Electric Discharge Machining (EDM) :: Fig. 1 Schematic Representation of The Basic Working Principle of EDM Process

Electric Discharge Machining (EDM):
1. Introduction
Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining
process, where electrical energy is used to generate electrical spark and material
removal mainly occurs due to thermal energy of the spark.
EDM is mainly used to machine difficult-to-machine materials and high strength

temperature resistant alloys. EDM can be used to machine difficult geometries in
small batches or even on job-shop basis. Work material to be machined by EDM has
to be electrically conductive.
2. Working Principle
Fig. 1 shows schematically the basic working principle of EDM process.
V
(-ve)
Fig. 1 Schematic representation of the basic working principle of EDM process.

In EDM, a potential difference is applied between the tool and workpiece. Both the
tool and the work material are to be conductors of electricity. The tool and the work
material are immersed in a dielectric medium. Generally kerosene or deionised water
is used as the dielectric medium. A gap is maintained between the tool and the
workpiece. Depending upon the applied potential difference and the gap between the
tool and workpiece, an electric field would be established. Generally the tool is
connected to the negative terminal of the generator and the workpiece is connected
to positive terminal. As the electric field is established between the tool and the job,
the free electrons on the tool are subjected to electrostatic forces. If the work function
or the bonding energy of the electrons is less, electrons would be emitted from the
tool (assuming it to be connected to the negative terminal). Such emission of
electrons are called or termed as cold emission. The “cold emitted” electrons are
then accelerated towards the job through the dielectric medium. As they gain velocity
and energy, and start moving towards the job, there would be collisions between the
electrons and dielectric molecules. Such collision may result in ionisation of the
dielectric molecule depending upon the work function or ionisation energy of the
dielectric molecule and the energy of the electron. Thus, as the electrons get
accelerated, more positive ions and electrons would get generated due to collisions.
This cyclic process would increase the concentration of electrons and ions in the
dielectric medium between the tool and the job at the spark gap. The concentration
would be so high that the matter existing in that channel could be characterised as
“plasma”. The electrical resistance of such plasma channel would be very less. Thus
all of a sudden, a large number of electrons will flow from the tool to the job and ions
from the job to the tool. This is called avalanche motion of electrons. Such movement
of electrons and ions can be visually seen as a spark. Thus the electrical energy is
dissipated as the thermal energy of the spark.
The high speed electrons then impinge on the job and ions on the tool. The kinetic
energy of the electrons and ions on impact with the surface of the job and tool
respectively would be converted into thermal energy or heat flux. Such intense
localised heat flux leads to extreme instantaneous confined rise in temperature which
would be in excess of 10,000oC.
Such localised extreme rise in temperature leads to material removal. Material
removal occurs due to instant vapourisation of the material as well as due to melting.
The molten metal is not removed completely but only partially.
As the potential difference is withdrawn as shown in Fig. 1, the plasma channel is no
longer sustained. As the plasma channel collapse, it generates pressure or shock
waves, which evacuates the molten material forming a crater of removed material
around the site of the spark.
Thus to summarise, the material removal in EDM mainly occurs due to formation of
shock waves as the plasma channel collapse owing to discontinuation of applied
potential difference.
Generally the workpiece is made positive and the tool negative. Hence, the electrons
strike the job leading to crater formation due to high temperature and melting and
material removal. Similarly, the positive ions impinge on the tool leading to tool wear.
In EDM, the generator is used to apply voltage pulses between the tool and the job.
A constant voltage is not applied. Only sparking is desired in EDM rather than arcing.
Arcing leads to localised material removal at a particular point whereas sparks get
distributed all over the tool surface leading to uniformly distributed material removal
under the tool.
3. Process Parameters
The process parameters in EDM are mainly related to the waveform characteristics.
Fig. 2 shows a general waveform used in EDM.
Fig. 2 Waveform used in EDM
The waveform is characterised by the

 The open circuit voltage - Vo
 The working voltage - Vw
 The maximum current - Io
 The pulse on time – the duration for which the voltage pulse is applied - ton
 The pulse off time - toff
 The gap between the workpiece and the tool – spark gap - 
 The polarity – straight polarity – tool (-ve)
 The dielectric medium
 External flushing through the spark gap.
4. Characteristics of EDM
(a) The process can be used to machine any work material if it is electrically
conductive
(b) Material removal depends on mainly thermal properties of the work material
rather than its strength, hardness etc
(c) In EDM there is a physical tool and geometry of the tool is the positive
impression of the hole or geometric feature machined
(d) The tool has to be electrically conductive as well. The tool wear once again
depends on the thermal properties of the tool material
(e) Though the local temperature rise is rather high, still due to very small pulse
on time, there is not enough time for the heat to diffuse and thus almost no
increase in bulk temperature takes place. Thus the heat affected zone is
limited to 2 – 4 m of the spark crater
(f) However rapid heating and cooling and local high temperature leads to
surface hardening which may be desirable in some applications
(g) Though there is a possibility of taper cut and overcut in EDM, they can be
controlled and compensated.
5. Dielectric
In EDM, as has been discussed earlier, material removal mainly occurs due to
thermal evaporation and melting. As thermal processing is required to be carried out
in absence of oxygen so that the process can be controlled and oxidation avoided.
Oxidation often leads to poor surface conductivity (electrical) of the workpiece
hindering further machining. Hence, dielectric fluid should provide an oxygen free
machining environment. Further it should have enough strong dielectric resistance so
that it does not breakdown electrically too easily but at the same time ionise when
electrons collide with its molecule. Moreover, during sparking it should be thermally
resistant as well.
Generally kerosene and deionised water is used as dielectric fluid in EDM. Tap water
cannot be used as it ionises too early and thus breakdown due to presence of salts
as impurities occur. Dielectric medium is generally flushed around the spark zone. It
is also applied through the tool to achieve efficient removal of molten material.
6. Electrode Material
Electrode material should be such that it would not undergo much tool wear when it
is impinged by positive ions. Thus the localised temperature rise has to be less by
tailoring or properly choosing its properties or even when temperature increases,
there would be less melting. Further, the tool should be easily workable as intricate
shaped geometric features are machined in EDM. Thus the basic characteristics of
electrode materials are:
 High electrical conductivity – electrons are cold emitted more easily and
there is less bulk electrical heating
 High thermal conductivity – for the same heat load, the local temperature
rise would be less due to faster heat conducted to the bulk of the tool and
thus less tool wear
 Higher density – for the same heat load and same tool wear by weight
there would be less volume removal or tool wear and thus less dimensional
loss or inaccuracy
 High melting point – high melting point leads to less tool wear due to less
tool material melting for the same heat load
 Easy manufacturability
 Cost – cheap
The followings are the different electrode materials which are used commonly in the
industry:
 Graphite
 Electrolytic oxygen free copper
 Tellurium copper – 99% Cu + 0.5% tellurium
 Brass
Material Removal Rate (MRR):

Electric Discharge Machining (EDM) :: Fig. 1 Schematic Representation of The Basic Working Principle of EDM Process

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Electric Discharge Machining (EDM) :: Fig. 1 Schematic Representation of The Basic Working Principle of EDM Process

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Electric Discharge Machining (EDM):

EDM is mainly used to machine difficult-to-machine materials and high strength

Fig. 1 Schematic representation of the basic working principle of EDM process.

The waveform is characterised by the

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