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Electro Discharge
Machining
Electrical discharge machining
Electric discharge machining also referred as spark machining or

spark erosion machining is a controlled metal removal process based
on the principle of erosive effects of electrical discharges (sparks)
taking place between conducting materials immersed in a dielectric
fluid.
Need for EDM
Extremely hard materials like tungsten carbide are difficult to

machine with conventional machining methods.
Further, very small workpieces may get damaged due to the excessive
cutting tool pressure.
Electrical discharge machining
EDM equipment
Power supply source

Tool electrode
Dielectric fluid
Servo feed mechanism
Pumps and filters
Power supply
DC power supply with voltage ranging from 50-450 V is used in EDM

machines.
In EDM process, electrical energy in the form of short duration
impulses are to be supplied at machining gap between the tool and
the workpiece.
Tool electrode
In EDM the shape of the tool is that desired in the workpiece.
The material selected for manufacturing EDM tools should be good
conductor of heat and electricity, easily machinable and resist the
deformation during erosion process.
Various materials like copper, zinc alloys, brass, graphite, tungsten,
silver tungsten etc., are used for manufacturing EDM tools.
Dielectric fluid
In EDM the tool and the workpiece are separated by a dielectric fluid.
The dielectric fluid may be mineral oil, kerosene, deionized water,
etc., and performs the following functions
Acts as a insulator until the potential is sufficiently high
Acts as a flushing medium to carry away the tiny particles of metal
removal
Acts as a cooling medium during machining
Servo feed mechanism
EDM machines are equipped with servo feed control mechanism that
automatically maintains a constant gap between the tool and the
workpiece.
Pump and Filters
Pumps and filters serves their usual purpose of circulating clean fluid
to the machining gap for efficient machining.
GK
TATA 407
TATA 207
TATA 2525
Then, this is what it means:
The first 1 or 2 numeral(s) represent (s) "Gross Vehicle
Weight"(GVW), in tonnage.
The last 2 numerals (in tens) indicate "Brake-horsepower" (BHP) of
engine used.
Now, you can relate:
Tata 407 Ex - has 4-tonnage (4000Kg) GVW & 70 bhp engine power.
Tata 2525 prima - has 25 tonnage GVW & 250bhp engine power.
& so on.
Process parameters
Influence of current
Influence of spark frequency
Spark gap
Typical gap between the tool and workpiece ranges from 0.01- 0.05
mm.
The smaller the gap, the closer the accuracy with good surface finish.
Advantages of EDM
Extremely hard materials can be easily machined with close tolerance.

Thin and small sized materials can be machined easily.
There is no contact between the tool and the workpiece. Therefore
delicate sections can be easily machined without any distortions
Fine holes can be easily drilled with this process.
Disadvantages of EDM
Suitable for electrically conductive workpieces

Slow material removal rate
Inability to machine sharp corners
Specific power consumption is very high
Overcut is formed due to side sparks
Tool wear occurs during machining, hence additional cost for the tool
WIRE CUT ELECTRIC DISCHARGE MACHINING
This is a special type of electric discharge machining that uses a small
diameter wire as a cutting tool on the work.
Working a principle of wire cut electric discharge machining is same
as that of electric discharge machining
Process Details of WCEDM
Tool Details
The tool used in WCEDM process is a small diameter wire as the
electrode to cut narrow kerf in the workpiece.
During the process of cutting the wire is continuously advanced
between a supply spoil and wire collector.
This continuous feeding of wire makes the machined geometry
insensitive to distortion of tool due to its erosion.
Material of wire can be brass, copper, tungsten or any other suitable
material to make EDM tool.
Normally, wire diameter ranges from 0.076 to 0.30 mm depending
upon the width of kerf.
Tool Feed Mechanism
Two type of movements are generally given to the total (wire). One is
continuous feed from wire supply spoal to wire collector.
Other is movement of the whole wire feeding system, and wire along
the kerf to be cut into the workpiece.
Both movements are accomplished with ultra accuracy and pre-
determined speed with the help of numerical control mechanism.
Dielectric Fluid and Spray Mechanism
Like EDM process dielectric fluid is continuously sprayed to the

machining zone.
This fluid is applied by nozzles directed at the tool work interface or
workpiece is submerged in the dielectric fluid container.
Rest of the process details in case of WCEDM process are same as
that in case of EDM process.
Suction flushing
Side flushing
Process Characteristics

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Electro Discharge

Electric discharge machining also referred as spark machining or

Extremely hard materials like tungsten carbide are difficult to

Power supply source

DC power supply with voltage ranging from 50-450 V is used in EDM

Extremely hard materials can be easily machined with close tolerance.

Suitable for electrically conductive workpieces

Like EDM process dielectric fluid is continuously sprayed to the

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