Intro PS NTMP-merged

Non-Traditional
Machining Processes
presented by
Partha Saha
Department of Mechanical Engineering
Need of Nontraditional
Manufacturing Processes
Such processes are emerging out

due to the limitations of the
conventional manufacturing
processes
Characteristics of
Conventional Machining
 Contact type
 Cutting force by the tool is inevitable
 Very thin job is not possible
 Large heat-affected zone
 High residual stress
 Poor surface integrity
 All complicated shapes are
not possible
What would be the right
manufacturing process?
– Case studies
Constraints posed
by shape and size
of the job features

Case 1: Square blind hole with
good surface finish & accuracy
40 mm
50 mm
Manufacturing of a square blind hole of 40 x 40 mm
(need  good finish and sharp corners)
Case 2: Circular blind hole
with high accuracy
Φ 10 mm
60 mm
Need  Manufacturing of a circular blind hole with accuracy
of (±) 100 micron, taper less than 0.5 degree
Case 3: Drilling of circular hole of very
small diameter & high aspect ratio
Φ 0.2 mm
5 mm
Aspect ratio = (hole dia./ depth)= (1:25)
Competition in manufacturing
industry today demands
 New products
 Better performance
 More features
 Low cost
 Energy efficiency
 Reduction of
residual stresses
 Low HAZ
Emergence of new exotic
materials
Super alloys, ceramics and
composites
• Too hard / brittle / difficult to
machine with traditional
process
• Improved mechanical, thermal, Product from quartz
& chemical properties
• Materials too flexible / slender
to handle
Solar cell
Case-4: Industrial marking and
drilling with highest accuracy
Branding goggles
Ink-jet nozzle drilling
20 micron hole with
high tolerance Microreactor channels in teflon
Efficient Marking and Drilling by Excimer Laser with Highest

Accuracy
Case 5: 3d-features on gold
foil by electroforming
Part made of gold foil of 10 µm
thickness
Hole diameter is 100 µm
Posts between the holes have a

height of 22.5 µm
and a base diameter of 50 µm.
Slots are 50 µm wide, and the

walls that define the slots are 50
µm wide and 22.5 µm high.
Dimensional tolerance +/- 3 µm

Case 6: Miniaturised components
Metallic micro gear Metallic micro mold

(diameter 300 (overall size 2-5 mm)
micron)
Classifications of NTM processes
Thermal NTM Processes

- Laser Beam Machining (LBM)
- Electron Beam Machining (EBM)
- Plasma Arc Machining (PAC)
- Electrical Discharge Machining (EDM) Laser cutting
Mechanical NTM Processes

(Plastic deformation / Abrasive Erosion)
- Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM)
- Water Jet Machining (WJM) Ultrasonic machining
- Abrasive Water Jet Machining (AWJM) of glass
Classifications of NTM
Processes
Electrochemical NTM Processes
- Electrochemical Machining (ECM)
- Electrochemical Grinding (ECG)
Electrochemical Machining
Chemical NTM Processes of complex surfaces
- Chemical Machining (CHM)
- Thermo chemical Machining (TCM)
Kinetic Energy (Atom by atom

knocking)
- Ion beam Electro-discharge Machining
Characteristics of Nontraditional
Machining (NTM) Processes
 Most NTM processes do not use mechanical
energy for material removal
 Nontraditional media for energy transfer
 Physical tool may or may not be present
 Material removal with chip formation or even

without chip formation
 Tool need not be harder than the work piece

material
Objective of this course
 To learn basic theory, working principle, and
characteristics of different NTM processes.
 To identify critical process variables and their effects

on process performance and product quality.
 To develop simple mathematical model relating MRR

with machining parameters in NTM.
 To develop understanding to properly assess the

capabilities, limitations, and potentials of NTM in
relations to various industrial applications.
Reference Books
 Nontraditional Manufacturing Processes by Gary F.
Benedict, Marcel Dekker,Inc
 Modern Machining Processes by P C Pandey & H S Shan,

Tata McGraw-Hill
 Nonconventional Machining by P K Mishra, Narosa

Publishing House
 Manufacturing Science by Amitabha Ghosh & A K Mallik,

Affiliated East-West Press
 Advanced Machining Processes, by El-Hofy, McGraw Hill

Electric Discharge Machining
by
Dr. P Saha
Department of Mechanical Engineering
IIT Kharagpur
Scheme of Presentation
• Process mechanism of EDM

• Types of EDM and EDM Operations
• Dielectric Fluids
• Flushing Techniques
• Process Parameters
• Pulses in EDM
• Power supply for EDM
• Simple theoretical model for MRR and Surface
roughness
• EDM Applications
09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 2

EDM is highly accurate and can Electrical Discharge Machining (EDM) is
a manufacturing process whereby a
. produce fine details and intricate
patterns. The main advantage of EDM desired shape is obtained using electrical
is that it can cut small or odd-shaped discharges (sparks). Material is removed
angles, detailed contours or cavities in
pre-hardened steel without the need
History pf EDM from the workpiece by a series of rapidly
recurring current discharges between two
for heat treatment to soften and re- electrodes, separated by a dielectric
harden them. liquid and subject to an electric voltage.
 B. R. Lazarenko and N. I. Lazarenko  investigated ways of

preventing the erosion of tungsten electrical contacts due to
sparking way back in 1943 .
 Finding  Erosion could be more precisely controlled if the

electrodes were immersed in a dielectric fluid  This
eventually led them to invent an EDM machine.
 [Ref: Electric Spark Method for the Machining of Metals, B. R. Lazarenko, N. I. Lazarenko, H. Brutcher
Technical Translations, 1950]

Electrical Breakdown
Rapid reduction in the resistance of an electrical

insulator that can lead to a spark jumping around or
through the insulator.
Dielectric breakdown is the failure of an insulating

material to prevent the flow of current under an
applied electrical stress. The breakdown voltage is
the voltage at which the failure occurs, and the
material is no longer electrically insulating.

Work Tank: The
Scheme of EDM
workpiece is mounted
inside this tank, which is
filled with dielectric fluid
Pressure Gauge: This

measures the pressure
of the dielectric fluid in
the system.
Filter: The filter cleans

the dielectric fluid by
removing particles
eroded from the
workpiece.
Pump: This circulates
the dielectric fluid from
the reservoir to the work
tank and through the
filter.
Potential difference Melts and

between the two A series of Intense evaporates the
electrodes sparks heat materials
Dielectric fluid

Charging voltage is applied A critical voltage is reached
Critical voltage establishes an

ionised column Builds avalanche of electrons
A high density current flows
Spark is initiated
Rapid rise of temperature Transfers heat to cathode

and anode
Melts and vaporises surfaces of
–ve and +ve electrode
Dielectric is decomposed
Ionization of Dielectric:
If the voltage is high Inertia of adjacent dielectric
enough and the gap creates high pressure
between the electrode
and the workpiece is
sufficiently small, the Stoppage of pulse results in an
intense electric field will implosive a blast
cause the dielectric fluid
to ionize at the point
where the electric field Removes molten debris of
is strongest. Ionization
means that the fluid's
anode and cathode Crater
atoms or molecules lose
or gain electrons, Leaves a crater behind
forming ions.
Material Removal Mechanism in EDM Voltage
Increase:
Initially, the
voltage between
the tool
electrode and
the workpiece is
ramped up.
This is
represented by
a rising curve on
the voltage
graph. The
voltage
increases until it
reaches a level
sufficient to
overcome the
dielectric
strength of the
fluid between
the electrodes.

Material Removal Mechanism in EDM

By controlling the spark
EDM energy, the operator
can manage the rate of
material removal, the
surface finish, and the
overall efficiency of the
machining operation.
Need  control the spark energy to employ for

machining
Sparking frequency  many thousands per
second
Final shape of the job  a result of thousands of
craters each one superimposed over the other
and it is inverse shape of that of the tool.

Type of EDM-ing Operations

Sinking by EDM
Machining through
holes: This process
involves creating holes
that go completely
through the workpiece.
In EDM, this is done by
using a tubular
electrode that rotates
and advances into the
workpiece
Three-dimensional die-
sinking: Die-sinking
Machining through holes
EDM involves using a
pre-shaped electrode
that is gradually brought
close to the workpiece
submerged in a
dielectric fluid. The
electrode does not
physically touch the
workpiece; instead, it is
brought close enough
for sparks to jump the
gap between the
electrode and the
workpiece.
Three dimensional die-sinking

Cutting with a blade: This
involves a thin, flat electrode
that resembles a blade. The
Cutting by EDM blade electrode moves down
or along the workpiece to
cut it into the desired shape.
The spark erodes the work
material directly under the
blade as it moves, which
allows for precise slicing of
the material.
Cutting with a rotating disc:

In this method, a disc-
shaped electrode rotates
around its central axis. As
the disc electrode is brought
close to the workpiece, the
electrical discharges occur
along the edge of the disc,
eroding the material in the
desired shape.
Cutting with a blade Cutting with a rotating disc Cutting with a ribbon: Similar
to the blade method, but
with a ribbon-like electrode
that is often wider than a
blade and can have different
shapes. It moves across the
workpiece to erode material
in a path determined by the
shape of the ribbon's edge.
Cutting with a wire: Also

known as wire EDM, this
method uses a thin,
continuously moving wire as
the electrode. The wire is fed
through the workpiece and
is controlled by a CNC
system to follow the desired
path for cutting. The
workpiece material is eroded
Cutting with a ribbon Cutting with a wire by sparks that occur

between the wire and the
workpiece. Wire EDM is
commonly used to cut
intricate and detailed shapes
with high precision.
Grinding by EDM
Internal grinding External grinding
Surface grinding Profile grinding

cnc
automatically
EDM Die-Sinking Machine
changes
electrodes
The servo head

controls the
vertical
movement of the
electrode
Working Tank:
The tank that
contains the
dielectric fluid
Dielectric
Reservoir: This
is a storage tank
for the dielectric
fluid

EDM Die-Sinking Machine

Servo System: The servo
system controls the relative
EDM Machine Elements motion between the workpiece

and the electrode. It precisely
maintains the gap between the
electrode and the workpiece to
ensure consistent spark
generation and to prevent
contact, which could damage
the workpiece or electrode. It's
often controlled by a CNC
(Computer Numerical Control)
system for high precision.
 Dielectric system
Elements  Servo system

of EDM  Electrodes: work piece
and tool
 Power supply

Dielectric Fluid in EDM

Main functions of dielectric Fluid in EDM
 To provide insulation in the gap between the

electrode and the workpiece below threshold voltage.
 Stabilize the spark process by ionizing and deionizing
the spark channel at fixed frequencies.
 Concentrate the spark channel.
 To flush the eroded particles, produced during
machining, from the discharge gap.
 To cool the section that was heated by the discharge
machining.

Ideal Characteristics Dielectric Fluid
 Good electrical discharge efficiency  enables
quick ionisation & deionisation
 Low viscosity  enables easy flow in narrow

gap
The flash point of a dielectric
fluid, which is used in EDM
(Electrical Discharge Machining)
 High flash point  reduces fire hazard

, refers to the lowest
temperature at which the fluid
can vaporize to form an ignitable
mixture in air. This is an
important safety characteristic
because it indicates the
 Good thermal & oxidation stability  less potential fire hazard of the fluid.
degradtion In the context of EDM (Electrical

Discharge Machining), a
dielectric fluid with high
dielectric strength is desirable
 Minimum odor  environment friendly

because it can sustain higher
voltages without causing a
premature spark.
 Low cost
Commonly used Dielectric Fluids in EDM
 Transformer oil
 Paraffin oil
 Lubricating oil
 Kerosene oil
 Deionized water  good ionizing and
deionizing capability/ high MRR, high
TWR, corrosive, good coolant  used in
WEDM
Flash points for common liquids
• Gasoline 4.5º C
• Ethanol 12.5º C
• Kerosene 49º C
• Diesel 62º C
• Vegetable Oil 327º C
The flash point for commonly used EDM
dielectric oils ranges from 71º C to 124º C.
The flash point of a dielectric fluid, which is used in EDM (Electrical Discharge Machining), refers to the lowest
temperature at which the fluid can vaporize to form an ignitable mixture in air. This is an important safety
characteristic because it indicates the potential fire hazard of the fluid.

Dielectric Fluid: This is the
insulating liquid used in the
EDM process. It acts as an
Dielectric System
electrical insulator until the
voltage between the electrode
and the workpiece is high
enough to break down its
insulating properties, at which
point it allows for spark
discharge. The fluid also helps
to cool the process and flush
away the eroded material from
the workpiece.
Reservoir: This is a tank where
 Dielectric fluid the dielectric fluid is stored when

not in use. It often serves as a
settling tank where debris from
the machining process can
settle out of the fluid before it is
 Reservoir filtered and reused.
Dielectric Filters: These are used to

remove the particulate matter
from the dielectric fluid after it
 Filters has passed through the

machining area. Clean fluid is
system crucial to maintain the

effectiveness and safety of the
EDM process.
 Pump Pump: This component

circulates the dielectric fluid
from the reservoir to the
machining area and back. A
 Delivery devices pump is essential to ensure a

continuous flow of dielectric fluid
, which is necessary for effective
spark generation and debris
removal.

Need for Flushing in EDM
 Inadequate flushing  result in arcing, decreased

electrode life, and increased production time.
 The fluid should have the ability to flow through the
spark gap, removing debris, chips, and particles eroded
by the EDM process.  low viscosity
Flushing Techniques
 Normal flushing
 Reverse flushing
 Jet flushing
 Immersion flushing
 Intermittent opening up the gap by lifting tool

Arcing: Without proper flushing, the debris from the eroded material can accumulate in the spark gap. This accumulation
can cause electrical discharges to occur at unintended points, leading to arcing. Arcing is undesirable because it can cause
damage to both the electrode and the workpiece, leading to poor surface finish and dimensional inaccuracies.
Decreased Electrode Life: As debris accumulates, the electrode may be subjected to more intense and erratic discharges
than intended. These irregular discharges can lead to increased wear or damage to the electrode, reducing its life.
Increased Production Time: When debris is not properly flushed away, it can cause unstable machining conditions. This
instability may require the machining process to be stopped frequently for cleaning, or it may slow down the process to
avoid damage, both of which can lead to increased production time.
Normal Flushing

Reverse Flushing

Jet Flushing

Tool Materials for EDM
Copper electrode
Bass electrode
Copper-tungsten electrode
Silver-tungsten electrode
Tungsten electrode
Graphite electrode
Copper impregnated graphite
Eletroformed electrode

Materials with "high in roughing"
capability allow for a higher
Selection of Tool Materials for EDM

Material Removal Rate (MRR)
during the initial stages of
machining
Material Wear Ratio MRR Fabrication Cost Application

Copper Low High in Easy Moderate All metals
roughing
Brass High High on Easy Low All metals
finish
range
Tungsten Lowest Low Difficult High Only where
small holes
are to be
drilled
W-Cu Low Low Difficult High High accuracy
alloys job
Copper- Low High Very Material All metals
Graphite delicate,
Difficult
Zn-based High High in Easily die- Low All metals
alloy roughing casted
Small Hole Drilling on Turbine Blade

Tool Wear In EDM, as the electrode (tool)
is used, it gradually wears down.
CNC-EDM systems can
compensate for this wear by
adjusting the tool path or by
Compensation for reduced physically moving the electrode

to maintain the correct position
relative to the workpiece.
length  tool wear

Electrode refeeding  brings
tool to a reference point
Automatic Tool Changer

Many tools mounted on a
magazine – called one at a
time by CNC program
Reduces tool-changing
time
CNC-EDM more popular
EDM Operations
 EDM equipped with CNC

 Better removal of debris and ease of machining in attaining
complex form
•Downwards
•Orbital
•Vectorial
•Angular
Downwards: This refers to the straightforward vertical
motion of the electrode towards the workpiece. It's the
basic movement required to erode the material directly
beneath the electrode.
Orbital: An orbital motion involves moving the electrode in
a circular or orbital path. This can help to enlarge a hole
beyond what would be possible with a simple downward
movement and can assist in the even distribution of wear
on the electrode and more uniform removal of material.
Vectorial: This might involve moving the electrode in a
linear path at any angle, not just vertically. The vectorial
movement can be used to create channels or complex
shapes within the workpiece.
09-Feb-23
Angular: Angular movement means the electrode is tilted at
an angle rather than being aligned perfectly vertically. This
P Saha, Mech Engg, IIT Kharagpur 31
allows for the machining of angled features within the
workpiece.
Expanding: This might refer to a movement where the electrode moves outward
in a spiral pattern to gradually increase the size of a hole or cavity.
Conical: This involves machining a conical shape, which would require the
•Expanding
electrode to move in a way that expands the cavity in both depth and diameter
simultaneously.
EDM Operations
Goto: This term is often used in programming to move the electrode directly to a
specific coordinate or position without machining along the way.
Helical: Helical movement implies that the electrode follows a helix or spiral path,
which could be used for creating threaded features or complex 3D contours.
Spin: This indicates that the electrode is rotated around its own axis while
•Conical
machining, which can help in creating a more uniform surface finish and assist in
the flushing of debris.
Rotation along C axis: This refers to the rotation of the electrode or workpiece
around the vertical axis (commonly referred to as the C-axis in CNC terminology),
enabling the machining of features at different orientations without having to re-
•Goto
fixture or move the workpiece.
•Helical
•Spin
•Rotation
along C axis
This refers to the rotation of the

electrode or workpiece around the
vertical axis (commonly referred to
as the C-axis in CNC terminology),
enabling the machining of
features at different orientations
without having to re-fixture or
move the workpiece.

Wire EDM

Wire EDM

Wire EDM

Servo system in EDM
To maintain pre-determined gap between the

electrodes
Gap bridged by electrically conductive
materials  signal to servo system  reverse
direction
Reciprocates towards work piece until
dielectric flushes gap
If flushing is inefficient  very long cycle
time
Gap Bridged by Electrically Conductive Materials: If debris from the erosion process, which is electrically conductive, starts to
bridge the gap, it can cause a short circuit, disrupting the controlled sparking process.
Signal to Servo System - Reverse Direction: The EDM machine constantly monitors the condition of the gap. If a short circuit is
detected (the gap being bridged by debris), the servo system receives a signal to reverse the direction of the electrode. This
retraction helps clear the gap by pulling the electrode away from the workpiece, allowing the dielectric fluid to flush out the
conductive particles.
Reciprocates Towards Workpiece Until Dielectric Flushes Gap: The electrode will then move back towards the workpiece to
continue the machining process once the gap is clear. This reciprocating action ensures that the machining process can continue
with the correct gap maintained.
Inefficient Flushing - Very Long Cycle Time: If the flushing system is not effective at removing the debris, the cycle time for
machining will increase. This is because the electrode will need to retract more frequently to clear the gap, slowing down the
overall process. Efficient flushing is thus critical for maintaining an optimal cycle time.
Servo Operation Based on Machining and Reference Voltage
100 Open circuit voltage
Yes, that's correct. When the operational

voltage range is small, it means that the
servo system is configured to respond to
even small changes in voltage. This is
indicative of high sensitivity. Here's what
happens:
Open Circuit Voltage: This is the voltage across the electrode and workpiece when no
current is flowing. No sparks are generated at this voltage because the dielectric fluid
between the electrode and the workpiece is not ionized.
Range of Voltage Where Sparking Occurs After Ionization: This indicates the voltage
range within which the dielectric fluid ionizes and sparks occur. The actual voltage at
Range of voltage where
which sparking begins is lower than the open-circuit voltage due to the gap between the
electrode and the workpiece. sparking occurs after ionization
Servo-Control Reference Voltage: This is a preset voltage level within the servo system
50
that acts as a threshold. When the voltage across the gap reaches this level, it signifies
that the gap is at the correct distance for optimal sparking. If the voltage drops below
this reference, it means the electrode is too close to the workpiece, and the servo
system will retract the electrode slightly to re-establish the correct gap.
Servo System Operational Voltage Range: This is the voltage range the servo system
allows during operation, determined by the sensitivity settings of the servo system. It's
the window of voltage in which the system will operate to maintain the gap.
32 Servo system (Decides

Servo-control 30 operational servo
reference voltage 28 voltage range sensitivity)
Servo Sensitivity: This is set by the operational voltage range. A 20
high servo sensitivity means that the servo system will react to
very small changes in voltage, adjusting the electrode position
frequently to maintain the precise gap required for sparking.
Conversely, low sensitivity means larger voltage fluctuations are
If operational voltage range could
needed before the servo adjusts the electrode position.
vary within a small range  high
If Operational Voltage Range Could Vary Within a Small Range -
High Servo Sensitivity: When the operational voltage range is
small, the servo system is highly sensitive to changes in the gap.
This is beneficial for fine machining where the gap needs to be
0 servo sensitivity
controlled very precisely, but it may lead to more frequent
retraction and advancement of the electrode, which can affect
machining time.
Pulses in EDM
 Performance measures such as MRR, tool

wear, and surface finish for the same energy
depend on the shape of the current pulses.
 Depending upon the situation in the gap
which separates both electrodes, principally four
different electrical pulses may be distinguished:
a) Open circuit or open voltage Open Circuit or Open Voltage: This refers to the
condition when there is no current flowing between
the electrode and the workpiece. The voltage is
present, but the gap is too wide for a spark to occur,
b) Effective discharges or real Sparks

or the machine is not in the process of machining.
Effective Discharges or Real Sparks: These are the
desired pulses in EDM, where the current flows
across the gap and creates sparks that erode the
material from the workpiece. This is the normal
c) Arcs and
operating condition for the EDM process.
Arcs: An arc occurs when there is a continuous
discharge of electricity across the gap, which is not
desired in standard EDM processes. Arcing can
lead to excessive tool wear and poor surface finish
d) Short circuits
on the workpiece because it can create a more
sustained and hotter discharge than a spark, which
can melt rather than vaporize the material.
Short Circuits: This happens when the electrode
comes into direct contact with the workpiece,
allowing current to flow without any resistance.
Short circuits are undesirable as they can cause
damage to the workpiece and the electrode, and
they interrupt the controlled erosion process.
voltage drops after spark in effective
Voltage Pulses in EDM discharge because resistance drops
Signal
Current
Signal
Effective Arc Short Open

Discharge Circuit Circuit

Puse Waveform for Effective Discharge

Pulse Generators
Controlled pulse generator governs shape and frequency

of pulsing. It enables
 rough machining (high energy and low frequency), or
 finish machining (low energy and high frequency)

Pulse Generators
Relaxation generator or RC generator

Pulse Generators
Electronic Pulse
Generator
This combines elements of both electronic

amplification and relaxation oscillator
methods (like the RC generator discussed
previously). The relaxation circuit charges
and then discharges to create a pulse, and
the electronic switch controls the timing and
duration of the pulse. The waveform on the
right side within the red circle shows a more
controlled and shaped pulse, which can be
tailored for specific applications in EDM.
Hybrid Pulse
Generator
(Electronic +
Relaxation)
Relaxation
Generator
Charging Discharging
portion portion

Relaxation Generator

Charging portion of a Relaxation Generator

Discharging portion of a Relaxation Generator

Pulse Shape of a Relaxation Generator
Saw-tooth curve  in actual operation of a RC-generator

(Vco/Vd)

Material Removal Rate in a Relaxation Generator

Vo

Process Parameters of EDM
 Peak current setting

 Gap voltage
 Capacitance
 Pulse on time
 Pulse off time
 Duty factor
 Polarity

Process Variables
Increase in current or spark voltage 

increased MRR, higher surface roughness
Low Inter-electrode Gap  low MRR, high
surface finish, better accuracy
Increase in spark frequency  improved
surface finish  as energy is shared by more
number of sparks  decreased crater size
Decreased pulse duration  low MRR, better
surface finish, low electrode wear

Effect of Polarity
Electro-discharge machining
characteristics of various
electrode-material combinations
For machining ferrous material with

copper tool, what polarity should be
given to the work piece and why?
Choosing iron “negative and cooper

tool “positive” gives a stronger
discharge than vice versa.
Iron atom can give away electrons
more easily… the negative polarity has to lose
electrons...

In EDM (Electrical Discharge Machining), the workpiece can be either negative or positive depending on the desired outcome for the machining
process. The polarity affects the direction of electron flow during the electrical discharges, and this has implications for the rate of tool wear, the
surface finish of the machined part, and the material removal rate.
When the workpiece is negative (cathode), it will tend to have a higher material removal rate, and the tool wear will be lower. This is often referred
to as reverse polarity.
Conversely, when the workpiece is positive (anode), it will tend to result in a better surface finish, but higher tool wear. This is often referred to as
straight polarity.
The choice between negative or positive polarity for the workpiece in EDM is made based on the specific requirements of the job, such as the
need for precision, surface quality, and tool life. The type of material being machined can also influence the choice of polarity.
Yes, in the context of EDM and electrical circuits in general, a negative polarity indicates a surplus of electrons, which means that
the negatively charged electrode (or workpiece, in the case of EDM with negative workpiece polarity) will tend to lose electrons.
Surface Integrity in EDM
Surface topography nad subsurface metallurgy
Recast Layer
Heat Affected Zone
Base Metal
Recast Layer
 Molten metal not flushed away,
resolidified on workpiece
 hardened due to fast cooling,
hardness (6o HRC),
 thin : 2.5 – 50 micron
 may contain micro-cracks
 should be removed
EDM Applications
Material : Steel
Dimensions : 200 x 150 mm
Electrode : One graphite
electrode for
rouging and
finishing
Machining time : 30 hours
Part of mould for casting a crankcase

EDM Applications
Material : Hardened Steel

Surface finish : 5 micron
Electrode : Copper electrode,
one for rouging, one
for finishing
Machining time : 3 hours 30 min
Machining of gear wheel cutter

EDM Applications
Material : Steel
Preliminary Machining : Boring a
50 mm diameter hole
Electrode: Two graphite
electrodes. One for
rouging and one for
finishing
Surface finish : 1.3 micron Ra
Machining time : 50 hours
Mould for a bottle (1 ½ litres)

EDM Applications
Material :
Die in carbide 63 mm, Punch in
carbide 20 mm
Geometric tolerance : 2 mm
Surface finish : 1.1 micron Ra
Relief angle :
Die 4 minutes, Punch 1 minute
Machining time :
Die:15 hours, Punch: 3.5 hours
Punch and die set for cutting razor blades

EDM Applications
Material : Hardened Steel

Electrode : Copper
Surface Finish: 0.14 mm
(polished)
Machining time: 1 hour 30 min
Machining of engraving of knurling wheel

EDM Applications
Material : Steel
Precision : 0.01mm
Electrode : Copper
Surface Finish: 0.4 mm Ra
Machining time: 9 hours
Two cavity mould with very fine surface finish

EDM Applications
Parts of dies for the forging of universal joints (automotive industry)

EDM Applications
Cutting of a connecting rod trimming die built up by welding

Thank You

Intro PS NTMP-merged

Uploaded by

Copyright:

Available Formats

Intro PS NTMP-merged

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Intro PS NTMP-merged

Uploaded by

Copyright:

Available Formats

Non-Traditional

Such processes are emerging out

Efficient Marking and Drilling by Excimer Laser with Highest

Hole diameter is 100 µm

Posts between the holes have a

Slots are 50 µm wide, and the

Dimensional tolerance +/- 3 µm

Metallic micro gear Metallic micro mold

Thermal NTM Processes

Mechanical NTM Processes

Kinetic Energy (Atom by atom

 Nontraditional media for energy transfer

 Physical tool may or may not be present

 Material removal with chip formation or even

 Tool need not be harder than the work piece

 To identify critical process variables and their effects

 To develop simple mathematical model relating MRR

 To develop understanding to properly assess the

 Modern Machining Processes by P C Pandey & H S Shan,

 Nonconventional Machining by P K Mishra, Narosa

 Manufacturing Science by Amitabha Ghosh & A K Mallik,

 Advanced Machining Processes, by El-Hofy, McGraw Hill

• Process mechanism of EDM

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 2

 B. R. Lazarenko and N. I. Lazarenko  investigated ways of

 Finding  Erosion could be more precisely controlled if the

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 3

Rapid reduction in the resistance of an electrical

Dielectric breakdown is the failure of an insulating

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 4

Pressure Gauge: This

Filter: The filter cleans

Potential difference Melts and

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 5

Critical voltage establishes an

A high density current flows

Rapid rise of temperature Transfers heat to cathode

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 7

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 8

Need  control the spark energy to employ for

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 9

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 10

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 11

Cutting with a rotating disc:

Cutting with a wire: Also

Cutting with a ribbon Cutting with a wire by sparks that occur

Internal grinding External grinding

Surface grinding Profile grinding

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 13

The servo head

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 14

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 15

EDM Machine Elements motion between the workpiece

Elements  Servo system

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 16

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 17

 To provide insulation in the gap between the

09-Feb-23 P Saha, Mech Engg, IIT Kharagpur 18

 Low viscosity  enables easy flow in narrow

 High flash point  reduces fire hazard