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Electrical
Discharge
Machining
Unit 95
95-2
Objectives
Define electrical discharge machining
and state its principle
Summarize the EDM process
Identify the advantages and the
limitations of electrical discharge
machining
Name the main operating systems of
wire-cut electrical discharge machines
95-3
95-4
95-5
Servo
Tool
Rectifier
Work
220-V AC Current Control
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
95-6
Principle of EDM
Controlled metal-removal technique where
electric spark used to cut (erode) workpiece
Takes shape opposite to that of cutting tool
95-7
95-8
Resistance-Capacitance Circuits
Combination of low frequency, high
voltage, high capacitance, and high
amperage results:
Rather coarse surface finish
Large overcut around tool
Larger metal particles being removed and more
space to flush out particles
95-9
95-10
Main Advantages of
Pulse-Type Circuit
Versatile and can be accurately controlled
for roughing and finishing cuts
Better surface finish produced as less metal
removed per spark
Many sparks per unit of time
95-11
The Electrode
Formed to shape of cavity desired
Characteristics of good electrode materials:
95-12
Electrode
Common materials (not general-purpose)
Graphite, cooper, copper graphite, copper tungsten,
brass, and steel
95-13
EDM Process
Servo mechanism
Automatically maintains constant gap ~.0005 to .
001 in. between electrode and work
Advance tool into workpiece, senses and corrects
any shorted condition by rapidly retracting tool
(vertical movement)
Feed control applied to table for horizontal moves
95-14
Characteristics of
Pulse-Type Circuits
1. Low voltages
2. Low capacitance
About 50 mF or less
3. High frequencies
95-15
95-16
95-17
Main Functions of
Dielectric Fluid
1. Serves as insulator between tool and
workpiece until required voltage reached
2. Vaporizes (ionizes) to initiate spark
between electrode and workpiece
3. Confines spark path to narrow channel
4. Flushes away metal particles to prevent
shorting
5. Acts as coolant for both electrode and
workpiece
95-18
Types of Dielectrics
Must be able to ionize and deionize rapidly
and have low viscosity
Allow them to be pumped through narrow
machining gap
95-19
Methods of Circulating
Dielectrics
Must be circulated under constant pressure
Pressure used generally begins with 5 psi
and increased until optimum cutting
obtained
Four methods to circulate dielectric fluid
All must use fine filters in system to remove
metal particles so they are not recirculated
95-20
95-21
95-22
Vacuum Flow
Negative pressure (vacuum) created in gap,
which causes dielectric to flow
through normal .001 in. clearance
between electrode and workpiece
Improves machining
efficiency, reduces smoke
and fumes and helps to
reduce or eliminate taper
in work
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Suction
95-23
Vibration
Pumping and sucking action used to cause
dielectric to disperse chips
from spark gap
Valuable for very
Vibration
small holes, deep holes,
or blind cavities
95-24
Metal-Removal Rates
Rate dependent on following factors:
95-25
95-26
Reverse-Polarity Machining
New development that promises to be major
breakthrough in reducing electrode wear
Molten metal from workpiece deposited on
graphite electrode about as fast as electrode
worn away
Operates best on low spark-discharge
frequencies and high amperage
Improves metal-removal rates and reduces
electrode wear
95-27
Overcut
Amount the cavity in the workpiece is cut
larger than the size of electrode used in
machining process
Distance between surface of work and
surface of electrode (overcut) is equal to
length of sparks discharged
Constant over all areas of electrode
95-28
Overcut
95-29
Surface Finish
Low metal-removal rates, surface finishes of 2 to 4
in. possible
High metal-removal rates, finishes of
1000 in. produced
Fast metal removal (roughing cuts)
High amperage, low frequency, high capacitance and
minimum gap voltage required
95-30
Advantages of EDM
Any material that is electrically conductive
can be cut, regardless of its hardness
Work can be machined in hardened state,
thereby overcoming deformation caused by
hardening process
Broken taps or drills can readily be removed
from workpieces
95-31
95-32
95-33
Limitations of EDM
Metal-removal rates are low
Material to be machined must be electrically
conductive
Cavities produced are slightly tapered but
can be controlled for most applications to as
little as .0001 in. in every .250 in.
95-34
95-35
95-36
The Process
Uses CNC to move workpiece along X and Y
axes in horizontal plane toward vertically
moving wire electrode
Electrode does not contact workpiece but
operates in stream of dielectric fluid
Directed to spark area between work and electrode
When in operation, dielectric fluid in spark area
breaks down, forming gas that permits spark to
jump between workpiece and electrode
Eroded material caused by spark washed away
95-37
Operating Systems
Four main operating systems of wire-cut
electrical discharge machines
Servo mechanism
Dielectric fluid
Electrode
Machine control unit
95-38
Servo Mechanism
Controls cutting current levels, feed rate of
drive motors, and traveling speed of wire
Automatically maintains constant gap of .
001 to .002 in. between wire and workpiece
Important there be no physical contact
95-39
Dielectric Fluid
95-40
Electrode
Spool of brass, copper, tungsten,
molybdenum, or zinc wire ranging from .
002 to .012 in. in diameter (2 to 100 lb)
Continuously travels from supply spool to
takeup spool so new wire always in spark area
95-41
Characteristics of
Electrode Materials
1.
2.
3.
4.
5.
95-42