ELECTRODE

DESIGN IN EDM

What is EDM ?

Why EDM ?
Ability to work on hardened materials
Low cutting and work holding forces

Complex profile capability

Blind cavities and sharp corners possible

Very advantageous in small holes machining

Only method to machine tungsten carbide

Process used for removing broken taps and drills

B. R. Lazarenko and N. I. Lazarenko

EDMing is an Art
Machine is a tool to achieve desired result by the user. Guidelines are given by the manufacturer but actual results depend a lot on the user.

Present knowledge

To machine with EDM process, 4 items are required:

An electrode
A work piece A dielectric fluid Electricity

Physical process
The EDM process takes place in 6 stages 1 The electrode approaches the work piece. The two units are energized.

2 Concentration of the electrical field towards the point, where the space between the electrode and workpiece is smallest.

3 Creation of an ionized channel between the electrode and workpiece

4 Breakdown of the spark. The work piece material melts locally and disintegrates. The electrode only wears out slightly.

5 The current is cut off, causing implosion of the spark.

6 Evacuation of the metallic particles by flushing with dielectric

There are two distinct EDM processes, both using the same physical principle:
Die sinking Wire cutting

Basic installation
Machine tool

Generator
Dielectric unit

Machine tool frames

C type Gantry type Moving column type Cantilever type

Further classification
- with/ without backslide

- work tank:
- rotating quill - servo:

- fixed / rise & fall type

- single/double door - hydraulic - ac/ dc servo motor - stepper - linear motor - pizo electric

Generator
Generate the required power at reqd.frequency

Control the servo

Control auxiliary functions

The main parameters of EDM process

1) Electrical parameters like, current ON, OFF time polarity
2) Electrode and work piece materials and

3) Flushing !

Why ON and OFF ?

We need SPARKING

not ARKING !

Current:

more current = more work but, there is a limit

amperes/ sq.cm. Area (electrodes projected area) Rule of the thumb : 10 amperes / sq. cm. maximum current it can handle without arcin in actual practice such extreme current density is rarely use Current density:

EDM finish Surface finish Scale Affected / recast layer

Polarity effects on commonly used metal pairs

Electrode Material
Copper Copper Copper Copper

Polarity of electrode
+ ve + ve - ve - ve

Work piece

% Wear

MRR

Steel Aluminum Tungsten carbide Copper

2-10 <3 35-60 35-45

Medium

Low
Low

Copper
Copper Tungsten Copper Tungsten Copper Tungsten Graphite Graphite Graphite Graphite

- ve
+ ve - ve - ve + ve - ve + ve - ve

Copper Tungsten
Steel Copper Tungsten carbide Steel Steel Aluminum Aluminum

40-60
1-10 20-40 35-50 <1 30-40 <1 10-20 High High Very High Medium Very High Medium

Electrode undersizing

ELECTRODE

WORK PIECE

Electrode size = reqd. cavity size ( 2G + 2Rmax + )

Thermal expansion effect

Diff. between Co. of expansion

for Copper and Steel = 4.5 m/meter/C for Graphite and Steel = - 9 m/meter/C Tungsten copper and Steel = 3 m/meter/C

WORK PIECE

Example: 40mm copper electrode becomes 40 + 0.4m*4.5 m *(50-20) C * = 40.054

Electrodes Reqd. cavity Roughing Finishing

Electrode etching

Electrode materials
Selection criteria :
material removing rate resistance to wear surface finish required raw material cost fabrication cost

Most commonly used electrode materials

electrolytic copper graphite brass tellurium copper copper tungsten tungsten

Copper
Melting pt. 1083C

Low cost Easy machinability Good for mirror finishing

Difficult to grind Inevitable burr problems High wear Weak for thin sections

Can be wire cut

Can be chemically etched

Graphite
A metalloid, sublimates at 3500C High cost Problematic dust Very brittle

High MRR Excellent wear resistance Good machinability High strength

Tellurium Copper

- ease of machining (Telco)

Tungsten Copper (70/30) - increased resistance to wear, very good machinability, good for tungsten carbide jobs high cost Tungsten - very high cost very good strength/wear characteristics low MRR Copper Graphite - best of everything at very high cost !

Electrode planning
Reqd. cavity 30mm dia. 50mm deep, 2um Ra
Step 1 decide maximum current from working area for finishing. decide settings to get max MRR at reqd. surface finish. calculate finishing electrode size. Step 2 with same considerations, decide roughing electrode size for zero wear . Step 3 from the % wear of finishing electrode, calculate number of passes reqd. for completing the job.

Orbiting

STATIC

ORBITING

Orbiting shapes

Orbiting
-reduced machining time

-reduced and uniform wear

-reduced number of electrodes

-improved surface finish

-improved accuracy

Electrode movement by
- rotating spindle with/without through flushing - electrode vibrator - horizontal servo

Bottle mould by hoz. servo

Orbiting systems
- mechanical, cam controlled (free loran), ok for roughing tapering possible.

- z lock loran, most commonly used, undercuts possible. - step loran, eccentricity increased in steps, tapering - vectoring, almost CNC, every motion possible.

- table orbiting

Z NC
Generator programmable in relation to z axis

GR. INCREASE STEP

GR. INCREASE STEP

STEP

GR. INCREASE

CNC EDM
-Advanced logic controllers -All axes controllable individually / simultaneously -Spindle rotation, C axis -Auto tool changer -Auto workpiece changer -Help functions

-IT friendly

Flushing
Three keys, for successful EDM are,

Flushing, flushing,

and flushing !

Dielectric
-a hydrocarbon based oil
(low flash pt. submerged working, needs anti-ark precaution)

Provide insulation Clean the gap Cool electrode and work piece

Viscosity of the dielectric

High viscosity - large spark gap high MRR rough surface large cavities, forging dies Low viscosity - small spark gap better surface finish tools, moulds,dies - micro machining

Very thin oils

PRECAUTIONS AGAINST FIRE HAZARDS While using Kerosene, Keep adequate level of Kerosene above the level of sparking. If the level of Kerosene falls bellow the level of overflow, the liquid

2. level

controller should stop the machine. 3. Do not play with this controller. Bypassing the controller by an operator is one of the major causes of the fire to the machine. 4. Keep the fire extinguisher, preferably of foam type, ready for use near the machine. Check the extinguisher periodically and make sure that it is in working condition. Train the machine operator to use the fire extinguisher properly. 5. The temperature controller fitted in the tank will stop the machine if the temperature of the Kerosene goes above 50 to 55 C. Do not disturb the

PRESSURE FLUSHING

WORK PIECE

ELECTRODE

FLUSHING POT THROUGH ELECTRODE

OIL IN

THROUGH WORKPIECE

SUCTION FLUSHING

FLUSHING POT

OIL OUT

THROUGH ELECTRODE
THROUGH WORKPIECE

PIN

PIN FORMATION

REMIDIES
ECCENTRIC

FLUSHING
HOLE

INCLINED HOLE

MULTI CHANNEL VACCUM FLUSHING

ROTATING ELECTRODE

SIDE FLUSHING

WRONG

RIGHT WRONG RIGHT

FLUSHING A NARROW SLOT

GAS

OIL IN

GAS OUT
ELECTRODE

WORK PIECE

WORK PIECE (-ve polarity)

ELECTRODE (+ve polarity)

EROSION ALLOWANCE

mm PER SIDE

4 3 2

100

150

200

300

500

700

1000

PROFILE PERIMETER mm

DISCHARGE DRESSING OF ELECTRODE

EDM THREADING

CONVENTIONAL

BY ORBITING

GUIDE NUT
WORKPIECE ELECTRODE
ELECTRODE

WORKPIECE

Special applications

EDM Drilling (using coreless electrode)

EDS (electric discharge sawing)

EDG (electric discharge grinding)

PIN

Pin formation by simple tube electrode

Coreless electrode