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Machining
Dr.S.Satish Kumar, Professor, Dept of Mech. Engineering
References
1. Modern machining Processes - P.C. Pandey & H.S Shan
2. Unconventional machining - P.K. Mishra
UNIT III
Syllabus
History of EDM
• In 1970 , the English scientist Priestley first detected the erosive effect of
electrical discharges on metals.
• EDM has found ready in the machining of hard metals or alloys which cannot be
machined easily by conventional methods.
• Application seen in machining of dies, tools made of tungsten carbides, Stellites
or hard steels.
Popularity of EDM
• Consider the case of a discharge between two electrodes (tool cathode and work
anode) through a gaseous or liquid medium
• The momentum with which positive ions strike the cathode (tool) is much less
than the momentum with which the electron stream impinges on the anode surface
• A compressive force is generated on the cathode surface by the spark which helps
reduce tool wear
Sinking by EDM
Grinding by EDM
Di-electric fluids
Flushing
• Correct circulation of dielectric fluid between electrode and work piece to obtain
highest machining accuracy
• Flushing in EDM can be achieved by anyone of the following methods
(i) Injection flushing
(ii) Suction flushing
(iii) side flushing
(iv) Flushing by dielectric pumping
Side flushing
When flushing holes cannot be drilled either in the work piece or the tool side flushing is
employed
ELECTRODES
Selection of electrodes
Four main factors determine the suitability of a material for use as an electrode
• Maximum possible material removal rate
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• Wear ratio
• ease with which it can be shaped or fabricated to the desired shape
• Cost
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Operating conditions on side clearance during boring
Process parameters
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Pulse energy at a constant voltage is varied by changing the size of the capacitors
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Machine tool selection
A variety of EDM machines ranging from small machines to large machines are available
The factors that have to be considered are
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Rotary pulse generators
The capacitor is charged using a diode. The circuit permits high metal removal rates.
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Static pulse generator (Controlled pulse circuit)
These circuits offer the advantage of faster rate of metal removal and low tool electrode
wear; The RC circuits are replaced with vacuum tubes and oscillators.
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Wire Cut EDM
The electrode wire is used only once, then discarded because the wire looses its form
after one pass through the workpiece
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Operational summary
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Review Questions
Part A
Part B
1. How gas, stacks and slugs and debris are formed during machining by EDM?
What are the provisions to be made for their removal?
2. What are the ways of gap flushing used in EDM? Explain in detail.
3. What are the functions of dielectric used in the machine? List its properties.
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4. In an EDM operation employing relaxation circuit, discuss the effects of
(i) charging resistance (ii) gap setting (iii) capacitance on the rate of metal
removal How does this type of machine compared with pulse generator
5. Discuss the factors influencing the choice of electrode material in EDM. Name
the best electrode material for finish machining a small die made of WC by EDM
process
6. Discuss the advantages of EDM as compared to other non traditional methods
with regard to (i) material removal rate (ii) accuracy (iii) surface finish
7. Explain with a neat sketch the working of Wire cut EDM.
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