Technology Manual Ps Cnc-V0

Technology Manual
For
Pulse Generator : PS CNC / ePULSE SERIES
Product : SMART CNC / XPERT
HEAD OFFICE : FACTORY :
Electronica Machine Tools Ltd. Electronica Machine Tools Ltd.

691/1A, Elektra House, 608/609,1 Saswad Road,
Pune Satara Road, Taluka Purandar,
Pune 411 037, India Pune 412 301, India
Tel. : +91 20 24232900 Tel. : +91 2115 222440 / 41
Fax : +91 20 24232907 Fax : +91 2115 222599
www.electronicaEMT.com
D: 01:312:07:00
INDEX
CHAPTER I : Introduction
(A) EDM Principle 1:1
(B) Concept of EDM 1:2
- Machine Tool
- Power Supply
- Dielectric Supply
CHAPTER II : Work Preparation 2:1
(1) Stability
(2) Viscosity
CHAPTER III : DIELECTRIC 3:1
- TYPE OF FLUSHING 3:2
CHAPTER IV : Setting up and Operation 4:1

CHAPTER V : Technology Guidelines 5:1
Technology charts :
T1: Cu. To O.H.N.S.
T2: Gr.1 To O.H.N.S.
T3: Gr.2 To O.H.N.S.
T4: Cu. To Carbide (Rev.)
T5: Tungsten Cu. To Carbide (Rev.)
Special Technology charts :
T6: Gr.2 To Titanium.

T7: Alu. To Alu.
CHAPTER - I
INTRODUCTION
(A) EDM Principle
Electric discharge machining (EDM) is a process of repetitive sparking cycles.
Graphical Representation of Sparking Cycles
TON TOFF
VP
t(uS)
J
Series of Electrical Pulses At The Interelectrode Gap
TON TOFF
Td
VP
t(u
js)
Interelectrode Gap Voltage Waveform During Sparking
TO N TO FF
IP TON TOFF t
(JuS )
VP
t(uS)
J
Interelectrode Gap Current Waveform During Sparking
Where : TON : Pulse ON period

TOFF : Pulse OFF period
Td : Spark initiation period (Ignition Delay)
VP : Open Gap Voltage
Vg : Average Gap voltage
IP : Machining peak current
ELECTRONICA MACHINE TOOLS LTD. 1:1

A series of electrical pulses generated by the pulse generator unit is applied between the
workpiece and the tool electrode. In the event of spark discharge, there is a flow of current
across the tool electrode - workpiece gap. The energy content of a single spark discharge
can be expressed as a product of TON x IP. Energy contained in a tiny spark discharge
removes a fraction of workpiece material, leaving behind a small crater on the workpiece
surface. Material removal is assisted with the spark discharge plasma temperature ranging
in excess of few thousand degrees centigrade.
In Electric discharge machining, the repetitive cycles of spark discharge results in bulk
material removal of workpiece (job). During the process, however, a fraction of material is
also removed from the tool electrode called as electrode wear. The cavity formed in the
workpiece is the replica of tool electrode that is used for machining. Electric discharge
machining leaves its mark onto the cavity surface texture (surface finish), typical of spark
machining conditions.
Better workpiece material removal and low tool electrode wear can be achieved by using
appropriate machining conditions. e.g. By increasing the spark energy, one can achieve an
increase in material removal rate but not so good surface finish. By lowering the spark
energy (lower IP & lower TON values), one can obtain better surface finish. Best surface
finish, however, can be achieved at the cost of machining time. This is because of the
lower material removal rates with the lower spark energy settings.
To achieve optimum results of material removal rate, overcut or surface-finish, the

machining parameters should be properly set.
(B) CONCEPT OF EDM
Electric Discharge Machine is comprised of a machine tool a power supply unit and a
dielectric supply unit.
MACHINE TOOL :
It comprises of a base, column, worktable and work head. Work table is mounted inside a
work tank. Work piece is mounted and clamped on the work table (with or without a
flushing pot).
An electrode is mounted on the platen using an axis corrector. Work tank is filled with
dielectric. As the machining proceeds the Z quill comes down till the preset distance is
reached.
POWER SUPPLY :
It comprises of Electric pulse generator motor driver for Z axis (or X,Y axes in some
models) and a logic controller.
ELECTRONICA MACHINE TOOLS LTD. 1: 2

DIELECTRIC SUPPLY :
While the machining is continued the machining Zone is submerged in a dielectric medium.
Also the machining Zone is continuously flushed with dielectric using different flush aids.
The spark discharge across the electrode and work piece causes ionization of dielectric.
Carbon dust formed as a part of machining is flushed away and passed through filter
assembly. Here it gets filtered and the dielectric can be reused for machining.

CHAPTER - II
WORK PREPARATION
Before starting to plan a job consider all possible factors such as:
Adequate arrangement of flushing holes is made.

Adequate size of flushing holes exists on electrode.
No accumulation of dirt in spark gap. Accumulated dirt will interrupt sparking
process frequently.
Flushing is given through electrode, if through job is impossible.
If flushing is not possible through workpiece or electrode, side pressure flushing is
applied.
Proper dielectric is selected suitable for the job.
The main fields of spark erosion application are -

- Micro machining
- Line to medium machining (tool and die production)
- Coarse machining, medium to large forging dies.
For micro and fine to medium machining, or up to a working current of appr.80A, a

highly fluid medium is recommended.
For working current above 80A , i.e. for larger current, a higher viscosity dielectric is
preferred. This will increase stock removal, which is especially important when high
stock removal rate is desired. This is applicable for medium to large cavity
machining e.g. Forging dies.
For micro machining i.e. good surface finish and less material to be removed,
distilled (de-ionised) water can be used. In comparison to a high viscosity dielectric
the erosion time can be reduced considerably. Diameter to erosion depth should not
exceed the ratio 1 : 5 and in no case erosion depth should exceed 3 mm.
Applications of micro machining are :
- Spinnerets (Synthetic products)

- Injector nozzles
- Micro dies
- Micro holes and profiles
- Finishing of a cavity at good surface finish etc. after roughing.
During spark erosion process innumerable discharges take place, leaving a certain
amount of waste products in the dielectric due to generation of heat during sparking.
These waste products are separable products.
Waste product consist of -
- Gas and carbon particles
- Eroded particles from workpiece and electrode.
We know that a high degree of pollution disturbs the erosion process and causes
frequent short circuits. An efficient filtering system is imperative. For finishing
operations (very small gap) filteration system has to be still more efficient
ELECTRONICA MACHINE TOOLS LTD 2:1

Flushing conditions are of imperative influence for the spark erosion process.
Various factors influence spark erosion process such as Stability, Viscosity etc.
1. STABILITY
Stability itself depends on

- Stock removal
- Electrode wear
- Taper (See Figure)
- Accuracy of shape
Flushing conditions are controlled by quantity of dielectric flowing in the gap.

Resistance to the flow is varied with the settings, as well as depth of erosion.
Insufficient dielectric flow will raise degree of pollution causing frequent short circuits.
Excessive dielectric flow affects ionisation process and cuts off sparks too early.
Both extremes will result in low metal removal and high electrode wear ultimately
resulting in distorted form profile of electrode resulting into instability.
2. VISCOSITY
Dielectric recommended by the manufacturer should be used. Apart from the other
factors quality of dielectric can influence metal removal and electrode wear in a
positive or negative manner. Higher viscosity dielectric gives more M.R.R. but a
rough surface and also needs more efficient pump and filteration system.

CHAPTER - III
DIELECTRIC
Thick dielectric (high viscosity) is suitable for large spark gaps (greater roughness),
and thin dielectrics for small spark gaps (smaller roughness).
Viscous dielectrics generally give a better rate of erosion if the gap is sufficiently large
(flushing and regulation difficulties if the roughness or the gap is too small). The flash point
of thick dielectrics should be higher than 100C.
The choice of the dielectric according to viscosity depends upon the work to be carried out.
Other criteria are the aromatic content (odour), iodine number (aging-resistance) and price.
FUNCTIONS OF A DIELECTRIC :
1. INSULATION :
Proper insulation is required between electrode and workpiece to avoid disruptive
discharges.
2. IONISATION :
Quick formation of electric field to provide very constricted spark path. More the
spark path is constricted higher is the energy density resulting in efficient
discharge.
3. COOLING :
Proper cooling of electrode and workpiece and condensation of metal gases into
liquid, which are developed during spark erosion process.
4. REMOVAL OF WASTE PARTICLES :

Proper flushing out of cavity.

Considering the above functions it is theoretically possible to use any insulating liquid as
a dielectric. But after going through the following requirements we find that only
hydrocarbons can be used as dielectric. These hydrocarbons can be produced by
distilling and refining mineral oil or can be synthesized by processing gases.
Synthetically produced hydrocarbons are pure and have better erosion effect with less
electrode wear.
There are many criteria for assessing dielectrics. Following are some of them.
1. It should have higher degree of metal removal and less electrode wear.
2. It should be odourless and the smoke should be non toxic. Also it should not create
skin irritation
3. Flash point should be higher.
4. Evaporation rate should be less.
5. Disruptive voltage should be more.
6. Particle suspension should be more for proper removal of waste carbon particles.
7. It should be easily filterable.
8. It should not have adverse effect on machine components.
9. It should have longer life for better price to performance ratio.
10. It should be easily available and economical.
Following are the specifications of EDM oil which fulfills all the above requirements.
CHARACTERISTICS TEST METHODS SEO 203 SEO 350 SEO 450

APPEARANCE VISUAL BRIGHT & CLEAR
DENSITY @ 15C D-1298 0.81 0.85 0.75
FLASH POINT COC C D-92 80 130 106
POUR POINT C D-97 -5 -4 -9
VISCOSITY cSt D-445 4 4.8 2.3
COPPER CORROSION D-130 <1 <1 <1
DIELECTRIC STRENGTH KV MIN. IS 6792 12 12 12
It is strongly recommended to use above oil to get the optimum performance of the
machine.
TYPES OF FLUSHING
The following types of flushing can be used in spark erosion process :

- Pressure flushing
- Vacuum flushing
- Motion flushing
- Combined flushing
- Side pressure flushing
Arrangement of flushing holes is very important. Few arrangements known are

- Central flushing hole
- Spaced flushing holes
- Inclined flushing holes
- Vent flushing

PRESSURE FLUSHING : CONTINUOUS FLUSHING
IMPULSE FLUSHING
COMBINED FLUSHING
SUCTION FLUSHING : CONTINUOUS FLUSHING
WHEN FLUSHING THROUGH JOB OR ELECTRODE IS

SIDE JET FLUSHING : IMPOSSIBLE. MOSTLY IN COMBINATION WITH AUTO
FLUSHING.
MOTION FLUSHING : MOTION FLUSHING GIVES HIGHER EFFICIENCY OF

FLUSHING WITH MOVING ELECTRODE.
ROTATING ELECTRODE WITH ROTARY DEVICE

GUARANTEES BEST ROUNDNESS, BETTER SURFACE
FINISH SHORTER EROSION TIME.
AUTO FLUSHING (MOSTLY USED FOR DEEP PROFILES)
IN COMBINATION WITH PRESSURE FLUSHING OR
IMPULSE FLUSHING (DURATION OF LIFT OFF SHOULD
BE SHORTEST POSSIBLE).
Apart from flushing holes gas discharge holes are also for provided as shown in Figure.
FLUSHING PRESSURE
Flushing pressure during erosion process is very important and depends on the size of the
gap.

Roughing - Large gap - Low pressure
Finishing - Small gap - High pressure
In order to get flushing through job we require a flushing pot, which incorporates a plate to
clamp workpiece (or negative copper electrode).
APPLICATIONS OF FLUSHING
Pressure flushing : In pressure flushing profile always gets slightly tapered at the top side,
because removed particles moved into this direction and there is sparking between these
particles and the job causing excessive gap at the top.
Pressure flushing
Flushing holes can be provided in workpiece having small profiles. Large profiles are
mostly pre-machined leaving 2 mm per side to final size to be eroded by spark erosion. For
such job additional flushing hole is not necessary.
If flushing holes are not possible through workpiece (forging dies etc.) or machining of
flushing holes in hardened steel or in carbide, than flushing through electrode can be
provided.

Insufficient material left per side could cause unstable machining conditions resulting in
more electrode wear.
SUCTION FLUSHING
Flushing holes through job for small profiles. Large profiles are pre-machined and
necessity of additional flushing holes is not necessary.
If no flushing holes through workpiece possible flushing holes through electrodes can be
provided.
- Vacuum flushing is applied for high quality cylindrical profiles.

- Vacuum flushing is mostly used for finishing operations.
- Vacuum flushing is used when accumulation of gas more likely to happen with pressure
flushing.
If we apply flushing through the electrode, a core inside the electrode remains, which leads
to unstable machining conditions and short circuits. To avoid the instability because of this
core, if there is an electrode with an inclined flushing hole the core will continuously be
machined off as shown in figure.

MOTION FLUSHING :
When machining round holes, rotating electrode arrangement is recommended which gives
better flushing conditions due to motion flushing and also eliminates the core as shown in
figure.
Flushing hole at the centre core remains
Displaced flushing hole, core is continuously machined off.
- Rotating electrode reduces erosion time

- Rotating electrode equalises wear, i.e. less difficulty in getting through the workpiece.
- Rotating electrode improves flushing effect.
SIDE FLUSHING :
- If flushing is not possible either through workpiece or electrode use side pressure flushing
combined with auto flushing.
- Side pressure flushing should be used in correct direction.

- Under no circumstances flushing from both sides should be applied, because this would
accumulate particles in spark gap and cause unstable working conditions.
As a last improvement impulse flushing with auto flushing should be applied.
All particles are removed by vacuum flushing through the centre hole of electrode.
- For ED machining of a slot use always side pressure flushing in length-wise direction,
never across the electrode (unstable working conditions).
- Electrode could vibrate due to flushing pressure and slot would get out of tolerance.
Always think about the proportion of flushing holes and geometry of electrode while
designing the electrode.
If flushing hole too large, then

- Flushing paths are of different length leading to bad flushing conditions.
- Possibility of more electrode wear increases because stream of dielectric always chooses
shortest way.
- These conditions cause accumulation of particles at the four corners resulting in unstable
working conditions and short circuits.

When possibility of accumulation of gases in electrode cavity is more leading to unstable
machining. Sometimes it is better to reverse the positions of job and electrode as shown in
Figure.
- One other possibility to improve working conditions is reversing workpiece and electrode.
- Gas then can go away easily.
Sometimes when all possible methods fail to improve flushing conditions, one can enlarge
the frontal spark gap because which the particles generated due to spark can come out with
less difficulty. This can be increased by increasing the working voltage.
In summary what spark erosion needs is the clean gap between the job and electrode. One
can choose the suitable flushing system to keep the spark gap clean either by system
explained in this manual or even by designing his own method leading to the same result.

CHAPTER - IV
INTRODUCTION
SETTING UP AND OPERATION
1. INTRODUCTION:
Following pages describe "Setting up and operation" of "ELEKTRA" systems.

For efficient working on these machines, understanding of various parameters
of Spark Erosion process is necessary. For this purpose, user is advised to go
through the following pages carefully.
For setting up, experience of general tool making is useful. Satisfactory

erosion work demands appropriate production and work planning.
WORK PLANNING ESTABLISHES
I. The working method, procedure and technique
II. Machine stages
III. Settings
IV. Electrodes and Fixtures
V. Attachments if any
2. SETTING UP THE MACHINE TOOL
1. INSTALLING :
Place the machine tool on leveling pads supplied with the machine.
The place should be free from dust, direct sunlight and direct heavy
vibrations. Level the machine using the sprit level (200 mm length; 0.02
mm sensitivity). First level the system base roughly. There are leveling
bolts provided on the system base for the purpose. Then level the
machine tool in both X & Y directions. Use leveling bolts provided on
the machine tool. Leveling should be done in 1 division of the level.
2. CLAMPING THE WORKPIECE:
The workpiece is normally clamped on the table with the bolts.
Care must be taken
- That the job is mounted centrally as far as possible.
- Not to distort the workpiece by excessive clamping forces.

- That the bolts lie as close as possible to the workpiece.
- That the clamps, bolts etc. Do not touch the electrode holder.
3. ALIGNING THE WORKPIECE :
Workpiece aligning is done in order to bring workpiece into a defined

position with respect to the table. The workpiece is generally, aligned
with respect to the X & Y axes with a dial gauge and the reference
surface is arranged parallel to the surface of the table.
4. CLAMPING AND ALIGNING OF ELECTRODE :
Electrodes are fixed to the end of the quill with a clamping device. For
this purpose there are various systems, attachments etc. For sequence
electrodes, a system must be used which allows the electrodes to be
changed quickly with accurate positioning. Aligning of electrode can be
done by use of a dial gauge, a precision tri square, or with separate
attachments given for the purpose. The axis of electrode in most cases
is brought perpendicular to surface of the job.
5. POSITIONING :
In order to get accurate positioning, the reference and machining

surfaces of both electrode and workpiece should be free of burr. Also,
these surfaces must be cleaned properly before positioning.
The axes are actuated with the help of D.C. Servo motor, and this
speed of quill can be controlled by `FR1, FR2, FR3. Initially, distance
between electrode and workpiece is more. Adjust FEED RATE to its
maximum pos. When electrode approaches workpiece, decrease the
FEED RATE to position FR3.
6. AUTOPOSITIONING/ EDGE FINDING/ CENTRE FINDING :
APOS/ EF/CF are used to bring electrode and workpiece in a pre-

defined position with respect to each other. Workpiece is first brought
to the correct position near the electrode. Then APOS or EF/CF is
selected as per requirement. In APOS the electrode keeps tapping on
the workpiece whereas in EF it touches the electrode and remains
there. In CF various options like internal or external centre finding are
available.

7. AUTO FLUSHING :
When no other method of flushing can be used, auto flushing is used.

This means lifting of electrode automatically at an adjustable time
interval. This creates a pumping effect and EDM products are
removed from the cavity. The amplitude of lifting also is adjustable
over a range. The time spent in lifting is non sparking time and so
should be kept minimum without the loss of stability of the process.
8. IMPULSE FLUSHING :
This is a combination of side jet and auto flushing. Jet flushing is taken
through a solenoid valve. The opening of this valve is synchronised
with the lifting of dielectric jet under impulse from the valve is directed
forwards the work gap to accomplish the necessary flushing.

CHAPTER - V
TECHNOLOGY GUIDELINES
1. ELECTRICAL PARAMETERS
As the name itself suggest the basic principle involved in this process is the conversion of
Electrical energy into heat energy. This heat energy heats the job material and the metal is
removed from the job. This heat energy has to be controlled if the end results like metal Removal
Rate or electrode wear are to be controlled. To control heat energy one has to control the
electrical energy applied across the electrode and workpiece through the electrical parameters like
current, and ON time.
In general the electrical energy per pulse is increased naturally material removal rate increases
and so also the surface roughness and electrode wear. The electrical energy is directly
proportional to the current flowing through the gap and the duration for which the current flowing.
Thus keeping the basic energy constant one can vary the duration constant one can very the
energy going into the gap in that duration. The increased energy also has the direct effect on
overcut and thus can be controlled through the electrical parameters.
2. SELECTION OF VARIABLES
For easy operation of the machine one should know the basic variables in EDM which are to be
selected while machining. Proper knowledge of these variables is advantageous in achieving the
desired results. Following table gives the variables available on the machine and the final results
required from the machine :
VARIABLES END RESULTS
CURRENT Metal Removal Rate

ON TIME Electrode Wear
OFF TIME Surface Finish
GAP VOLTAGE Over Cut
If one of these variables is varied keeping others constant, the end results also vary. As a
guideline following table gives the trend of end results if one variable is increased keeping others
constant.
VARIABLE INCREASED MRR WEAR FINISH OVER CUT
CURRENT Increases Increases Decreases Increases
ON TIME Increases Decreases Decreases Increases
OFF TIME Decreases Increases No effect
GAP VOLTAGE Decreases Increases

If variables are decreased instead of increasing the effect on end results is exactly opposite to that
given in above table.
While selecting the parameters overall effect of all the parameters on the end results is to be seen.
Thus it may be possible that effect of variation in one parameter can be reduced or nullified by
variation in some other parameter. This effect can be used advantageously to improve the end
results like electrode wear or surface finish by changing more than one parameter at a time.
Thus the four electrical parameters given on the pulse generator (viz. ON TIME, Current, OFF
TIME and GAP VOLTAGE used to control the output variables of the spark erosion cavity. It
should be noted that there is no specific rule to quantify exactly the effect of these variables.
Hence the selection of these parameters has to be done based on the experience and the
geometry of electrode. The parameters have to be varied if the geometry of the electrode is
changed.
3. MACHINING PARAMETERS
Ip : Step setting of Peak Current (in Ampere)
This is for selection of pulse peak current.
Range : 0 to 50 A
Higher the Ip settings larger are the peak current value.
Increase in Ip values will increase the pulse discharge energy, which in turn can improve the
removal rate.
For higher value of Ip, gap conditions may become unstable with improper combination of TON and
settings. As and when the discharging conditions becomes unstable one must reduce the Ip value or
decrease to achieve stability.

Ton : Pulse ON Time (in Sec).
During this period the voltage (Vp) is applied across the electrode / Workpiece.
Range : 0.25 to 3000
Ton and current Ip determines together with the average gap voltage the discharge power and has
influence on the surface roughness, overcut and undersize.
The single pulse discharge energy increases with increasing TON period, resulting in higher cutting rate
and reduced electrode wear. With higher values of TON, however, surface roughness tends to be higher.
The higher value of discharge energy, with improper combination of TON, & Ip, may cause arcing /
instability.
: Pulse Duty factor
This is to vary the pulse off time in terms of pulse duty factor in steps.
Range : 1 to 32
Higher the setting, lower is pulse off time i.e. TOFF and larger is the machining efficiency.
With a higher value of , there is more number of discharges in a given time, resulting in increase in
material removal rate (MRR).
Using lower values of may cause slight increase in percent electrode wear and also reduces the
machining efficiency. Value of has only a marginal effect on the surface roughness, overcut and
undersize.
The chart values are given at optimum machining conditions. However, the complicated jobs may require
lower duty factor so as to improve the stability and reduce arcing tendency. As and when the discharging
conditions become unstable one can lower the . With lower pulse duty factor the average gap current will
reduce.
4. GUIDELINE PARAMETERS
Apart from these parameters, the technology guideline chart also includes following two
parameters for process monitoring purpose.
Gap Volt (Sv) : Average gap voltage (in Volts).
This is the actual value of gap voltage read on voltmeter.

Set the value of Gap Voltage, as given in the guideline chart, with the help of Gap control
parameter Sv.
Low values of gap voltage can give rise to increase in removal rate. However, application of very
low values has arcing tendency. Higher values of gap voltage can increase overcut values and
result in relatively lower removal rates.
Gap Cur. (A) : Average machining gap current (in Ampere).
This is the actual value of gap current read on ammeter.

The values of average machining current given in the guideline charts are for test condition
parameters and may be different for actual machining parameters.
Flushing : Flushing pressure (in Kg/cm2) of dielectric through the workpiece
Flushing of the machining gap removes the eroded particles of electrodes (workpiece and tool)
from the gap and keeps it clean and cool. This is important to achieve stable machining condition.
Too low flushing causes accumulation of debris in the machining gap resulting in unstable
machining and arcing tendency.
Too high flushing causes increase in electrode wear.
Keep appropriate flushing pressure.
MRR (mm3/min) : Material Removal rate.
This is a rate of workpiece material removal per unit time.
Calculation of MRR :
1000 x [Weight Loss (gm)]

MRR (mm3/min) = --------------------------------------------------------
Density (gm/cc) x [machining time (min)]
For workpiece material of steel, the formula for M.R.R. can be written as ...
1000 x [Workpiece Weight Difference (gm)]

MRR (mm3/min) = ------------------------------------------------------------------------------
7.8 (gm/cc) x [machining time (min)]
where Density of Steel = 7.8 gm/cc.
% Electrode Wear : It is defined as the ratio of volumetric electrode wear and workpiece material
removal, measured in percent.
Calculation of Electrode Wear :
Case 1. Electrode : Copper

Volumetric 1000 x [Electrode Weight Difference (gm)]
Electrode Wear = ---------------------------------------------------------------------------
(mm3/min) 8.9 (gm/cc) x [machining time (min)]
Case 2. Electrode : Graphite
Volumetric Ele. face area (mm2) x [Ele. Height Difference (mm)]

Electrode = ------------------------------------------------------------------------------
Wear (mm3/min) [machining time (min)]
Volumetric Electrode Wear (mm3/min)

Electrode Wear (%) = ---------------------------------------------------------------- x 100
MRR (mm3/min)
Ra (um) : Average Surface Roughness
This is an average surface roughness value achievable under the test conditions as given in the
technology chart.
Use the surface finish plate for visual comparison of the machined job surface finish.
2G (Gap) (mm) : Overcut
This is the lateral machining gap measured as the difference of machined cavity dimension and
the actual size of electrode, commonly referred as overcut.
2G (mm) = Machined cavity size - Actual electrode size
Use these values for calculating the required size of the electrodes.
RG (Gap) (mm) : Undersize
Undersize is a size with which tool electrode is designed with due consideration to the overcut,
surface roughness and safety margin.
RG (mm) = 2 G + 2 Rmax + Safety Margin
Where, G - sparkgap (overcut)

Rmax (l) -surface roughness on the lateral side

The maximum surface roughness value i.e. Rmax on the sidewall of the cavity bears a relation
with the average roughness value Ra. The surface roughness values - Ra, as quoted in the
technology charts, are the measured values of the frontal surface. Ra values for the lateral cavity
surface, however, are smaller than the frontal Ra values by a factor of about 60 - 70%. Calculate
the lateral average surface roughness Ra (l) by multiplying the chart Ra value with a multiplication
factor of 0.6 - 0.7.
Then the ratios Rmax (lateral) / Ra (lateral) are given for a range value of Ra (l).
Ra (l) (um) Ratio Rmax (l)/Ra (l)
0.1 - 0.2 11 - 9
0.3 - 1.0 7 -6
1.0 - 6.3 4.6 - 5
6.3 - 100 4.6 - 4.3
The purpose of safety margin is to compensate for variations in the mechanical characteristics (i.e.
Rmax & G), inaccuracies in the positioning and making of the electrode, and any conicality (arising
during machining). Too high a value of safety margin affects the erosion time with the next stage.
Too low a value of safety margin may obstacle the removal of roughing traces with the last stage.
For this reason it is preferable to consider RG not as a fixed value but a quantity variable within
small limit.
Somewhat higher values come into consideration as in the following cases :
- If the machining depth is greater than 10 mm

- If the flushing conditions are unfavorable
- If the exchange accuracy of the electrode is not very good
Electrode should be undersized by the appropriate amount keeping in view the safety margin.
Test Area (cm2) : This is the electrode sparking area used under the given test conditions.
Test area, under the given test conditions, has been used keeping in view the safer values of
current density.
5. GUIDELINE ON ANTIARCING CORRECTIVE ACTION
During machining, due to in appropriate machining conditions like poor flushing, gap condition
deteriorates and sometimes may even lead to arcing. Arcing in the gap can ruin the job as well as
the costly formed electrode. An unintentional happening of this kind can be avoided by taking
proper care while machining. Ensure that the machining conditions have been set properly (refer
technology guideline charts).
Machine is provided with twofold in-built facilities to avoid such an incidence like arcing.

These are :
CC1 , CC2 corrective action .
Machining gap is being constantly monitored by the generator unit with the help of Vg. As and
when the arcing tendancy occurs, Vg decreases and generator takes the following corrective
actions. First of all the off time (Toff) is made double in case of CC1.
If the arcing persists then as a next step the ON time is reduced and the OFF time is made 5
times than original.

6. NOTE ON HOW TO SELECT TECHNOLOGY SETTING FOR ROUGHING & FINISHING
The technology charts are given as guidelines for the user. By using the guidelines operator can
plan the machining operations. The guidelines, however, are devised under the test conditions. To
achieve optimum values of removal rate and electrode wear in actual job conditions, one must use
his experience for handling the number of machining parameters.
The guideline charts cover all the possible settings available on the generator. Using the settings
prepared under test conditions, any experienced operator will be able to decide upon the number
of electrodes required and set of machining parameters for a given electrode geometry. In actual
job operation, operator may have to adjust the flushing condition or duty factor and so on. By
applying these conditions appropriately the operator can achieve high removal rate and low
electrode wear.
General Considerations :
Pulse ON period Ton : With a known electrode material, the type of machining (roughing, semi-
finishing or finishing), % electrode wear requirement and the quality of machined surface
(roughing, semi-finishing or finishing) will decide the values of pulse Ton periods to be used during
machining.
Operation --> Finishing Semifinishing Roughing
Ton (uSec) --> 2 - 100 50 - 150 100 - 1000
Pulse ON periods of 1000 or 2000 uSec can be used in roughing operation. With these Ton
periods, however, M.R.R. values are relatively lower with negligible % electrode wear and higher
overcuts.

The above operating conditions are valid, in general, for Cu or Graphite electrodes. With a change
in tool electrode material the range of Ton values may change with the kind of machining
operation.
Current Density :With a known electrode material and size, current density value for the same will
decide machining current setting in roughing operation for the small to medium surface area of the
electrode.
e.g. For copper electrode : Max. Current density : 5 - 7 Amp per cm2
With normal pulse current density is 5 A/cm2 (approx.) in roughing operation.
For graphite electrode : Current density : 7 - 10 Amp per cm2
Current density in roughing operation can be 8 to 12 A/cm2 if higher material removal is desired
and 3 to 7 A/cm2 if lower electrode wear is expected.
For Tungsten Copper : Current density : 12 - 15 Amps per cm2
Gap Voltage :Average gap voltage across the gap can be varied, in situations where the job
under operation is smaller in size, complicated jobs or difficult flushing conditions. Under such
circumstances, generally, the gap voltage maintained should be higher than stated (by about 10 -
20 %). But it results in higher overcut values, which one should take into prior consideration.
Flushing Pressure : In electric discharge machining, flushing is of very much importance, since the
dielectric flushing of the spark gap keeps the gap clean and removes spark eroded particles from
the gap. It has a great influence on machining stability, which in turn affects the removal rate and
electrode wear.
The guideline values given for the flushing pressure may needs to be varied within limits to get
stable machining operation.
Pulse duty factor : As and when the machining operation becomes factor unstable, duty factor may be
lowered (lower values of than stated)
Selection of technology settings for spark machining of a job needs some amount of preplanning
which involves the following steps.
1. Calculate the actual sparking area of electrode (by referring to the required cavity size). Select
accordingly the safe working current with known test area.
Then select Ton periods from the Technology Chart by referring to the % electrode wear values
allowable as per the application.

2. With the selected value of safe working current decide upon the number of operational steps (parameter settings)
from roughing to finishing operation through optional intermediate step of semifinishing. This should be done by
keeping in mind the required job accuracies (like perpendicularity, parallelism, ovality), electrode tool wear and
desired surface finish. Select accordingly the number of electrodes required.
It is not wise to obtain a surface with a surface roughness value of about 1 - 2 um Ra from a rough surface of 10
um Ra or so in just two steps viz. roughing to finishing. Instead, one should adopt an intermediate step of
semifinishing. As a rule of thumb, choose a semifinishing setting with a surface roughness value which is one third
value as that achieved in roughing operation and about twice the value as that is to be achieved in finishing
operation.
The number of electrodes can be 2 to 3 (or more) depending upon the required job precision.
3. With the selected parameter settings calculate the roughing and finishing electrode sizes as :
Electrode size = Required size - (2 G) where 2 G = overcut
As a general practice, first calculate the finishing electrode size with the above expression.
One must leave some machining allowance for finishing operation (generally few hundred
microns, typically 0.2 mm). Next, calculate the semifinishing electrode size with the above
expression, by taking the required size to be the finishing electrode size plus the machining
allowance left for finishing operation. Here again leave some machining allowance for
semifinishing operation (typically 0.5 to 1 mm).
Step 1 : Finishing Electrode Size = E3 = Required cavity size - RG
Where, RG is the undersizing amount for finish machining electrode.
( RG (mm) = 2 G + 2 Rmax + Safety Margin
2 G - Overcut for finish machining setting

2 Rmax - Lateral Surface roughness after finishing
Safety margin - Leave some margin while calculating the Margin electrode size, for lapping or any other post
processing of finished EDM cavity, if required. If not, let this be 0)
Step 2 : Semifinishing Electrode Size = E2 = E3 - RG
Where, RG is the under sizing amount for semifinish machining electrode.
( RG (mm) = 2 G + 2 Rmax + Safety Margin
ELECTRONICA MACHINE TOOLS LTD. 5 : 10

2 G - Overcut for semifinish machining setting
2 Rmax - Lateral Surface roughness after semifinishing
Safety margin - For finish machining operation one must leave some safety margin - typically 0.2
mm.)
Step 3 : Roughing Electrode Size = E1 = E2 - RG
Where, RG is the undersizing amount for rough machining electrode.
RG (mm) = 2 G + 2 Rmax + Safety Margin
2 G - Overcut for rough machining setting

2 Rmax - Lateral Surface roughness after roughing
Safety margin - For semifinish machining operation one must leave some safety margin -
typically 0.5-1 mm)
Calculate minimum electrode height required, by considering the % electrode wear, to erode the
required quantity of job material.
Manufacture the electrodes as per the calculated dimensions and with the required dimensional
accuracies.
7. SURFACE FINISH PLATE ( optional )
Definition : This is a surface finish reference plate provided for reference.

Usage : This is a quick check reference for comparing the machined job finish.
SR. VDI Ra IP TON Vg Ig

NO. NO. M (A) S (V) (A)
1. 12 0.4 1 0.5 10 60 0.05
2. 15 0.56 1 1 10 60 0.08
3. 18 0.8 1 2 10 50 0.5
4. 21 1.12 2 5 12 45 1
5. 24 1.6 2 20 12 45 1.5
6. 27 2.24 3 20 12 45 2
7. 30 3.15 4 50 12 40 3
8. 33 4.5 6 50 26 40 4
9. 36 6.3 8 100 26 36 6
10. 39 9 8 150 26 36 7
11. 42 12 10 200 24 30 7.5
12. 45 18 14 500 24 30 12
NOTE : 1.Test Conditions : Electrode - Oxygen free copper
Workpiece - OHNS (48-50 Rc)
Dielectric EDM oil
2. Use Surface finish Plate for visual
comparison of the machined surface finish.
3. A tolerance of 2 VDI of maximum units has to be allowed in the measure of

surface finish.

* SPECIAL NOTE :
It needs a very high degree of skill to achieve a very good surface finish such as 0.4, 0.56, 0.8
Ra.
Further to this it is necessary to have pre-eroded surface of particular value to achieve such
surface finishes.
It is also necessary that electrode used is having better surface finish than the required surface
finish
In order to achieve this surface finish values it is necessary to follow certain steps before using
final parameters as mentioned in the table for surface finish plate.
Following are the initial parameters to be used for respective settings for VDI 12,15,18
respectively.
VDI 18
1. Achieve the basic surface finish of 0.9 Ra with 25mm dia. Copper electrode.
2. Use following settings before the final finishing settings.
Ton Tau IP IB SV SF TDI TW Rd AFC Polarity

50 16 0 1 75 30 60 0.6 3 101 Nor
20 16 0 1 80 30 60 0.6 3 101 Nor
10 16 0 1 85 30 60 0.6 3 101 Nor
5 16 0 1 90 30 60 0.6 3 101 Nor
Electrode size 10 mm dia.

Electrode lapped to 1/3 of required finish.
VDI 15

5 16 0 1 90 30 60 0.6 3 101 Nor
4 16 0 0 95 30 60 0.6 3 101 Nor
2 16 0 0 95 30 60 0.6 3 101 Nor

VDI 12

2 16 0 0 95 30 60 0.6 3 101 Nor
0.5 16 0 0 95 30 60 0.8 3 101 Nor
2 16 0 0 95 30 60 0.8 5 101 Rev


FINISH REFERENCE CHART
VDI 3400 Ra Rt max. Class
CH Micro mm ISO 1302

0 0.1 0.8
1 0.11 0.88
2 0.12 0.96
N3
3 0.14 1.12
4 0.16 1.28
5 0.18 1.44
6 0.2 1.6
7 0.22 1.76
8 0.25 2
N4
9 0.28 2.24
10 0.32 2.56
11 0.35 2.8
12 0.4 3.2
13 0.45 3.6
14 0.5 4
15 0.56 4.48 N5
16 0.63 5.04
17 0.7 5.6
18 0.8 6.4
19 0.9 7.2
20 1 8
21 1.12 8.96
N6
22 1.26 10.08
23 1.4 11.2
24 1.62 12.96
25 1.8 14.4
26 2 16
27 2.2 17.6 N7
28 2.5 20
29 2.8 22.4
30 3.2 25.6
31 3.5 28
32 4 32
N8
33 4.5 36
34 5 40
35 5.6 44.8
36 6.3 50.4
37 7 56
38 8 64
N9
39 9 72
40 10 80
41 11.2 89.6
42 12.6 100.8
43 14 112
N10
44 16 128
45 18 144

TECHNOLOGY GUIDELINES M/C MODEL :- SCNC SERIES
TRIAL SETUP
TEST CONDITIONS
ELECTRODE (E) COPPER
ELECTRODE POLARITY POSITIVE
WORKPIECE (W) O.H.N.S. (48-53 Rc)
DIELECTRIC EDM OIL
FLUSHING CONDITION PRESSURE FLUSHING, THROUGH WORKPIECE, HOLE
MAINS VOLTAGE # 3PH.,415V LINE TO LINE
TEST TIME 0.5 HR. FOR Ip = 5A & MORE
1.0 HR. FOR Ip < 5A
# NOTE : MAINS VOLTAGE REGULATED WITHIN 1%
VERSION :- 11/2012/03 ELECTRONICA MACHINE TOOLS LTD. T1 PAGE :- 1

ELECTRODE MATERIAL : COPPER DIELECTRIC : EDM OIL PRESSURE FLUSHING

WORKPIECE MATERIAL : STEEL (48 TO 53 HRC ) 0.1 KG /CM 2
Ecode No. Ton TAU IP IB EPOL SV SF TDI MRR % GL GF RA RMAX

WEAR
1 0.25 16 0 A NOR 75 30 60 0.00 0.00 0.5 8.0
2 0.5 16 0 A NOR 75 30 60 0.00 0.00 0.55 8.0
3 1 16 0 A NOR 75 30 60 0.00 0.00 0.58 9.0
4 2 16 0 A NOR 75 30 60 0.00 0.00 0.65 9.0
5 5 16 0 A NOR 75 30 60 0.00 0.00 0.7 10.0
6 10 16 0 A NOR 75 30 60 0.00 0.00 0.75 11.0
7 20 16 0 A NOR 75 30 60 0.00 0.00 0.8 12.0
8 50 16 0 A NOR 75 30 60 0.00 0.00 0.85 12.0
9 100 16 0 A NOR 75 30 60 0.00 0.00 0.9 14.0
10 150 16 0 A NOR 75 30 60 0.00 0.00 0.95 14.0
11 0.25 16 0.5 A NOR 75 30 60 0.02 0.02 0.8 12.0
12 0.5 16 0.5 A NOR 75 30 60 0.02 0.02 0.85 12.0
13 1 16 0.5 A NOR 75 30 60 0.03 0.03 1.2 14.0
14 2 16 0.5 A NOR 75 30 60 0.03 0.03 1.5 14.0
15 5 16 0.5 A NOR 75 30 60 0.04 0.04 1.7 16.0
16 10 16 0.5 A NOR 75 30 60 0.045 0.045 1.9 18.0
17 20 16 0.5 A NOR 75 30 60 0.05 0.05 2 20.0
18 50 16 0.5 A NOR 75 30 60 0.06 0.06 2.2 24.0
19 100 16 0.5 A NOR 75 30 60 0.07 0.07 2.4 28.0
20 150 16 0.5 A NOR 75 30 60 0.08 0.08 2.6 32.0
21 5 16 1 A NOR 75 30 60 2.1 8.5 0.05 0.05 2.00 16.0
22 10 16 1 A NOR 75 30 60 3.6 4.6 0.055 0.055 2.20 20.0
23 20 16 1 A NOR 75 30 60 4.0 2.2 0.06 0.06 2.50 24.0



WEAR
24 50 16 1 A NOR 75 30 60 3.7 1.5 0.070 0.070 2.70 26.0
25 100 16 1 A NOR 75 30 60 3.6 0.5 0.080 0.080 2.90 30.0
26 150 16 1 A NOR 75 30 60 1.8 0.2 0.090 0.090 3.20 34.0
27 200 16 1 A NOR 75 30 60 0.7 0.0 0.010 0.010 3.40 36.0
28
29
30
31 5 20 1.5 A NOR 75 30 60 2.5 8.8 0.060 0.060 2.00 18.0
32 10 20 1.5 A NOR 75 30 60 3.4 3.9 0.065 0.065 2.40 22.0
33 20 20 1.5 A NOR 75 30 60 4.6 1.2 0.070 0.070 2.80 26.0
34 50 20 1.5 A NOR 75 30 60 4.1 0.8 0.080 0.080 3.00 30.0
35 100 20 1.5 A NOR 75 30 60 3.9 0.2 0.095 0.095 3.20 32.0
36 150 20 1.5 A NOR 75 30 60 3.1 0.1 0.110 0.110 3.40 34.0
37 200 20 1.5 A NOR 75 30 60 1.8 0.0 0.125 0.125 3.60 38.0
38
39
40
41 5 20 2 A NOR 75 30 60 2.7 11.2 0.070 0.070 2.20 20.0
42 10 20 2 A NOR 75 30 60 4.6 3.3 0.075 0.075 2.60 25.0
43 20 20 2 A NOR 75 30 60 4.8 1.4 0.080 0.080 3.00 30.0
44 50 20 2 A NOR 75 30 60 4.3 0.9 0.090 0.090 3.40 35.0
45 100 20 2 A NOR 75 30 60 4.1 0.2 0.100 0.100 3.60 38.0
46 150 20 2 A NOR 75 30 60 3.4 0.0 0.115 0.115 3.80 42.0



WEAR
47 200 20 2 A NOR 75 30 60 2.0 0.0 0.130 0.130 4.00 44.00
48 300 20 2 A NOR 75 30 60 1.0 0.0 0.150 0.150 4.20 48.00
49
50
51 5 20 3 A NOR 75 30 60 10.9 5.0 0.080 0.080 3.70 34.00
52 10 20 3 A NOR 75 30 60 11.0 3.0 0.085 0.085 3.80 35.00
53 20 20 3 A NOR 75 30 60 11.3 1.3 0.090 0.090 4.50 38.00
54 50 20 3 A NOR 75 30 60 14.6 1.0 0.100 0.100 4.70 39.00
55 100 20 3 A NOR 75 30 60 11.7 0.1 0.120 0.120 5.70 40.00
56 200 20 3 A NOR 75 30 60 9.9 0.0 0.140 0.140 5.80 48.00
57 300 20 3 A NOR 75 30 60 2.1 0.0 0.160 0.160 6.00 52.00
58
59
60
61 5 26 6 A NOR 60 30 60 15.4 7.0 0.090 0.090 4.40 40.00
62 10 26 6 A NOR 60 30 60 18.7 6.0 0.095 0.095 4.90 46.00
63 20 26 6 A NOR 60 30 60 28.1 2.2 0.100 0.100 5.60 50.00
64 50 26 6 A NOR 60 30 60 24.7 2.2 0.110 0.110 6.00 54.00
65 100 26 6 A NOR 60 30 60 24.3 0.2 0.120 0.120 6.70 57.00
66 150 26 6 A NOR 60 30 60 21.2 0.1 0.140 0.140 6.80 60.00
67 200 26 6 A NOR 60 30 60 20.9 0.1 0.160 0.160 7.00 64.00
68 300 26 6 A NOR 60 30 60 18.2 0.0 0.180 0.180 7.20 68.00
69 400 26 6 A NOR 60 30 60 15.0 0.0 0.200 0.200 7.40 72.00



WEAR
70 750 26 6 A NOR 60 30 60 13.5 0.0 0.220 0.220 7.60 76.00
71 50 26 10 A NOR 60 30 60 42.0 1.3 0.120 0.120 5.80 48.00
72 75 26 10 A NOR 60 30 60 45.0 1.0 0.170 0.170 6.10 56.00
73 100 26 10 A NOR 60 30 60 47.0 0.5 0.140 0.140 6.20 58.00
74 150 26 10 A NOR 60 30 60 42.0 0.2 0.160 0.160 6.50 62.00
75 200 26 10 A NOR 60 30 60 40.0 0.1 0.180 0.180 6.70 67.00
76 300 26 10 A NOR 60 30 60 36.0 0.0 0.200 0.200 7.40 74.00
77 400 26 10 A NOR 60 30 60 35.0 0.0 0.225 0.225 7.80 80.00
78 750 26 10 A NOR 60 30 60 20.0 0.0 0.260 0.260 8.70 89.00
79
80
81 100 26 15 A NOR 60 30 60 76.0 1.0 0.160 0.160 6.40 62.00
82 150 26 15 A NOR 60 30 60 78.0 0.8 0.190 0.190 6.80 64.00
83 200 26 15 A NOR 60 30 60 84.0 0.6 0.205 0.205 7.60 74.00
84 300 26 15 A NOR 60 30 60 80.0 0.0 0.225 0.225 8.00 78.00
85 400 26 15 A NOR 60 30 60 72.0 0.0 0.255 0.255 8.40 82.00
86 500 26 15 A NOR 60 30 60 68.0 0.0 0.280 0.280 10.00 94.00
87 750 26 15 A NOR 60 30 60 64.0 0.0 0.305 0.305 11.50 102.00
88
89
90
91 100 26 20 A NOR 60 30 60 113.0 0.7 0.190 0.190 7.20 68.00
92 150 26 20 A NOR 60 30 60 115.0 0.2 0.215 0.215 7.60 74.00



WEAR
93 200 26 20 A NOR 60 30 60 125.0 0.1 0.230 0.230 8.20 78.00
94 300 26 20 A NOR 60 30 60 102.0 0.0 0.260 0.260 8.60 84.00
95 500 26 20 A NOR 60 30 60 92.0 0.0 0.295 0.295 9.20 90.00
96 750 26 20 A NOR 60 30 60 90.0 0.0 0.330 0.330 9.50 94.00
97 1000 26 20 A NOR 60 30 60 87.0 0.0 0.355 0.355 9.80 96.00
98
99
100
101 150 26 25 A NOR 60 30 60 120.0 1.7 0.240 0.240 7.70 74.00
102 200 26 25 A NOR 60 30 60 135.0 1.4 0.260 0.260 8.40 78.00
103 300 26 25 A NOR 60 30 60 140.0 1.0 0.295 0.295 9.00 86.00
104 400 26 25 A NOR 60 30 60 146.0 0.7 0.320 0.320 9.40 92.00
105 500 26 25 A NOR 60 30 60 138.0 0.0 0.340 0.340 9.70 98.00
106 750 26 25 A NOR 60 30 60 132.0 0.0 0.375 0.375 10.40 108.00
107 1000 26 25 A NOR 60 30 60 128.0 0.0 0.410 0.410 12.00 115.00
108
109
110
111 150 26 30 A NOR 60 30 60 142.0 1.5 0.250 0.250 8.40 82.00
112 200 26 30 A NOR 60 30 60 154.0 1.2 0.265 0.265 8.88 86.00
113 400 26 30 A NOR 60 30 60 162.0 1.0 0.300 0.300 9.40 92.00
114 500 26 30 A NOR 60 30 60 174.0 0.5 0.335 0.335 9.80 96.00
115 1000 26 30 A NOR 60 30 60 158.0 0.0 0.380 0.380 10.40 102.00



WEAR
116 1500 26 30 A NOR 60 30 60 146.0 0.0 0.440 0.440 11.20 112.00
117
118
119
120
121 150 26 35 A NOR 60 30 60 200.0 0.8 0.255 0.255 8.84 84.00
122 200 26 35 A NOR 60 30 60 210.0 0.6 0.275 0.275 9.00 89.00
123 400 26 35 A NOR 60 30 60 218.0 0.5 0.315 0.315 10.00 98.00
124 500 26 35 A NOR 60 30 60 229.0 0.3 0.345 0.345 11.00 105.00
125 1000 26 35 A NOR 60 30 60 207.0 0.2 0.400 0.400 11.50 112.00
126 1500 26 35 A NOR 60 30 60 202.0 0.1 0.455 0.455 12.50 125.00
127 2000 26 35 A NOR 60 30 60 195.0 0.0 0.480 0.480 13.80 137.00
128 3000 26 35 A NOR 60 30 60 182.0 0.0 0.510 0.510 15.20 150.00
129
130
131 150 26 40 A NOR 60 30 60 224.0 0.6 0.265 0.265 10.20 97.00
112 200 26 40 A NOR 60 30 60 234.0 0.5 0.295 0.295 10.40 102.00
133 400 26 40 A NOR 60 30 60 242.0 0.4 0.345 0.345 11.20 110.00
134 500 26 40 A NOR 60 30 60 257.0 0.3 0.360 0.360 12.50 118.00
135 1000 26 40 A NOR 60 30 60 240.0 0.2 0.445 0.445 12.70 125.00
136 1500 26 40 A NOR 60 30 60 226.0 0.0 0.480 0.480 14.00 139.00
137 2000 26 40 A NOR 60 30 60 205.0 0.0 0.495 0.495 15.40 153.00
138 3000 26 40 A NOR 60 30 60 189.0 0.0 0.525 0.525 17.00 165.00



WEAR
139
140
141 200 26 45 A NOR 60 30 60 267.0 0.3 0.310 0.310 11.00 110.00
142 400 26 45 A NOR 60 30 60 307.0 0.2 0.380 0.380 12.80 124.00
143 500 26 45 A NOR 60 30 60 319.0 0.2 0.400 0.400 13.60 130.00
144 1000 26 45 A NOR 60 30 60 305.0 0.2 0.460 0.460 14.00 138.00
145 1500 26 45 A NOR 60 30 60 290.0 0.1 0.485 0.485 15.50 150.00
146 2000 26 45 A NOR 60 30 60 270.0 0.0 0.510 0.510 17.00 168.00
147 3000 26 45 A NOR 60 30 60 250.0 0.0 0.550 0.550 18.70 185.00
148
149
150
151 200 26 50 A NOR 60 30 60 261.0 0.4 0.330 0.330 12.60 124.00
152 400 26 50 A NOR 60 30 60 336.0 0.3 0.410 0.410 14.50 140.00
153 500 26 50 A NOR 60 30 60 352.0 0.2 0.425 0.425 15.20 145.00
154 1000 26 50 A NOR 60 30 60 327.0 0.1 0.475 0.475 16.80 152.00
155 1500 26 50 A NOR 60 30 60 300.0 0.0 0.495 0.495 17.50 165.00
156 2000 26 50 A NOR 60 30 60 285.0 0.0 0.530 0.530 18.50 184.00
157 3000 26 50 A NOR 60 30 60 268.0 0.0 0.575 0.575 20.30 202.00
158
159
160
161
162

TRIAL SETUP
TEST CONDITIONS
ELECTRODE (E) GRAPHITE 1
DIELECTRIC EDM OIL
1.0 HR. FOR Ip < 5A

ELECTRODE MATERIAL : GRAPHITE-1 DIELECTRIC : EDM OIL PRESSURE FLUSHING


WEAR
401 5 16 0 A NOR 75 30 60
402 10 16 0 A NOR 75 30 60
403 20 16 0 A NOR 75 30 60
404 50 16 0 A NOR 75 30 60
405 100 16 0 A NOR 75 30 60
406 150 16 0 A NOR 75 30 60
407 200 16 0 A NOR 75 30 60
408
409
410
411 5 16 0.5 A NOR 75 30 60
412 10 16 0.5 A NOR 75 30 60
413 20 16 0.5 A NOR 75 30 60
414 50 16 0.5 A NOR 75 30 60
415 100 16 0.5 A NOR 75 30 60
416 150 16 0.5 A NOR 75 30 60
417 200 16 0.5 A NOR 75 30 60
418
419
420 2 16 1 A NOR 75 30 60 1.76 1.95 0.05 0.05 2.74 27.26
421 5 16 1 A NOR 75 30 60 1.43 2.77 0.04 0.04 1.45 13.83
422 10 16 1 A NOR 75 30 60 2.50 2.80 0.04 0.04 2.40 14.40
423 20 16 1 A NOR 75 30 60 1.76 1.95 0.05 0.05 2.74 27.26



WEAR
424 30 16 1 A NOR 75 30 60
425 50 16 1 A NOR 75 30 60 2.5 2.80 0.042 0.042 2.4 14.4
426 100 16 1 A NOR 75 30 60 1.23 0.82 0.07 0.07 2.84 28.86
427
428
429
430
431 5 20 1.5 A NOR 75 30 60
432 10 20 1.5 A NOR 75 30 60 1.65 3.52 0.04 0.04 2.68 24.85
433 20 20 1.5 A NOR 75 30 60 2.57 1.40 0.035 0.035 2.87 26.67
434 50 20 1.5 A NOR 75 30 60 1.87 1.38 0.04 0.04 2.74 27.77
435 100 20 1.5 A NOR 75 30 60 1.27 1.22 0.035 0.035 2.87 28.68
436 150 20 1.5 A NOR 75 30 60
437 200 20 1.5 A NOR 75 30 60
438
439
440
441 5 20 2 A NOR 75 30 60
442 10 20 2 A NOR 75 30 60
443 20 20 2 A NOR 75 30 60
444 50 20 2 A NOR 75 30 60
445 100 20 2 A NOR 75 30 60
446 150 20 2 A NOR 75 30 60



WEAR
447 200 20 2 A NOR 75 30 60 1.83 0.30 0.08 0.08 3.57 35.25
448 300 20 2 A NOR 75 30 60 1.13 0.35 0.10 0.10 3.89 37.18
449
450
451 5 20 3 A NOR 75 30 60 7.55 0.99 0.10 0.10 4.59 38.15
452 10 20 3 A NOR 75 30 60 8 2.30 0.06 0.06 3.88 34.76
453 20 20 3 A NOR 75 30 60 12 1.02 0.07 0.07 4.77 39.46
454 50 20 3 A NOR 75 30 60 7.5 0.99 0.10 0.10 4.59 38.15
455 100 20 3 A NOR 75 30 60 10 0.40 0.10 0.10 6.00 36.00
456 200 20 3 A NOR 75 30 60 17.8 0.71 0.11 0.11 5.9 46.21
457 300 20 3 A NOR 75 30 60 21.3 0.51 0.13 0.13 6.14 52.77
458
459
460
461 5 26 6 A NOR 50 30 60
462 10 26 6 A NOR 50 30 60
463 20 26 6 A NOR 50 30 60
464 50 26 6 A NOR 50 30 60 24.75 1.34 0.07 0.07 6.08 54.35
465 100 26 6 A NOR 50 30 60 26.20 0.34 0.10 0.10 6.67 57.20
466 150 26 6 A NOR 50 30 60 29.80 0.30 0.10 0.10 6.85 57.65
467 200 26 6 A NOR 50 30 60 25.35 0.15 0.11 0.11 7.30 57.7
468 300 26 6 A NOR 50 30 60 12.76 0.05 0.12 0.12 7.69 58.74
469 400 26 6 A NOR 50 30 60 4.57 0.05 0.13 0.13 7.90 59.7



WEAR
470 750 26 10 A NOR 50 30 60 29.24 2.20 0.18 0.18 14.00 84.00
471 50 26 10 A NOR 50 30 60 34.28 3.41 0.07 0.07 7.12 51.2
472 75 26 10 A NOR 50 30 60 40.75 2.40 0.09 0.09 7.96 53.65
473 100 26 10 A NOR 50 30 60 43.75 0.59 0.11 0.11 8.24 57.65
474 150 26 10 A NOR 50 30 60 43.48 0.41 0.12 0.12 9.24 60.82
475 200 26 10 A NOR 50 30 60 49.32 0.29 0.13 0.13 9.38 63.11
476 300 26 10 A NOR 50 30 60 45.53 0.05 0.15 0.15 10.47 63.05
477 400 26 10 A NOR 50 30 60 31.62 0.00 0.17 0.17 11.00 64.59
478 750 26 10 A NOR 50 30 60 48.00 0.00 0.19 0.19 18.00 108.00
479
480
481 100 26 15 A NOR 50 30 60 91.44 1.47 0.12 0.12 8.87 56.93
482 150 26 15 A NOR 50 30 60 119.40 1.26 0.12 0.12 9.27 59.42
483 200 26 15 A NOR 50 30 60 72.63 0.10 0.13 0.13 10.95 62.62
484 300 26 15 A NOR 50 30 60 61.29 0.09 0.13 0.13 11.94 64.64
485 400 26 15 A NOR 50 30 60
486 500 26 15 A NOR 50 30 60 50.4 0.06 0.17 0.17 12.05 69.18
487 750 26 15 A NOR 50 30 60 41.87 0.05 0.19 0.19 12.88 72.84
488
489
490
491 100 26 20 A NOR 50 30 60 101.2 0.73 0.24 0.24 13.66 72.49
492 150 26 20 A NOR 50 30 60 121.9 0.6 0.16 0.16 11.9 63.43



WEAR
493 200 26 20 A NOR 50 30 60 117.9 0.98 0.18 0.18 12.33 70.91
494 300 26 20 A NOR 50 30 60 101.2 0.73 0.24 0.24 13.66 72.49
495 500 26 20 A NOR 50 30 60
496 750 26 20 A NOR 50 30 60 0.28 0.28 28 168
497 1000 26 20 A NOR 50 30 60 0.32 0.32 30 192
498
499
500
501 150 26 25 A NOR 50 30 60 181.7 0.63
502 200 26 25 A NOR 50 30 60 195.5 0.58
503 300 26 25 A NOR 50 30 60 132.6 0.56 0.18 0.18 11.86 65.45
504 400 26 25 A NOR 50 30 60 123.9 0.60 0.20 0.20 12.67 72.26
505 500 26 25 A NOR 50 30 60 119.9 0.57 0.20 0.20 13.14 77.88
506
507
508
509
510
511
512 200 26 30 A NOR 50 30 60 257.4 0.42 0.18 0.18 14.20 79.23
513 400 26 30 A NOR 50 30 60 145.9
514
515



WEAR
516
517
518
519
520
521
522
523 400 26 35 A NOR 50 30 60 229.4 0.15 0.225 0.225
524
525
526
527
528
529
530
531
532
533
534 500 26 40 A NOR 50 30 60 261.5 0.28 0.375 0.375
535
536
537
538



WEAR
539
540
541
542
543
544
545
546
547
548
549
550
551 200 26 50 A NOR 50 30 60 363 0.4 0.4 0.4
552 300 26 50 A NOR 50 30 60 351.3 0.31 0.425 0.425
553 400 26 50 A NOR 50 30 60 327.7 0.23 0.45 0.45
554
555
556
557
558
559
560

TRIAL SETUP
TEST CONDITIONS
ELECTRODE (E) GRAPHITE 2
DIELECTRIC EDM OIL
1.0 HR. FOR Ip < 5A



WEAR
801 5 16 0 A NOR 80 30 60 0.61 6.18
802 10 16 0 A NOR 80 30 60 0.62 6.20
803 20 16 0 A NOR 80 30 60 0.63 6.80
804 50 16 0 A NOR 80 30 60 0.68 6.94
805 100 16 0 A NOR 80 30 60 0.70 7.22
806 150 16 0 A NOR 80 30 60 0.77 8.30
807 200 16 0 A NOR 80 30 60 0.83 11.70
808
809
810
811 5 16 0.5 A NOR 80 30 60 1.50 13.70
812 10 16 0.5 A NOR 80 30 60 1.54 13.67
813 20 16 0.5 A NOR 80 30 60 1.72 15.08
814 50 16 0.5 A NOR 80 30 60 1.75 18.71
815 100 16 0.5 A NOR 80 30 60 1.94 19.10
816 150 16 0.5 A NOR 80 30 60 2.13 20.43
817 200 16 0.5 A NOR 80 30 60 2.32 .23.64
818
819
820
821 5 16 1 A NOR 80 30 60 1.43 2.77 0.040 0.040 1.45 13.83
822 10 16 1 A NOR 80 30 60 2.5 2.8 0.045 0.045 2.40 19.45
823 20 16 1 A NOR 80 30 60 2.76 1.95 0.050 0.050 2.74 22.46



WEAR
824 50 16 1 A NOR 80 30 60 2.15 1.45 0.065 0.065 2.82 24.85
825 100 16 1 A NOR 80 30 60 1.9 1.26 0.070 0.070 3.04 26.35
826 150 16 1 A NOR 80 30 60 1.23 0.82 0.085 0.085 3.12 28.86
827 200 16 1 A NOR 80 30 60 1.1 0.65 0.095 0.095 3.98 29.85
828
829
830
831 5 20 1.5 A NOR 75 30 60 1.62 10.25 0.050 0.050 2.10 18.62
832 10 20 1.5 A NOR 75 30 60 1.19 6.29 0.065 0.065 2.40 19.40
833 20 20 1.5 A NOR 75 30 60 2.62 4.89 0.075 0.075 2.85 21.45
834 50 20 1.5 A NOR 75 30 60 2.32 3.8 0.085 0.085 3.15 22.86
835 100 20 1.5 A NOR 75 30 60 2.56 2.25 0.100 0.100 3.35 26.90
836 150 20 1.5 A NOR 75 30 60 2.62 1.89 0.115 0.115 3.90 30.45
837 200 20 1.5 A NOR 75 30 60 2.71 1.35 0.125 0.125 4.15 35.80
838
839
840
841 5 20 2 A NOR 75 30 60 1.46 12.32 0.060 0.060 2.35 18.41
842 10 20 2 A NOR 75 30 60 1.61 7.45 0.075 0.075 2.60 20.18
843 20 20 2 A NOR 75 30 60 2.75 5.50 0.090 0.090 2.90 24.48
844 50 20 2 A NOR 75 30 60 3.12 3.33 0.100 0.100 3.45 30.00
845 100 20 2 A NOR 75 30 60 3.45 2.89 0.110 0.110 4.30 35.45
846 150 20 2 A NOR 75 30 60 3.60 1.25 0.125 0.125 4.80 40.18



WEAR
847 200 20 2 A NOR 75 30 60 6.23 0.3 0.130 0.130 5.00 42.86
848
849
850
851 5 20 3 A NOR 75 30 60 3.67 22.07 0.055 0.055 4.59 34.76
852 10 20 3 A NOR 75 30 60 8.77 9.69 0.080 0.080 4.88 36.45
853 20 20 3 A NOR 75 30 60 10.18 8.78 0.105 0.105 4.92 39.46
854 50 20 3 A NOR 75 30 60 19.82 1.32 0.110 0.110 5.40 38.15
855 100 20 3 A NOR 75 30 60 16.85 1.33 0.130 0.130 5.80 40.12
856 150 20 3 A NOR 75 30 60 13.94 0.785 0.145 0.145 6.20 42.35
857 200 20 3 A NOR 75 30 60 10.23 0.52 0.160 0.160 6.35 44.65
858
859
860
861 5 26 6 A NOR 60 30 60 16.02 3.82 0.070 0.070 4.80 36.85
862 10 26 6 A NOR 60 30 60 23.10 2.83 0.095 0.095 5.20 39.85
863 20 26 6 A NOR 60 30 60 30.80 1.50 0.105 0.105 5.80 45.80
864 50 26 6 A NOR 60 30 60 31.80 1.45 0.120 0.120 6.08 54.35
865 100 26 6 A NOR 60 30 60 33.69 1.42 0.140 0.140 6.67 56.20
866 150 26 6 A NOR 60 30 60 35.46 1.40 0.160 0.160 6.85 57.65
867 200 26 6 A NOR 60 30 60 38.21 1.34 0.175 0.175 7.30 59.70
868 300 26 6 A NOR 60 30 60 32.8 1.12 0.190 0.190 7.80 64.50
869



WEAR
870
871 20 26 10 A NOR 60 30 60 40.46 4.52 0.120 0.120 5.80 45.45
872 50 26 10 A NOR 60 30 60 41.26 4.12 0.125 0.125 6.80 53.25
873 100 26 10 A NOR 60 30 60 43.21 3.76 0.150 0.150 8.24 57.65
874 150 26 10 A NOR 60 30 60 45.30 3.20 0.175 0.175 9.24 60.82
875 200 26 10 A NOR 60 30 60 45.30 2.8 0.180 0.180 9.38 63.11
876 300 26 10 A NOR 60 30 60 48.66 2.2 0.195 0.195 10.47 65.25
877 400 26 10 A NOR 60 30 60 59.87 1.80 0.215 0.215 11.00 66.31
878
879
880
881 20 26 15 A NOR 60 30 60 50.5 2.0 0.130 0.130 8.87 56.93
882 50 26 15 A NOR 60 30 60 51.52 1.9 0.140 0.140 9.35 58.00
883 100 26 15 A NOR 60 30 60 50.19 1.6 0.170 0.170 10.95 62.62
884 150 26 15 A NOR 60 30 60 70.17 1.31 0.180 0.180 11.50 64.56
885 200 26 15 A NOR 60 30 60 53.55 0.15 0.185 0.185 10.38 67.45
886 300 26 15 A NOR 60 30 60 66.24 0.13 0.210 0.210 12.05 69.18
887 400 26 15 A NOR 60 30 60 61.965 0.13 0.225 0.225 11.21 72.84
888 500 26 15 A NOR 60 30 60 54.7 0 0.240 0.240 13.15 74.58
889 750 26 15 A NOR 60 30 60 52.14 0 0.250 0.250 13.95 86.50
890
891 20 26 20 A NOR 60 30 60 95.3 0.3 0.140 0.140 9.98 56.83
892 50 26 20 A NOR 60 30 60 94.96 3.86 0.150 0.150 11.90 63.43



WEAR
893 100 26 20 A NOR 60 30 60 111.08 2.38 0.170 0.170 12.33 70.91
894 150 26 20 A NOR 60 30 60 116.71 2.12 0.190 0.190 13.66 72.49
895 200 26 20 A NOR 60 30 60 136.98 1.7 0.200 0.200 14.47 74.55
896 300 26 20 A NOR 60 30 60 142 1.13 0.220 0.220 15.19 79.25
897 400 26 20 A NOR 60 30 60 147.85 0.98 0.235 0.235 15.68 82.45
898 500 26 20 A NOR 60 30 60 145 0.32 0.260 0.260 15.82 88.56
899
900
901 50 26 25 A NOR 60 30 60 132.32 4.5 0.170 0.170 12.31 80.00
902 100 26 25 A NOR 60 30 60 137.45 3.8 0.185 0.185 12.92 84.00
903 150 26 25 A NOR 60 30 60 142.53 3.2 0.205 0.205 14.03 87.00
904 200 26 25 A NOR 60 30 60 154.12 2.2 0.230 0.230 14.15 92.00
905 300 26 25 A NOR 60 30 60 160.78 1.75 0.245 0.245 14.77 96.00
906 400 26 25 A NOR 60 30 60 175.45 1.02 0.270 0.270 15.38 100.00
907 500 26 25 A NOR 60 30 60 162.14 0 0.285 0.285 16.46 107.00
908
909
910
911 75 26 30 A NOR 60 30 60 160.57 4.88 0.180 0.180 13.65 82.50
912 100 26 30 A NOR 60 30 60 169.43 3.31 0.200 0.200 14.31 93.00
913 150 26 30 A NOR 60 30 60 163.66 1.46 0.220 0.220 15.48 96.00
914 200 26 30 A NOR 60 30 60 141.77 1.01 0.240 0.240 15.69 102.00
915 300 26 30 A NOR 60 30 60 140.31 0.88 0.270 0.270 16.62 108.00



WEAR
916 500 26 30 A NOR 60 30 60 127.35 0.37 0.420 0.420 17.85 116.00
917
918
919
920
921 75 26 35 A NOR 60 30 60 170.09 0.27 0.200 0.200 16.12 92.00
922 150 26 35 A NOR 60 30 60 259.83 0.18 0.220 0.220 17.10 106.00
923 200 26 35 A NOR 60 30 60 229.4 0.15 0.275 0.275 17.23 112.00
924 300 26 35 A NOR 60 30 60 234.19 0 0.350 0.350 17.69 115.00
925 400 26 35 A NOR 60 30 60 220.51 0 0.400 0.400 18.46 120.00
926 500 26 35 A NOR 60 30 60 157.26 0 0.480 0.480 19.38 126.00
927
928
929
930
931 75 26 40 A NOR 60 30 60 208.55 0.26 0.240 0.240 17.25 102.54
932 150 26 40 A NOR 60 30 60 279.49 0.19 0.280 0.280 18.55 115.00
933 200 26 40 A NOR 60 30 60 274.36 0.17 0.360 0.360 18.86 120.00
934 300 26 40 A NOR 60 30 60 229.06 0 0.380 0.380 19.54 127.00
935 400 26 40 A NOR 60 30 60 220.43 0 0.400 0.400 19.85 129.00
936 500 26 40 A NOR 60 30 60 197.44 0 0.420 0.420 21.38 139.00
937
938



WEAR
939
940
941 150 26 45 A NOR 60 30 60 228.64 0.43 0.320 0.320 20.02 126.00
942 200 26 45 A NOR 60 30 60 292.58 0.36 0.360 0.360 20.80 130.00
943 300 26 45 A NOR 60 30 60 297.7 0.3 0.420 0.420 20.92 134.00
944 400 26 45 A NOR 60 30 60 265.81 0.2 0.460 0.460 21.38 139.00
945 500 26 45 A NOR 60 30 60 220.51 0.17 0.500 0.500 22.62 147.00
946
947
948
949
950
951 150 26 50 A NOR 60 30 60 244.44 0.42 0.360 0.360 21.10 137.00
952 200 26 50 A NOR 60 30 60 363 0.4 0.400 0.400 21.85 142.00
953 300 26 50 A NOR 60 30 60 351.3 0.31 0.425 0.425 22.46 146.00
954 400 26 50 A NOR 60 30 60 327.7 0.23 0.450 0.450 22.92 149.00
955 500 26 50 A NOR 60 30 60 326.5 0.16 0.560 0.560 24.00 156.00
956
957
958
959
960

TRIAL SETUP
TEST CONDITIONS
ELECTRODE (E) COPPER TUNGSTEN
ELECTRODE POLARITY NEGATIVE
WORKPIECE (W) CARBIDE
DIELECTRIC EDM OIL
FLUSHING CONDITION PRESSURE FLUSHING, THROUGH WORKPIECE, HOLE DIA.6MM
1.0 HR. FOR Ip < 5A


WORKPIECE MATERIAL : CARBIDE (REV) 0.1 KG /CM 2

WEAR
2801 2 16 0 A REV 40 30 60 0.60 3.80
2802 5 16 0 A REV 40 30 60 0.70 4.60
2803 10 16 0 A REV 40 30 60 0.80 7.50
2804 20 16 0 A REV 40 30 60 0.90 8.40
2805 50 16 0 A REV 40 30 60 1.20 12.40
2806
2807
2808
2809
2810
2811 2 16 1 A REV 40 30 60 0.70 5.40
2812 5 16 1 A REV 40 30 60 0.80 6.00
2813 10 16 1 A REV 40 30 60 0.90 7.90
2814 20 16 1 A REV 40 30 60 1.20 9.80
2815
2816
2817
2818
2819
2820
2821 2 16 1 A REV 40 30 60 0.80 8.00
2822 5 16 1 A REV 40 30 60 0.90 8.60
2823 10 16 1 A REV 40 30 60 0.90 9.30



WEAR
2824 20 16 1 A REV 40 30 60 1.20 10.60
2825
2826
2827
2828
2829
2830
2831 2 16 2 A REV 40 30 60 1.00 8.70
2832 5 16 2 A REV 40 30 60 1.20 9.40
2833 10 16 2 A REV 40 30 60 1.40 11.90
2834 20 16 2 A REV 40 30 60 1.60 14.60
2835
2836
2837
2838
2839
2840
2841 2 16 2 A REV 40 30 60 1.10 9.60
2842 5 16 2 A REV 40 30 60 1.10 11.10
2843 10 16 2 A REV 40 30 60 1.40 12.80
2844 20 16 2 A REV 40 30 60 1.80 16.30
2845
2846



WEAR
2847
2848
2849
2850
2851 2 16 3 A REV 40 30 60 0.49 23.15 0.03 0.03 1.40 11.50
2852 5 16 3 A REV 40 30 60 0.53 22.60 0.03 0.03 1.50 12.60
2853 10 16 3 A REV 40 30 60 0.43 21.62 0.05 0.05 1.70 16.50
2854 20 16 3 A REV 40 30 60 0.54 20.34 0.08 0.08 2.60 18.90
2855
2856
2857
2858
2859
2860
2861 5 16 6 A REV 40 30 60 1.95 31.50 0.04 0.04 1.60 17.20
2862 10 16 6 A REV 40 30 60 1.23 24.58 0.05 0.05 2.20 18.80
2863 20 16 6 A REV 40 30 60 1.10 28.15 0.06 0.06 2.90 21.00
2864 30 16 6 A REV 40 30 60 2.56 26.23 0.08 0.08 3.80 23.80
2865 50 16 6 A REV 40 30 60 3.92 23.45 0.11 0.11 4.90 29.30
2866
2867
2868
2869



WEAR
2870
2871 10 16 10 A REV 40 30 60 3.98 31.14 0.06 0.06 2.60 21.00
2872 20 16 10 A REV 40 30 60 4.43 28.58 0.07 0.07 3.30 27.20
2873 30 16 10 A REV 40 30 60 3.70 26.48 0.09 0.09 4.10 29.80
2874 50 16 10 A REV 40 30 60 4.87 24.21 0.13 0.13 5.00 34.40
2875
2876
2877
2878
2879
2880
2881 10 16 15 A REV 40 30 60 6.30 43.60 0.08 0.08 3.40 27.20
2882 20 16 15 A REV 40 30 60 8.33 43.86 0.10 0.10 3.90 32.30
2883 30 16 15 A REV 40 30 60 7.75 40.68 0.12 0.12 4.60 36.30
2884 50 16 15 A REV 40 30 60 9.14 36.89 0.15 0.15 5.70 39.90
2885 75 16 15 A REV 40 30 60 12.31 34.22 0.18 0.18 7.10 48.50
2886
2887
2888
2889
2890
2891 10 16 20 A REV 40 30 60 7.57 67.40 0.10 0.10 3.60 29.70
2892 20 16 20 A +VE 40 30 60 8.84 53.60 0.11 0.11 4.30 35.50



WEAR
2893 30 16 20 A REV 40 30 60 9.54 52.17 0.13 0.13 4.90 44.90
2894 50 16 20 A REV 40 30 60 10.63 49.45 0.17 0.17 6.10 52.20
2895 75 16 20 A REV 40 30 60 14.11 46.62 0.19 0.19 8.50 57.30
2896
2897
2898
2899
2900
2901 10 16 25 A REV 40 30 60 9.27 71.45 0.12 0.12 4.40 38.20
2902 20 16 25 A REV 40 30 60 10.60 68.60 0.14 0.14 5.10 47.70
2903 30 16 25 A REV 40 30 60 10.88 61.63 0.15 0.15 6.10 53.30
2904 50 16 25 A REV 40 30 60 11.68 56.70 0.18 0.18 7.30 59.30
2905 75 16 25 A REV 40 30 60 15.74 51.96 0.21 0.21 9.40 65.30
2906
2907
2908
2909
2910
2911 10 16 30 A REV 40 30 60 11.81 82.20 0.13 0.13 4.90 41.70
2912 20 16 30 A REV 40 30 60 12.13 76.85 0.15 0.15 5.80 49.80
2913 30 16 30 A REV 40 30 60 12.52 70.80 0.17 0.17 6.80 58.10
2914 50 16 30 A REV 40 30 60 13.99 65.12 0.20 0.20 8.10 68.80
2915 75 16 30 A REV 40 30 60 17.86 59.60 0.24 0.24 11.10 74.20



WEAR
2916
2917
2918
2919
2920
2921 10 16 35 A REV 40 30 60 14.11 91.94 0.15 0.15 6.50 47.20
2922 20 16 35 A REV 40 30 60 15.00 83.87 0.16 0.16 7.80 56.10
2923 30 16 35 A REV 40 30 60 14.94 77.16 0.18 0.18 8.60 64.70
2924 40 16 35 A REV 40 30 60 15.17 74.20 0.20 0.20 9.30 68.80
2925 50 16 35 A REV 40 30 60 16.24 71.60 0.23 0.23 10.40 75.10
2926 75 16 35 A REV 40 30 60 19.20 66.34 0.26 0.26 12.70 83.00
2927
2928
2929
2930
2931 10 16 40 A REV 40 30 60 15.67 96.23 0.17 0.17 6.70 52.40
2932 20 16 40 A REV 40 30 60 16.28 87.54 0.19 0.19 8.00 63.90
2933 30 16 40 A REV 40 30 60 16.35 81.30 0.20 0.20 9.30 72.80
2934 40 16 40 A REV 40 30 60 17.11 79.65 0.22 0.22 10.60 77.50
2935 50 16 40 A REV 40 30 60 17.85 75.50 0.25 0.25 12.70 81.00
2936 75 16 40 A REV 40 30 60 20.92 69.78 0.29 0.29 15.70 92.50
2937
2938



WEAR
2939
2940
2941 10 16 45 A REV 40 30 60 17.26 98.96 0.18 0.18 7.00 57.50
2942 20 16 45 A REV 40 30 60 18.20 91.45 0.20 0.20 8.30 68.30
2943 30 16 45 A REV 40 30 60 18.15 87.65 0.21 0.21 10.10 78.00
2944 40 16 45 A REV 40 30 60 19.17 84.23 0.24 0.24 12.80 88.10
2945 50 16 45 A REV 40 30 60 20.10 80.00 0.27 0.27 14.30 93.90
2946 75 16 45 A REV 40 30 60 22.07 73.86 0.31 0.31 18.90 101.70
2947
2948
2949
2950
2951 10 16 50 A REV 40 30 60 19.13 103.00 0.20 0.20 7.40 62.80
2952 20 16 50 A REV 40 30 60 19.75 99.56 0.21 0.21 9.00 72.50
2953 30 16 50 A REV 40 30 60 20.27 93.70 0.23 0.23 12.30 85.40
2954 40 16 50 A REV 40 30 60 21.01 89.26 0.26 0.26 15.00 92.00
2955 50 16 50 A REV 40 30 60 20.22 84.40 0.29 0.29 17.10 98.20
2956 75 16 50 A REV 40 30 60 23.96 79.86 0.34 0.34 22.70 109.40
2957
2958
2959
2960

TRIAL SETUP
TEST CONDITIONS
ELECTRODE (E) COPPER TUNGSTEN
ELECTRODE POLARITY NEGATIVE
WORKPIECE (W) CARBIDE
DIELECTRIC EDM OIL
FLUSHING CONDITION PRESSURE FLUSHING, THROUGH WORKPIECE, HOLE DIA.6MM
1.0 HR. FOR Ip < 5A

ELECTRODE MATERIAL : TUNGSTEN COPPER DIELECTRIC : EDM OIL PRESSURE FLUSHING


WEAR
3201 2 16 0 A REV 40 30 60 0.60 3.10
3202 5 16 0 A REV 40 30 60 0.80 4.80
3203 10 16 0 A REV 40 30 60 0.80 6.40
3204 20 16 0 A REV 40 30 60 0.90 8.40
3205 50 16 0 A REV 40 30 60 1.20 12.80
3206
3207
3208
3209
3210
3211 2 16 0.5 A REV 40 30 60 0.70 5.40
3212 5 16 0.5 A REV 40 30 60 0.70 6.90
3213 10 16 0.5 A REV 40 30 60 0.90 8.10
3214 20 16 0.5 A REV 40 30 60 1.10 9.90
3215
3216
3217
3218
3219
3220
3221 2 16 1 A REV 40 30 60 0.70 7.30
3222 5 16 1 A REV 40 30 60 0.80 8.10
3223 10 16 1 A REV 40 30 60 1.00 9.70



WEAR
3224 20 16 1 A REV 40 30 60 1.30 11.20
3225
3226
3227
3228
3229
3230
3231 2 16 1.5 A REV 40 30 60 1.20 8.50
3232 5 16 1.5 A REV 40 30 60 1.20 9.60
3233 10 16 1.5 A REV 40 30 60 1.30 10.40
3234 20 16 1.5 A REV 40 30 60 1.60 12.90
3235
3236
3237
3238
3239
3240
3241 2 16 2 A REV 40 30 60 1.40 7.70
3242 5 16 2 A REV 40 30 60 1.40 10.10
3243 10 16 2 A REV 40 30 60 1.60 13.30
3244 20 16 2 A REV 40 30 60 1.90 15.70
3245
3246



WEAR
3247
3248
3249
3250
3251 2 16 3 A REV 40 30 60 0.65 29.20 0.04 0.04 1.40 10.10
3252 5 16 3 A REV 40 30 60 0.88 21.00 0.05 0.05 1.50 12.00
3253 10 16 3 A REV 40 30 60 0.92 14.50 0.07 0.07 1.90 12.80
3254 20 16 3 A REV 40 30 60 0.94 14.40 0.08 0.08 2.70 14.20
3255 50 16 3 A REV 40 30 60 0.82 13.70 0.11 0.11 3.70 27.90
3256
3257
3258
3259
3260
3261 5 16 6 A REV 40 30 60 1.88 16.67 0.09 0.09 2.10 13.60
3262 10 16 6 A REV 40 30 60 2.85 14.76 0.11 0.11 2.80 17.80
3263 20 16 6 A REV 40 30 60 4.31 14.35 0.12 0.12 3.30 21.00
3264 30 16 6 A REV 40 30 60 2.31 14.16 0.13 0.13 3.70 26.70
3265 50 16 6 A REV 40 30 60 1.68 14.02 0.14 0.14 4.30 30.10
3266
3267
3268
3269



WEAR
3270
3271 5 16 10 A REV 40 30 60 3.80 19.25 0.11 0.11 2.28 14.80
3272 10 16 10 A REV 40 30 60 4.31 17.40 0.13 0.13 3.10 23.50
3273 20 16 10 A REV 40 30 60 5.72 16.07 0.14 0.14 3.50 27.70
3274 30 16 10 A REV 40 30 60 6.05 16.45 0.15 0.15 3.90 32.40
3275 50 16 10 A REV 40 30 60 5.11 15.87 0.17 0.17 5.10 39.60
3276
3277
3278
3279
3280
3281 10 16 15 A REV 40 30 60 8.18 21.0 0.15 0.15 3.80 30.20
3282 20 16 15 A REV 40 30 60 8.64 19.35 0.16 0.16 4.20 35.20
3283 30 16 15 A REV 40 30 60 8.46 19.05 0.17 0.17 4.80 40.10
3284 50 16 15 A REV 40 30 60 8.08 19 0.19 0.19 5.90 46.70
3285 75 16 15 A REV 40 30 60 7.84 18.25 0.21 0.21 6.08 48.60
3286
3287
3288
3289
3290
3291 10 16 20 A REV 40 30 60 8.88 29.42 0.17 0.17 4.30 32.80
3292 20 16 20 A REV 40 30 60 10.45 27.23 0.18 0.18 4.80 38.60



WEAR
3293 30 16 20 A REV 40 30 60 14.75 25.61 0.19 0.19 5.43 43.40
3294 50 16 20 A REV 40 30 60 11.86 24.71 0.21 0.21 6.50 50.70
3295 75 16 20 A REV 40 30 60 10.25 21.45 0.22 0.22 7.15 57.20
3296
3297
3298
3299
3300
3301 10 16 25 A REV 40 30 60 12.03 22.25 0.19 0.19 4.60 36.80
3302 20 16 25 A REV 40 30 60 12.05 21.75 0.2 0.2 5.46 43.70
3303 30 16 25 A REV 40 30 60 14.61 21.29 0.21 0.21 6.55 52.40
3304 50 16 25 A REV 40 30 60 13.9 20.9 0.23 0.23 7.19 57.50
3305 75 16 25 A REV 40 30 60 12.15 18.45 0.25 0.25 7.99 63.90
3306
3307
3308
3309
3310
3311 10 16 30 A REV 40 30 60 14.68 22.2 0.20 0.20 5.38 43.00
3312 20 16 30 A REV 40 30 60 16.42 19.16 0.21 0.21 6.28 50.20
3313 30 16 30 A REV 40 30 60 16.69 18.18 0.23 0.23 7.11 56.90
3314 50 16 30 A REV 40 30 60 16.23 17.96 0.24 0.24 8.08 64.60
3315 75 16 30 A REV 40 30 60 15.95 16.25 0.26 0.26 9.16 73.30



WEAR
3316
3317
3318
3319
3320
3321 10 16 35 A REV 40 30 60 17.62 28.43 0.21 0.21 5.94 47.50
3322 20 16 35 A REV 40 30 60 18.32 25.40 0.22 0.22 7.05 56.40
3323 30 16 35 A REV 40 30 60 20.25 25.15 0.23 0.23 8.05 64.40
3324 40 16 35 A REV 40 30 60 22.27 23.67 0.24 0.24 8.45 67.62
3325 50 16 35 A REV 40 30 60 25.27 23.17 0.26 0.26 9.03 72.20
3326 75 16 35 A REV 40 30 60 23.45 21.59 0.28 0.28 9.75 78.00
3327
3328
3329
3330
3331 10 16 40 A REV 40 30 60 18.50 25.15 0.22 0.22 6.59 52.70
3332 20 16 40 A REV 40 30 60 23.63 24.97 0.23 0.23 8.38 67.00
3333 30 16 40 A REV 40 30 60 25.27 24.51 0.24 0.24 8.78 70.20
3334 40 16 40 A REV 40 30 60 26.67 24.52 0.25 0.25 9.21 73.71
3335 50 16 40 A REV 40 30 60 25.04 23.01 0.27 0.27 9.68 77.40
3336 75 16 40 A REV 40 30 60 23.45 21.45 0.31 0.31 10.84 86.70
3337
3338



WEAR
3339
3340
3341 10 16 45 A REV 40 30 60 23.42 25.80 0.23 0.23 7.20 57.60
3342 20 16 45 A REV 40 30 60 26.61 26.26 0.24 0.24 8.48 67.80
3343 30 16 45 A REV 40 30 60 30.46 26.35 0.25 0.25 9.48 75.80
3344 40 16 45 A REV 40 30 60 30.15 26.18 0.26 0.26 9.95 79.59
3345 50 16 45 A REV 40 30 60 19.48 25.31 0.28 0.28 10.76 86.10
3346 75 16 45 A REV 40 30 60 17.45 23.26 0.34 0.34 11.94 95.50
3347
3348
3349
3350
3351 10 16 50 A REV 40 30 60 27.64 30.44 0.25 0.25 7.86 62.90
3352 20 16 50 A REV 40 30 60 31.40 30.99 0.26 0.26 9.21 73.70
3353 30 16 50 A REV 40 30 60 35.94 31.09 0.28 0.28 10.38 83.00
3354 40 16 50 A REV 40 30 60 35.58 30.89 0.31 0.31 10.89 87.15
3355 50 16 50 A REV 40 30 60 22.99 29.87 0.33 0.33 11.66 93.30
3356 75 16 50 A REV 40 30 60 20.59 27.45 0.35 0.35 13.01 104.10
3357
3358
3359
3360

ELECTRODE MATERIAL : GR2 DIELECTRIC : EDM OIL PRESSURE FLUSHING

WORKPIECE MATERIAL : TITANIUM 0.1 KG /CM 2
Sr. No Ton TAU IP IB EPOL SV SF TDI MRR %

WEAR
1 75 12 6 A REV 80 30 60 9.8 43
2 100 12 6 A REV 80 30 60 7.8 33
3 100 12 10 A REV 80 30 60 12.2 39
4 200 12 10 A REV 80 30 60 18.7 25
5 150 12 15 A REV 80 30 60 22.5 28
6 200 12 15 A REV 80 30 60 22.4 22
7 150 12 20 A REV 80 30 60 22.1 39
8 200 12 20 A REV 80 30 60 26.7 32
9 200 12 25 A REV 80 30 60 38.2 43
10 300 12 25 A REV 80 30 60 66.3 23
VERSION :- 11/2012/03 ELECTROICA MACHINE TOOLS LTD. T6 PAGE : 1

ELECTRODE MATERIAL : ALUMINUM DIELECTRIC : EDM OIL PRESSURE FLUSHING

WORKPIECE MATERIAL : ALUMINUM 0.1 KG /CM 2
SR. TON Tau IP IB EPOL SV SF TDI MRR %

NO. MM / min WEAR
1. 5 18 3 A NOR 75 30 60 1.2 50.0

2. 10 18 3 A NOR 75 30 60 1.2 25.0
3. 20 18 3 A NOR 75 30 60 2.5 7.5
4. 50 18 3 A NOR 75 30 60 2.5 5.0
5. 100 18 3 A NOR 75 30 60 6.2 0.0
6. 5 18 6 A NOR 50 30 60 4.9 80.0
7. 10 18 6 A NOR 50 30 60 4.9 75.0
8. 20 18 6 A NOR 50 30 60 7.4 36.7
9. 50 18 6 A NOR 50 30 60 7.4 13.3
10. 100 18 6 A NOR 50 30 60 19.8 2.5
11. 150 18 6 A NOR 50 30 60 49.4 0.0
12. 200 18 6 A NOR 50 30 60 39.5 0.0
13. 50 18 10 A NOR 50 30 60 24.7 20.0
14. 75 18 10 A NOR 50 30 60 54.3 9.1
15. 100 18 10 A NOR 50 30 60 123.5 8.0
16. 150 18 10 A NOR 50 30 60 103.7 4.8
17. 200 18 10 A NOR 50 30 60 113.6 0.0
18. 100 18 15 A NOR 50 30 60 187.7 2.6
19. 150 18 15 A NOR 50 30 60 197.5 2.5
20. 200 18 15 A NOR 50 30 60 197.5 2.5
21. 400 18 15 A NOR 50 30 60 192.6 2.6

ELECTRODE MATERIAL : ALUMINUM DIELECTRIC : EDM OIL PRESSURE FLUSHING

WORKPIECE MATERIAL : ALUMINUM 0.1 KG /CM 2
SR. TON Tau IP IB EPOL SV SF TDI MRR %

NO. MM / min WEAR
22. 100 18 20 A NOR 50 30 60 123.5 8.0

23. 150 18 20 A NOR 50 30 60 182.7 5.4
24. 200 18 20 A NOR 50 30 60 251.9 2.0
25. 400 18 20 A NOR 50 30 60 222.2 1.1
26. 100 18 30 A NOR 50 30 60 419.8 4.1
27. 150 18 30 A NOR 50 30 60 464.2 3.2
28. 200 18 30 A NOR 50 30 60 395.1 3.1
29. 400 18 30 A NOR 50 30 60 424.7 2.3
30. 100 18 40 A NOR 50 30 60 414.8 3.6
31. 150 18 40 A NOR 50 30 60 622.2 3.2
32. 200 18 40 A NOR 50 30 60 666.7 2.2
33. 400 18 40 A NOR 50 30 60 444.4 2.2
34. 200 18 50 A NOR 50 30 60 760.5 3.2
35. 400 18 50 A NOR 50 30 60 879 2.8
36. 500 18 50 A NOR 50 30 60 691.4 2.1

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Technology Manual

Product : SMART CNC / XPERT

HEAD OFFICE : FACTORY :

Electronica Machine Tools Ltd. Electronica Machine Tools Ltd.

CHAPTER IV : Setting up and Operation 4:1

Special Technology charts :

T6: Gr.2 To Titanium.

(A) EDM Principle

Electric discharge machining (EDM) is a process of repetitive sparking cycles.

Graphical Representation of Sparking Cycles

Series of Electrical Pulses At The Interelectrode Gap

Interelectrode Gap Voltage Waveform During Sparking

Interelectrode Gap Current Waveform During Sparking

Where : TON : Pulse ON period

ELECTRONICA MACHINE TOOLS LTD. 1:1

To achieve optimum results of material removal rate, overcut or surface-finish, the

(B) CONCEPT OF EDM

ELECTRONICA MACHINE TOOLS LTD. 1: 2

ELECTRONICA MACHINE TOOLS LTD. 1:3

Adequate arrangement of flushing holes is made.

The main fields of spark erosion application are -

For micro and fine to medium machining, or up to a working current of appr.80A, a

Applications of micro machining are :

- Spinnerets (Synthetic products)

ELECTRONICA MACHINE TOOLS LTD 2:1

Stability itself depends on

Flushing conditions are controlled by quantity of dielectric flowing in the gap.

ELECTRONICA MACHINE TOOLS LTD 2:2

4. REMOVAL OF WASTE PARTICLES :

ELECTRONICA MACHINE TOOLS LTD 3:1

CHARACTERISTICS TEST METHODS SEO 203 SEO 350 SEO 450

The following types of flushing can be used in spark erosion process :

Arrangement of flushing holes is very important. Few arrangements known are

ELECTRONICA MACHINE TOOLS LTD 3:2

SUCTION FLUSHING : CONTINUOUS FLUSHING

WHEN FLUSHING THROUGH JOB OR ELECTRODE IS

MOTION FLUSHING : MOTION FLUSHING GIVES HIGHER EFFICIENCY OF

ROTATING ELECTRODE WITH ROTARY DEVICE

ELECTRONICA MACHINE TOOLS LTD 3:3

Finishing - Small gap - High pressure

ELECTRONICA MACHINE TOOLS LTD 3:4

- Vacuum flushing is applied for high quality cylindrical profiles.

ELECTRONICA MACHINE TOOLS LTD 3:5

Flushing hole at the centre core remains

Displaced flushing hole, core is continuously machined off.

- Rotating electrode reduces erosion time

- Side pressure flushing should be used in correct direction.

ELECTRONICA MACHINE TOOLS LTD 3:6

As a last improvement impulse flushing with auto flushing should be applied.

If flushing hole too large, then

ELECTRONICA MACHINE TOOLS LTD 3:7

- Gas then can go away easily.

ELECTRONICA MACHINE TOOLS LTD 3:8

SETTING UP AND OPERATION

Following pages describe "Setting up and operation" of "ELEKTRA" systems.

For setting up, experience of general tool making is useful. Satisfactory

WORK PLANNING ESTABLISHES

I. The working method, procedure and technique

II. Machine stages