high velocity gas into the
gap facilitates removal of debris and prevents excessive
heating of the tool and work piece at the discharge spots.
Tool rotation during machining not only facilitates flushing
but also improves the process stability by reducing arcing
between the electrodes The technique was developed to
decrease the pollution caused by the use of liquid dielectric
which leads to production of vapor during machining and
the cost to manage the waste. Dry EDM method with the
shortest machining time compare to oil die sinking EDM,
& lowest electrode wear ratio. Work removal rate also get
enhanced by dry EDM.

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833
Fig.2 Principle of Dry Electrical Discharge Machining (DEDM)
[Choudhary & Jadoun (2014)]
1.3 Technology development of Dry EDM
The tool electrode is flushed with pressure gas from the
inside to bring the melted metal away from the erosion
zone. Rotation of the tool electrode stabilizes the process
and enhances the removal rate. Therefore a rotational
symmetric tool electrode with interior channel is employed.
Beside usual tube electrode also multi channel electrode are
employed. The process can be used to drill some holes or,
if the tool is moved like in milling machining, free form
can be machined. Beside the usual EDM parameters as
open circuit voltage, sparking time and pause time, new
parameters are introduced with dry EDM, like flushing
pressure, rotation speed, form, wall thickness of the
electrode as well as its motion
Fig. 2 Dry Electric discharge machine
1.4 Components of DEDM
1. Work-piece-all the conductive material can be worked
by EDM
2. Tool Electrode-The EDM electrode is the tool that
determines the shape of the cavity to be produce.
3. Compressor- An air compressor is a device that
converts power (usually from an electric motor, a
diesel engine or a gasoline engine) into kinetic energy
by compressing and pressurizing air, which, on
command, can be released in quick bursts.
4. Pressure Gauge –Gauge pressure usually refers to
the pressure difference between ambient
atmospheric pressure & the pressure in a vessel.
5. Air dryer- A compressed air dryer is a device for
removing water vapor from compressed air.
Compressed air dryers are commonly found in a wide
range of industrial and commercial facilities. The
process of air compression concentrates atmospheric
contaminants, including water vapor
6. Tubular electrode The tubular electrode mounted in
the dry EDM attachment spindle receives the
compressed air.
7. Servo system-The servo system is commanded by
signals from gap voltage sensor system in the power
supply and control the feed of electrode & workpiece
to precisely match the rate of material removal.
8. Power supply-The power supply is an important part
of any EDM system. It transform the alternating
current from the main utility supply into the pulse
direct current (DC) required to produce the spark
discharge at the machining gap.
9. The DC pulse generator is responsible for supplying
pulses at a certain voltage and current for specific
amount of time.
1.5 Applications, advantages & Disadvantages
A. Applications of DEDM
 Enhancement of machined surface functional properties,
such as wear resistance, corrosion resistance and reduced
friction coefficient, through surface modification.
 Improvements in performance parameters such as MRR,
WR and SQ
 Making and machining of micro product & sophisticated
micro mechanical Element. It is the use of light, thin,
compact, special purposes work such as micro-engines,
micro-pumps, micro-robots etc.
 The production of these microelements with traditional
methods is restricted due to various Complications.
 Complicated die contours in hard materials can be
produced to a high degree of accuracy and surface finish.
B. Advantages of DEDM
 Environmentally conscious manufacturing,
 Manufacturing process cost reducing,
 Simplification of machine tool structure,

3. International Journal of Emerging Technology and Advanced Engineering
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834
 Improvement of performance characteristics,
 Decreased dielectric medium cost.
 Less electrolytic corrosion
 Low residual stress
 High MRR using oxygen as dielectric fluid
 Machining of complex shape.
C. Limitations of DEDM
 The machine structure can be made compact since no
working basin, fluid tank and fluid circulation system
needed.
 The need for electrical conductivity
 Taper effect at the edge of machined cavity
 The processing reaction force is much smaller that in
conventional EDM.
 It is possible to change supplying gas according to
different applications.
 The residual stress is small since the melting
resolidification layer is thin.
 Working gap is narrower than in conventional EDM.
 The process is possible in vacuum condition as long as
there is a gas flow.
II. PARAMETERS OF DRY-EDM
Parameters of Dry EDM mainly classified into two
categories: process parameters & performance Parameters
2.1 Process Parameters
The process parameters in EDM are used to control the
performance measures of the machining process.
1. Supply voltage: The input voltage applied across the
tool electrode and workpiece is called the supply or open
circuit voltage.
2. Discharge Current: The discharge current (Id) is a
measure of the amount of electrical charges flowing
between the tool and workpiece electrode. As the flow of
electrical charges is the heating mechanism in electro-
thermal erosion,
3. Discharge Energy (Em): This is the electrical energy
that is available for material removal. The magnitude of
Em is calculated from measured pulse on time, discharge
voltage and discharge current values.
4. Peak Current: The peak current, one of most important
parameters in EDM, is measured in units of amperage
and is the amount of power used in discharge machining.
It is a preset level that the current reaches during each
pulse on-time. High current values will improve the
MRR sacrificing the surface finish, and tool wear rate.
5. Pulse On-time: The pulse on time represents the duration
of discharge and is the time during which the electrode
material is heated by the high temperature plasma
channel. Material removal is directly proportional to the
amount of energy applied during this on-time .A longer
pulse on time will increase the discharge energy.
6. Pulse off time: The pulse off time represents the duration
when no discharge exists and the dielectric is allowed to
deionise and recover its insulating properties. A longer
pulse off time improves machining stability as arcing is
eliminated.
7. Duty Cycle: It is a percentage of the on-time relative to
the total cycle time. This parameter is calculated by
dividing the on-time by the total cycle time (on-time
pulse off-time).
8. Gas Pressure: A pressure gauge and pressure valve are
also fitted in the dielectric line to know the pressure and
to control the pressure.
2.2 Performance Parameters
These parameters measure the various process
performances of EDM results.
1. Material Removal Rate (MRR): MRR is a performance
measure for the erosion rate of the workpiece and is
typically used to quantify the speed at which
machining is carried out. It is expressed as the
volumetric amount of workpiece material removed per
unit time.
2. Tool Wear Rate (TWR): TWR is a performance
measure for the erosion rate of the tool electrode and is
a factor commonly taken into account when
considering the geometrical accuracy of the machined
feature. It is expressed as the volumetric amount of
tool electrode material Removed per unit time.
3. Surface quality (SQ): Surface quality is a broad
performance measure used to describe the condition of
the machined surface. It comprises components such as
surface roughness (SR), extent of heat affected zone
(HAZ), recast layer thickness and micro-crack density.
III. COMPARISIONS OF DIELECTRIC EDM & DRY EDM
Basic Comparisons between the dielectric EDM & Dry
EDM listed the table-1 and Shown in the fig.3, fig.4, fig.5.

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Table I
Comparision Of Dielectric EDM & Dry EDM
Dielectric EDM Dry EDM
Lower material
removal rate
Better material removal rate
Less surface roughness
achieved during EDM
Surface roughness achieved During
DEDM milling is higher by 0,2 μm
(about 20%) than during EDM milling
in kerosene.
Dielectric fluid used as
liquids
Dielectric fluid used as gases
More electrolytic
corrosion
Less electrolytic corrosion
Manufacturing &
machining cost more
Manufacturing & machining cost less
No Pollution control &
human skin effect
protections
Pollution Prevention in Machining and
Metal Fabrication
Tool Electrode wear is
more for any pulse
duration
Tool Electrode wear is negligible
Fig.3 Material removal rate
Fig. 4 Electrode Wear
Fig.5 machining time

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IV. LITERATURE REVIEW
Table II
Research Progress in Dry EDM [1985-2014]
Researcher contribution Year wise
Ramani et. al. [1985]: Firstly introduce in dry EDM 1985 NASA Technical report It is briefly reported that argon and helium gas were used
as dielectric medium to drill holes using tubular copper electrode.
Kunieda et. Al. [1991]: oxygen gas introduced in discharge gap based dielectric in water increased removal rate.
Kunieda et al [1997]: Electrical discharge machining can be achieved in gas.
Yoshida et al [1999]: tool electrode is almost negligible for any pulse duration in dry EDM.
Kunieda et al [2001]: narrower gap, no corrosion of work piece and high finish cutting in dry EDM.
Zhang et al [2002]: EDM with ultrasonic aid (UEDM) can be achieved in gas medium.
Wang et al [2003]: dry EDM removes environmental pollution due to liquid dielectric. Better straightness with dry EDM.
Kunieda et al [2003]: oxidation of work pieces due to the usage of oxygen electrode wear is almost negligible increase MRR.
Curodeau et al [2003]: a thermoplastic composite electrode used in dry EDM using air as dielectric medium.
Z. B. Yu et al [2003]: dry EDM is suitable for 3D milling of difficult to cut materials such as cemented carbide.
Kunieda et al [2004]: improvement of dry EDM by controlling the discharge gap using a piezoelectric actuator.
Wang T. et al [2004]: the explosive force and electrostatic force acting on wire electrode decrease in dry WEDM.
Zhang et al [2004]: ultrasonic vibration improves MRR in gas by increasing the effective discharge.
Li L.Q [2004]: discharge passage extends rapidly in the gas medium of dry EDM.
Yu et. Al. [2004]: demonstrated the effectiveness of the dry EDM method in machining of cemented carbide. Dry EDM was used for groove
milling and three- dimensional milling. Copper-tungsten tubes were used as tool electrodes and high velocity oxygen gas was used as the
dielectric. Dry EDM performance was compared to oil die sinking EDM and oil EDM milling. It was found that dry EDM milling produces
the smallest form deviation due to very low tool wear ratio. The machining speed in dry EDM is higher than for oil milling EDM but lower
than oil die-sinking EDM. However, it was argued that the total time required for making multiple electrodes in die-sinking EDM puts it at a
disadvantage to dry EDM milling. Fewer tool electrodes are required in dry EDM due to lower tool wear. The total machining time for dry
EDM may then be lower than die-sinking EDM.
Zhang et al [2005]: a theoretical model of surface roughness in ultrasonic vibration assisted EDM (UEDM) in gas.
Kao et al. [2006] applied the near-dry process in wire EDM using water-air mixture and found its benefit of better machining stability and
higher MRR than the wet EDM in finishing process. Also, using the gas or liquid-gas dielectric medium, the dielectric disposal of dry or
near dry EDM is cleaner than that of PMD EDM.
ZhanBo et al. [2006]: Optimum combination of depth of cut, gas pressure & pulse duration 25µm it is lead to maximum material removal
rate & minimum tool wear.
S. K. Saha and S. K. Choudhury et.al [2009] studied parametric Analysis of the process has been performed with tubular copper tool
electrode and mild steel work piece. Experiments have been conducted using air as the dielectric medium to study the effect of gap voltage,
discharge current, pulse-on time, duty factor, air pressure and spindle speed on material removal rate (MRR), surface roughness (Ra) and
tool wear rate (TWR).
Shue k. Y. et al. [2010]: Dry Electrical discharge machining (Dry EDM), using gas as dielectric, has been developed to solve problems
against environment. It has both advantages of high material removal ratio (MRR) and low relative electrode wear ratio (REWR)
Masahiro Fujiki [2011]: Achieve high material removal rate in tool path planning for the near-dry electrical discharge machining (EDM)
milling process using tubular electrode with a lead angle.
Wang T. et. Al. [2013]: Main advantages of dry finishing of WEDM such as better straightness, lower SR and shorter gap length.
Roth R. et al. [2013] heat energy from the oxidation has only a little effect on the material removal rate and that the main difference between
oxygen and less oxidizing gases is to find in different stability and time efficiency of the process.
Xue Bai et al. [2013] The experimental results showed that the MRR of PMND-EDM increased with the increase of peak current, pulse on
time, flow rate, and air pressure, decreased with the increase of pulse off time and tool rotational speed, and increased firstly and then
decreased with the increase of powder concentration.
Murican et al. [2013] the results it is observed that a maximum MRR of 9.94 mm3/min is obtained and MRR is influenced by discharge
current followed by Ton and duty factor. A minimum tool wear of 0.048 mm3/min is obtained and tool wear is influenced by discharge
current and duty factor.
Linking et al. [2013] experimental results show an increase in the MRR for both the oxygen-mixed EDM and the cryogenically cooled
workpiece technique, along with a decrease in the surface roughness value (Ra) for the latter.
Deshmukh et al. [2014] investigates near-dry electrical discharge machining to achieve the high material removal rate and better surface
finish simultaneously. In near-dry EDM liquid and air mixture is used as dielectric medium and in wet EDM only liquid is used as dielectric.

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Table-III
Researchers work Contribution based on workpiece, Tool Electrode & Parameters
Researchers Contribution Year Wise Work piece Tool
Electrode
Electrical parameters Non-Electrical Parameters
Kunieda and Yoshida, (1997)
Investigated dry EDM method &
compared its performance with EDM in
oil.
Steel (S45C) Copper Voltage,
current,
Pulse duration,
polarity
Wall thickness of pipe electrode,
Air pressure, rotation and plenary
motion of tool
Zhang et al.(2002) Proposed and
Investigated ultrasonic vibration EDM
Steel Copper Voltage,
pulse
duration,
Pipe wall Thickness,
Electrode vibration
amplitude, effects of gas medium
ZhanBo Yu et al. (2004) Dry Electrical
discharge Machining of cemented
carbide.
cemented
Carbide.
Copper
tungsten pipe
Discharge current
Discharge duration
Discharge interval
Open voltage
Rotation of the electrode
Assist Gas Oxygen.
Zhang et al. (2006) Applied ultrasonic to
improve the efficiency in EDMi n gas
medium
AISI 1045
steel
Copper Open
voltage,
Pulse duration,
Discharge current
Gas pressure,
Wall thickness,
actuation
amplitude
Kao, C.C. et al.(2006)
Dry wire electrical discharge machining
Of thin workpiece
Al 6061 copper
wire
electrode
Spark cycle T, spark on-time
duration Ton,
air flow rate,
workpiece thickness,
Jia Tao et al. (2008) Experimental Study
of the Dry and Near-Dry Electrical
Discharge Milling Processes
AISI H13 tool steel copper Discharge Current
pulse duration
pulse interval
Gap Voltage
Open circuit Voltage, Polarity,
Electrode rotary speed
Depth of cut
Electrode diameter
Pressure of the dielectric fluid
S.K.Saha et. al. (2009) Multi–objective
optimization of the dry electric discharge
machining process
EN32 mild steel Tubular
copper tool
Electrode
Tool Positive polarity, workpiece
negative polarity
Tubular tool Electrode Rotation
K. Bonny et al. (2009) EDM
machinability and dry sliding friction of
WC-Co cemented carbides
WC-Co cemented
carbides
brass
(CuZn37)
wire electrode
Open voltage
Pulse duration
Pulse interval
Servo voltage
Pulse ignition height
Maximum speed
Flushing pressure
Wire tension
Wire winding speed
Govindan et al. (2010) Experimental
characterization of material removal in
dry electrical discharge drilling
SS 304 Copper Gap Voltage,
Discharge Current,
Pulse off Time
Oxygen pressure
Electrode speed
Radial clearance shield
Cheke et Al. (2011) comparative
performance of wet and near-dry EDM
Process for machining of oil hardned non
sinking Steel material
Oil hardened non
shrinking steel
material
hollow copper
alloy electrode
discharge
current, pulse on time, gap
voltage and pulse off time
NO
Roth R. et Al. (2012) Influence of the
Anode Material on the Breakdown
Behavior in Dry Electrical Discharge
Machining
SS304
Cemented Carbide.
Copper,
Cemented
Carbide.
Open voltage, current, spark
voltage, pause time.
Flushing pressure
Electrode rotation
Flushing fluid
(Oxygen )
Murickan et al. (2013)
Experimental investigation of Dry
Electrical Discharge Machining on SS
316L
SS 316L Copper discharge current, pulse-on time,
duty factor
spindle speed
Skrabalak et al. (2013) Optimization of
dry EDM milling process
Inconel 617 and
hardened
(55-60HRC) tool
steel (NC61.2063)
Copper No Electrode tool rotation speed, flow
rate, composition of gas mixture
Roth R. et al. (2013) Influence of
oxidizing gas on the stability of dry
electrical discharge machining process.
SS304 Copper Open voltage
Discharge current
Discharge duration
Interval duration
Electrode polarization (-)
Flushing pressure
Electrode rotation speed
Boopathi et al. (2014) study of water
assisted dry wire cut electrical discharge
machining
HSS Molybdenum
wire
Pulse Width , discharge current Inlet pressure, flow rate,

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V. CONCLUSIONS &FUTURE SCOP OF EDM
 Dry EDM is eco friendly machining. Pollution is
reduced by use of gas instead of oil based dielectric.
Harmful & toxic fumes are not generated during
machining. Material removal rate (MRR) &electrode
wear ratio (EWR) also get enhanced by dry EDM.
This technique should be supported and more
investigation should be made since it helps to save the
environment. Main advantage of dry EDM (DEDM)
 Very less work has been reported on Material
Removal Rate (MRR) improvement. Also on material
like water hardened die steel, molybdenum high speed
steel (HSS) have none tried as a work materials in
near-dry EDM & powder mixed EDM (PMEDM).
The same may be tried in future works.
 Hollow tube and eccentric drilled hole type electrode
are reported to have positive impact on MRR due to
improved flushing condition. Such designs need
investigations for more work materials to evaluate
their case to case effects.
 For Dry EDM Ceramic materials both conductive and
nonconductive materials not so much work is carried
out. So, for future we can consider this material for
research work in Dry EDM. For analysis and
optimization we can use soft computing techniques
like GA, Fuzzy Logic, and ANN are carried out.
 Use of near-dry EDM in micro machining.
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Authors Biographies
Er. Sushil Kumar Choudhary, Pursuing PhD from
Industrial & Production Engineering, G.B.Pant
University of Agriculture & Technology Pantnagar,
Uttarakhand, India.
Email:Sushil_think@rediffmail.com
Dr. R.S. Jadoun, Professor & Head of Department
Industrial & Production Engineering, G.B.Pant
University of Agriculture & Technology,
Pantnagar, Uttarakhand, INDIA
Email.;rsjadoun@gmail.com