25-03-2015

ME6324:Modern Machining Processes

Electrical Discharge Machining( EDM)

& Wire EDM

By
Dr.Deepak Lawrence.K
Mechanical Engineering Department
NIT Calict,Kerala,India

Electrical Discharge Machining

Wire EDM

Die sinking EDM Hole drilling EDM

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Electrical Discharge Machining

Electrical Discharge Machining (EDM) is the
process of machining electrically conductive
materials by using precisely controlled sparks
that occur between an electrode and a
workpiece in the presence of a dielectric fluid

Close-up view of EDM machining

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Electrical Discharge Machining

No longer is EDM a "non-conventional"
machining method.
It is claimed that EDM is now the fourth most
popular machining method. The first three are
milling, turning, and grinding.
Three basic EDM processes:
wire EDM,
ram EDM, and
small hole EDM drilling
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Basic EDM system.

Ram EDM

Ram EDM, also known as conventional EDM, sinker EDM, die

sinker, vertical EDM, and plunge EDM is generally used to
produce blind cavities as shown in Figure.
In ram EDM sparks jump from the electrode to the workpiece.
This causes material to be removed from the work piece by
melting and vaporization.
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Wire EDM

In wire EDM, the spark jumps from the wire electrode to

the workpiece and erodes metal both from the wire
electrode and the workpiece. Wire EDM is used primarily
for through hole machining as shown in Figure
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Hole drilling EDM

Small hole EDM drilling, also known as fast hole EDM drilling, hole popper
uses a hollow electrode to drill holes by means of electrical discharge
machining by eroding material from the workpiece
Hole drilling EDM uses low cost electrode tube (normally brass or copper
material) to drill holes on a electrically conductive material at a very high
speed, the hole depth diameter ratio can reach up to 200.
The hole diameter is normally from 0.3mm to 3.0mm, with five axis
configuration the machine can drill hole at any angles on a inclined surface
workpiece.
This technology is widely used for hole machining in aerospace, energy,
cutting tools, automotive, medical, mold and die industries.

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Electrical Discharge Machining

Electrical Discharge Machining (EDM) is the
process of machining electrically conductive
materials by using precisely controlled sparks
that occur between an electrode and a
workpiece in the presence of a dielectric fluid

Close-up view of EDM machining

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EDM-fundamentals
EDM can be used to machine conductive materials of any hardness
(for example steel or titanium) to an accuracy of up to one-thousandth
of a millimeter with no mechanical action.
EDM removes material by a series of rapidly recurring electric arcing
discharges between an electrode (the cutting tool) and the work
piece, in the presence of an energetic field.
The EDM cutting tool is guided along the desired path very close to
the work piece but it does not touch the piece.
Consecutive sparks produce a series of micro-craters on the work
piece and remove material along the cutting path by melting and
vaporization.
By virtue of these properties, EDM is one of the key technologies in
mold and tool making.
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EDM-fundamentals
EDM differs from most chip-making machining
operations in that the electrode does not make
physical contact with the workpiece for material
removal.
Since the electrode does not contact the
workpiece, EDM has no tool force. The electrode
must always be spaced away from the workpiece by
the distance required for sparking, known as the
sparking gap.
Should the electrode contact the workpiece,
sparking will cease and no material will be removed
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EDM-fundamentals

Another basic fundamental of the process is that only one spark occurs at any
instant. Sparking occurs in a frequency range from 2,000 to 500,000 sparks per
second causing it to appear that many sparks are occurring simultaneously.
In normal EDM, the sparks move from one point on the electrode to another as
sparking takes place
The spark removes material from both the electrode and workpiece, which increases the
distance between the electrode and the workpiece at that point. This causes the next
spark to occur at the next-closest points between the electrode and workpiece

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EDM-fundamentals

EDM is a thermal process; material is removed by heat.

Heat is introduced by the flow of electricity between the
electrode and workpiece in the form of a spark.
Material at the closest points between the electrode and
workpiece, where the spark originates and terminates,
are heated to the point where the material vaporizes
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EDM-fundamentals
While the electrode and workpiece should never
feel more than warm to the touch during EDM,
the area where each spark occurs is very hot.
The area heated by each spark is very small so
the dielectric fluid quickly cools the vaporized
material and the electrode and workpiece
surfaces.
However, it is possible for metallurgical changes
to occur from the spark heating the workpiece
surface.
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Dielectric fluid
A dielectric material is required to maintain the sparking
gap between the electrode and workpiece.
This dielectric material is normally a fluid.
Die-sinker type EDM machines usually use hydrocarbon
oil, while wire-cut EDM machines normally use deionized
water.
The main characteristic of dielectric fluid is that it is an
electrical insulator until enough electrical voltage is
applied to cause it to change into an electrical conductor
When the spark is turned off, the dielectric fluid
deionizes and the fluid returns to being an electrical
insulator.

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Dielectric fluid
Dielectric fluid used in EDM machines provides
important functions in the EDM process.
These are:
controlling the sparking-gap spacing between
the electrode and workpiece;
cooling the heated material to form the EDM
chip; and
removing EDM chips from the sparking area.

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EDM-fundamentals

Spark occurs within a column of ionized dielectric fluid.

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EDM-fundamentals
As each spark occurs, a small amount of the electrode
and workpiece material is vaporized.
The vaporized material is positioned in the spark-ing gap
between the electrode and workpiece in what can be
described as a cloud.
When the spark is turned off, the vaporized cloud
solidifies.
Each spark then produces an EDM chip or a very tiny
hollow sphere of material made up of the electrode and
workpiece material.
For efficient machining, the EDM chip must be removed
from the sparking area. Removal of this chip is
accomplished by flowing dielectric fluid through the
sparking gap.
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EDM-fundamentals

Spark-OFF

Spark-ON

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EDM-fundamentals

Spark-OFF: vaporized cloud solidifies to form

EDM chip.

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EDM FINISH
The finish that is created by the EDM process is the
result of tiny craters being formed by the random
impacts of thousands of sparks.
After each cycle the rim of the created crater forms
a new high point, making it a likely target for a new
cycle.
The EDM spark generated chips is of the size 2m
only
Due to this situation overlapping micro-craters are
formed, accounting for the random nature of the
Electrical Discharge Machined surface.
This Surface Finish(SF) is one of the attractive
features of EDM in many industries.
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EDM Spark generator

EDM machines use different kinds of sparks
depending on the electronic circuitry provided.
Sparking is normally produced by one of two
types of EDM-power supplies:
resistor-capacitor power supply, and
pulse-power supply

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EDM -principles

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RAM EDM

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Basic EDM system.

In a basic, ram -type EDM system , the ram head is driven up and down with
extreme accuracy by a servo-driven system. The servo system is controlled by
a microprocessor connected to the power supply
The power supply is solid-state and is also microprocessor controlled. One
lead from the power supply is connected to the work piece , which is
immersed in a tank of dielectric oil.
The dielectric tank is connected to a dielectric pump, an oil reservoir, and a
filter system.
The pump provides pressure for flushing the work area and moving the oil
while the filter system removes and traps debris in the oil.
The oil reservoir stores surplus oil and provides a container for draining the
oil between operations.

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Basic EDM system.

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Basic EDM system.

The other lead from the power supply is connected to the electrode. The power supply
provides a pulsed DC output to the electrode /work piece system. On-times and offtimes are set manually, along with voltage and current values.
When the EDM machine is turned on, the servo microprocessor , sensing that the gap
is too wide for cutting to take place, signals the servo mechanism to lower ram head
When the first spark jumps the gap, downward travel of the ram head stops. With the
gap setting held constant, the process gradually erodes the surface.
When enough metal has been removed to change the gap distance, the
microprocessor senses this and signals the servo mechanism to advance the ram
head sufficiently to maintain the proper gap width and the process continues.
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Basic EDM circuit

Lazarenko resistor-capacitor (R-C) EDM circuit

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EDM

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Spark-ON/OFF time for EDM RC circuit

Spark-ON/OFF time is determined using the following

T=RxC
where:
T = time (seconds)
R = resistance (ohms)
C = capacitance (farads)
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EDM RC circuit

Variation of voltage with time using an RC generator

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Pulse-power-supply waveform-Principle

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Pulse-power-supply waveform

ON and OFF times determine spark frequency

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Basic transistor sparking circuit for EDM

When an electronic signal from the switch control turns the transistor ON and OFF, it
causes the transistor to act like an electronic switch that can be opened or closed.
During spark-ON time, the transistor is closed to let electricity flow from the DC-power
source to the electrode, across the sparking gap to the workpiece, and then back to
the DC-power source.
During the OFF time, the transistor is open, stopping the flow of electricity. Spark-ON
and -OFF times are set by the EDM-power-supply controls, either manually or, if a CNCcontrolled machine, by computer program.
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EDM-Mechanism
Application of voltage pulses causes electrical
breakdown to the dielectric in a channel.
The breakdown arises from the acceleration
toward the anode of both electrons emitted
from the cathode by the applied field and the
stray electrons present in the gap.
These electrons collide with neutral atoms of
the dielectric, thereby creating positive ions and
further electrons, which in turn are accelerated
respectively toward the cathode and anode.
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EDM-Mechanism

When the electrons and the positive ions reach the anode and cathode,they
give up their kinetic energy in the form of heat.
Temperatures of about 8000 to 12,000C and heat fluxes up to 1017 W/m2
are attained.
With a very short duration spark of typically between 0.1 to 2000 s the
temperature of the electrodes can be raised locally to more than their normal
melting points.
Owing to the evaporation of the dielectric, the pressure on the plasma
channel rises rapidly to values as high as 200 atmospheres. Such great
pressures prevent the evaporation of the superheated metal.
At the end of the pulse, the pressure drops suddenly and the superheated
metal evaporates explosively. Metal is thus removed from the work .
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EDM-Mechanism

A charged electrode is brought near the work piece

. Between them is an insulating oil, known in EDM
as dielectric fluid
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EDM-Mechanism

As the number of ionic (charged) particles increases, the

insulating properties of the dielectric fluid begin to decrease
along a narrow channel centered in the strongest part of the
field. Voltage has reached its peak, but current is still zero.
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EDM-Mechanism

A current is established as the fluid becomes less

of an insulator . Voltage begins to decrease.

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EDM-Mechanism

Heat builds up rapidly as current increases and the

voltage continues to drop. The heat vaporizes some of
the fluid, work piece , and electrode , and a discharge
channel begins to form between the electrode and work
piece
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EDM-Mechanism

A vapor bubble tries to expand outward, but its expansion is limited by a rush of ions
towards the discharge channel l. These ions are attracted by the extremely intense
electromagnetic field that has built up. Current continues to rise, voltage drops.
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EDM-Mechanism

Near the end of the Spark-ON time, current and voltage have stabilized, heat and
pressure within the vapor bubble have reached their maximum, and some metal is
being removed. The layer of metal directly under the discharge column is in a molten
state, but is held in place by the pressure of the vapor bubble. The discharge channel
now consists of a superheated plasma made up of vaporized metal, dielectric oil, and
carbon with an intense current passing through it.
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EDM-Mechanism

At the beginning of the off-time, current and

voltage drop to zero. The temperature decreases
rapidly, collapsing the vapor bubble and causing
the molten metal to be expelled from the work
piece

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EDM-Mechanism

Fresh dielectric fluid rushes in, flushing the debris

away and quenching the surface of the work piece.
Un expelled molten metal solidifies to form what is
known as the recast layer

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EDM-Mechanism

The expelled metal solidifies into tiny spheres dispersed in the

dielectric oil along with bits of carbon from the electrode.The
remaining vapor rises to the surface. Without a sufficient offtime, debris would collect making the spark unstable. This
situation could create a DC arc which can damage the
electrode and the work piece
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CONTROLLING THE SPARK

Each cycle has an ON time and an off-time that are expressed in units of
microseconds (figure).
Since all the work is done during ON time, the duration of these pulses and the
number of cycles per second (frequency) are important.

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CONTROLLING THE SPARK

Once the open gap voltage creates an ionization

path for current flow, the voltage decreases to the
working gap voltage . Current increases until it
reaches peak current during the effective ON time
portion of the cycle.
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CONTROLLING THE SPARK

Metal removal is directly proportional to the amount of energy applied during

the ON time
This energy is controlled by the peak amperage and the length of the ON
time
The longer the ON time pulse is sustained the more work piece material will
be melted away.
The resulting crater will be broader and deeper than a crater produced by a
shorter ON time. These large craters will create a rougher surface finish .
Extended on-times also allow more heat to sink into the work piece and
spread, which means the recast layer will be larger and the heat affected
zone will be deeper.
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Amperes
The amperes available for most EDM-power supplies
(pulse wave form based) range from1400 A.
EDM-power-supply output is rated in amperes. Ampere
output indicates the material-removal capability of the
unit.
The ampere output indicates the material-removal
capabilities of the power supply.
As amperes increase, material-removal rates also
increase and the surface finish becomes coarser
There are two types of amperes:
1. peak amperesdetermined by the amplitude of the
amperes as shown by the square-wave diagram and
2. average amperesdetermined by peak amperes, with
consideration for the spark-ON and -OFF time.
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DUTY CYCLE
Rarely are spark-ON and -OFF times equal in actual
EDM operations
To determine average machining amperes,
calculate the ratio of spark-ON to -OFF time
Duty cycle = ON/(ON + OFF)
where:
ON = spark-ON time in microseconds
OFF = spark-OFF time in microseconds
Ia = Ip duty cycle
where:
Ia = average amperes
Ip = peak amperes
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DUTY CYCLE

average-ampere output based on a short duty

cycle, with a peak output of 100 A

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Average ampere output based on long duty cycle

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Frequency
Frequency is the number of cycles produced across the
gap in one second. The higher the frequency , the finer
the surface finish that can be obtained. As the number of
cycles per second increases, the length of the ON time
decreases
Short on-times remove very little metal and create
smaller craters. This produces a smoother finish with less
thermal damage to the W/P.
Frequency (in kiloHertz) is calculated by dividing 1000 by
the cycle time (on-time + off-time) in microseconds (s),

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EDM Spark energy

Spark energy is determined by the amount of
electrical power contained in each spark,
multiplied by the amount of time the electrical
power is flowing.
spark energy in EDM is

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Effect of duty cycle and frequency on surface

finish

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Electronic-switch ON/OFF and R-C-power supplies

In comparing the two types of power supplies, it is important
to know that both electronic-switch ON/OFF and R-C-power
supplies are used in die-sinker- and wire-cut-machining
applications.
The electronic switch ON/OFF-power supply produces the
greatest efficiency for most EDM applications and it is the
most commonly used type. The electronic-switch, ON/OFFpower supply has the capability of machining with either
graphite or metallic electrodes at higher amperes.
In general, the R-C-power supply is primarily considered for
applications that require a fine surface finish or for the
drilling of small, precise micro-holes.
R-C-power supplies have an approximate 15A maximum limit
for machining. They are also used primarily with metallic
electrodes. R-C-power supplies, therefore, work well for
applications that require lower ampere-sparking output.
Creating fine surfaces or drilling small precision holes are
typical applications.
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Profile of a single EDM pulse,

a, ionization time; b, discharge time;

c, deionization time; d, rest time.
Most of the electrode wear occurs
during the ionization time.

Three-dimensional schematic of the EDM

spark. The spark energy available for material
removal is proportional to the product of
effective on-time, current, and spark voltage.
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Spark
Each sparking occurrence between the electrode and workpiece is
determined by the strength of the dielectric fluid.
Dielectric strength for a typical hydrocarbonoil fluid is 170 volts per mil. A mil is equal to .001 in. (0.025mm)
During the electrode advance time, 170 V is applied between the
electrode and the work piece.
This voltage is called open-circuit voltage, since there is no electricity
flowing between the electrode and the work piece.
With the voltage equal to 170 V and the spacing equal to .001 in.
(0.025 mm), the dielectric fluid ionizes and changes from an
electrical insulator into an electrical conductor.
Electricity flows between the electrode and the work piece through
the ionized dielectric fluid.

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Spark

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Spark
When the power supply is turned ON, but the
electrode is not close enough to the work piece
for sparking to occur, the voltmeter will indicate
open-circuit voltage.
Voltage indicated during sparking is the
machining voltage.
Open-circuit voltage may be in a normal range
of 100300 V. Machining voltage is normally in a
range of 2050 V.

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Dielectric strength
dielectric strength is based on a voltage and a
dimension;
dielectric strength for dielectric fluid is
expressed as a particular number of volts per mil
(dimension);
the dielectric fluid changes from an electrical
insulator into an electrical conductor when the
voltage and dimension equal the fluids dielectricstrength rating; the point at which the dielectric
fluid changes from an electrical insulator into an
electrical conductor is called the ionization point
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Spark -basics

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Spark -basics

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Spark -basics

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Spark -basics

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Spark -basics

Dielectric-fluid atomic charge, without electrode-to-workpiece voltage

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Spark -basics

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Spark -basics

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Spark -basics

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Spark -basics

Positive vapor cloud attracted to negative electrode.

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Spark -basics

Spark OFF, vapor cloud cools to form chip.

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Spark -basics

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Spark -basics

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OVERCUT

Overcut is the gap distance between the electrode and the workpieces
machined surface produced by sparking.. Overcut is expressed as a perside dimension.
This per-side dimension must be taken into consideration when designing the
electrode for die-sinker machines and the programmed path for wire-cut
machines.
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Overcut

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Overcut

The width of the EDM cavity is always larger than the electrode and
the difference is called the overcut (see figure).
The overcut gets larger as amperage and on-times are increased.
These two parameters directly affect the size of the overcut and the
roughness of the finish .
The amount of overcut has to be known in order to properly undersize
the electrode . Most equipment manufacturers supply accurate
overcut information.
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Overcut
Overcut is determined by the dielectric strength of
the dielectric fluid.
Dielectric strength is specified as a voltage and a
dimension at which the dielectric fluid changes
from an electrical insulator to an electrical
conductor.
A typical hydrocarbon oil may have a dielectric
strength of 200 V per mil (.001 in. or 0.025 mm).
EDM machines often use an open circuit voltage of
100 V.
The spark-length distance for a machine using an
open-circuit voltage of 100 V may be calculated for
this particular dielectric fluid using a ratio formula
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Overcut

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Overcut information

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Ionization and Electrode Wear

The spark is the electricity flowing through the ionized column of dielectric fluid.
Within the ionized column, electrons separate from the dielectric-fluid atoms and flow
from the negative-polarity electrode toward the positive-polarity work piece.
Since the dielectric-fluid atoms in the column are missing electrons, they are
positively charged and flow from the positive-polarity work piece toward the negative
polarity electrode.
These positively charged atoms are known as positive ions.
Within the column then, there are electrons flowing in one direction and positive ions
flowing in the other direction.

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Ionization and Electrode Wear

The nature of electricity as it flows through the

column

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Ionization and Electrode Wear

The weight of a positive ion, consisting of the
atom nucleus and remaining electrons, is
thousands of times greater than the weight of
an electron.
Since the positive ion has such a heavy weight,
it accelerates much slower than the electron.
Fewer positive ions than electrons arrive at the
bombardment surface during sparking, which is
why electrons are considered the primary
source of energy for EDM material removal.
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Ionization and Electrode Wear

Most of the electrode wear occurs during the ionization time.

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EDM chip

Vapor clouds combine and cool to form EDM chip.

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Polarity
Electrical polarity of the electrode and
workpiece determines the direction of flow for
electrons and positive ions.
Some EDM manufacturers describe electrode
and workpiece polarity as standard and reverse.
This description is not acceptable since not all
manufacturers use the same polarity for
standard and reverse.
It is now a practice to say the polarity of
electrode ! (work is of opposite polarity)
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Polarity
It is possible to use either negative or positive electrode
polarity for machining with most die-sinker machines
EDM researchers have determined that positive
electrode polarity is useful for reducing electrode wear or
providing more stable servo operation when using
certain electrode and workpiece materials.
Positive electrode polarity usually removes workpiece
material at a lower rate than negative electrode polarity.
However, positive electrode polarity reduces wear of
copper and graphite electrodes when settings
recommended by the machine manufacturer are used for
spark control.

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Polarity

Polarity refers to an electrical condition determining the

direction of the current flow relative to the electrode .
The polarity of the electrode can be either positive or
negative. Depending on the application, some electrode
/work metal combinations give better results when the
polarity is changed.
Generally with graphite , a positive electrode gives
better electrode wear characteristics and a negative
electrode gives better speed(high MRR).

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Polarity for various electrode-work combinations

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ELECTRODE WEAR
Electrode wear is a result of either electron or
positive-ion bombardment.
When the electrode is negative, it is bombarded by
positive ions. When the electrode is positive, it is
bombarded by electrons.
As electrons or positive ions crash into the surface
of the electrode, heat is generated.
The heat vaporizes the electrode material and a
small amount of electrode material is removed with
each spark.
This removal of material is electrode wear.
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Electrode wear

Electrode wear is specified in one of four ways,

1. corner wear,
2. end wear,
3. side wear, and
4. volumetric wear.

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CORNER WEAR

Illustrates the number of sparks required to

produce a flat surface, as compared to the
amount required to produce a 90 corner.
The number of sparks originating from a point on the electrode surface determines electrode wear
Electromagnetic fields tend to concentrate at the electrode corners (figure ), subjecting the corners to
greater wear.
Many sparks must originate from the electrode corner to produce the machined shape in the
workpiece.
By comparison, each spark on the flat surface of the electrode machines a corresponding point on the
workpiece. Since each spark removes material from the electrode, more material is removed from the
corner than the flat surface, causing electrode wear to be greater on the corner.
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CORNER WEAR
Corner wear is the difference between the
original electrode length and the point on the
electrode corner that still retains the original
corner shape.
Corner wear is the standard for determining the
length of the electrode or the number of
electrodes required to complete the work piece
shape in die-sinking operations

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CORNER WEAR

Electrode with shape extending over full length

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END WEAR

End wear is the difference between the original electrode length and the electrode
length after machining.
For the illustration, the work piece has a hole, pre-drilled before EDM, which is used
for dielectric-fluid flow to remove EDM chips.
As the electrode machines the work piece, there are no sparks between the end of
the electrode and the work piece in the area of the pre-drilled hole. The electrode end
remains the original length of the electrode
After the EDM operation is completed, the electrodes end wear is noted by
measuring the cylindrical extension of the electrode material that has passed through
the pre-drilled hole.

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SIDE WEAR
Side wear is the comparison between the
original electrode length and the side surface of
the electrode that shows the full electrode
shape after the machining operation is
complete.
Side wear is the wear used as a reference on
circular electrodes, since corner wear is not a
consideration.

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VOLUMETRIC WEAR
Volumetric wear is the comparison of the
electrodes total volume prior to EDM, to the
electrodes volume upon completion of machining.
There are instances when this type of wear is used
to compare the volume of electrode consumed to
the volume of workpiece machined.
EDM-research engineers often use volumetric wear
for studying and analyzing the EDM process.
Seldom is it used for actual EDM operations in
industry
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Electrode wear

Terms used in expressing wear of EDM

electrodes

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Corner wear ratios for different electrode materials

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EDM-Electrodes

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ELECTRODE MATERIAL
electrode materials must be electrically conductive
Should have high melting point,
an ability to be easily machined, and
a low cost
No single electrode material provides all of the desired
features for any particular application
In the following discussion of electrode materials, cost
comparisons are made by assigning copper a value of 1
Electrode material costs are usually less than fabrication
costs and EDM machine time. Thus, the cheapest
material does not necessarily result in the lowest overall
cost.
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ELECTRODE MATERIALS
Thee material should possess the essential
qualities of good metal removal,low wear, and
the ability to be accurately machined and
fabricated at low cost.
The five commonly used electrode materials are
copper, brass, zinc, tungsten, and Graphite.
These materials can fall into two main
categories: metallics and graphite

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Graphite
Graphite is the most commonly used electrode material because of
good machinability and EDM wear characteristics.
Small, flush holes are easy to drill. It is available in a great variety of
size and form. Commercially available EDM grades range in grain sizes
ranging from 100 microns for a coarse grade, down to 1 micron for
fine-grade material.
the cost factor, compared to copper, was 1.3 to 24, with most grades
falling between 2.6 and 10. A drawback of graphite is that it is dirty to
machine;
Graphite has very good wear qualities. Although it is very machinable,
graphite dust must be considered when machining the material.
Graphite does not melt, but rather sublimes, meaning it goes from a
solid directly into a gas, without melting and going through a liquid
state.
Graphite may not be recommended for machining tungsten carbide.
It may not be recommended for use with R-C-power-supply operations.

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Graphite Electrode

Making- Graphite Electrode

Graphites are divided into the following six classes according to theirparticle
size:
Angstrofine Ultrafine 1-5 microns
Superfine 6-10 microns
Fine 11-20 microns
Medium 21-100 microns
Coarse>100 microns
Graphites in the Coarse classification are not suitable for EDM purposes. 103

Graphite Electrode

104

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Graphite Electrode

Isotropic structure.

Anisotropic structure.

105

Potential electrodes for EDM

Only graphite and tungsten composites remain

solid at temperatures remotely near gap conditions.
Graphite does not change to a liquid when heated,
but sublimes.

106

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COPPER
It often is used for R-C-power-supply operations
Copper has good EDM wear, good conductivity, and is
economical.
Copper is difficult to grind but has good no-wear-machining
characteristics.
It does not machine as well as brass or graphite.
Nonetheless, it is used almost as much as graphite, and is
especially good for machining tungsten carbide.
Copper is preferred for finishes better than 0.5m Ra
Copper is readily available and normally specified as
electrolytic grade or tellurium-copper alloy. .
Tellurium copper is copper with the element tellurium added
and it is equivalent in machinability to free-machining brass.
It is only be slightly more expensive than copper (cost
factor, 1.2), and it is nearly as machinable as brass.
107

BRASS
Brass is readily available. The grade used is
normally specified as free-machining brass.
is inexpensive and easy to machine
It has a fairly good wear ratio when machining
steel, and a very high wear ratio when machining
tungsten carbide.
Brass is not normally recommended for use with RC-power supplies.
It is often used for tubular electrodes in specialized
small-hole EDM drilling machines where high wear is
acceptable.
108

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Tungsten and Tungsten Composites

Theoretically tungsten is the best of the metallics
for use as an electrode .
With its very high strength, density, hardness, and
a melting point near 3400C, tungsten resists the
damaging effects of the EDM process very well
indeed.
There are two main problems associated with using
pure tungsten as an electrode material.
It is very difficult to machine and extremely
expensive, which limits its usefulness as an
electrode material.
Tungsten is used to make small holes (<0.2 mm) for
which electrodes with flush holes are not available
109

COPPER TUNGSTEN
Copper tungsten is a sintered material made
from copper and tungsten, with a common ratio
of 70% tungsten and 30% copper.
It has very good wear characteristics. Difficult
to machine except by grinding, copper tungsten
is often used for machining tungsten carbide

110

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Electrodes of EDM
COPPER GRAPHITE
Copper graphite is fine-grain graphite that is infiltrated with
copper.
It has the qualities of graphite, plus the electrical conductivity
of copper.
It is 1.5 to 2 times more expensive than the same graphite
without copper, thus making it from 5 to 20 times more
expensive than copper
The flexural strength is higher than the comparable grade of
graphite, making it good for thin cross-section electrodes.
Electrical conductivity is greatly improved, but corner wear is
not as good as it is for the same grade of pure graphite.
This material works well on tungsten carbide.
ZINC ALLOYS
Zinc alloys may be used as an electrode material, but the
wear characteristics are very poor.
111

Claim by leading commercial EDM electorde OEM

USA 90 %
Europe-75 %
Asia-55 %

112

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25-03-2015

EDM system components

113

Servo mechanism-EDM

When the EDM machine is turned on, the servo microprocessor , sensing that
the gap is too wide for cutting to take place, signals the servo mechanism to
lower ram head
When the first spark jumps the gap, downward travel of the ram head stops.
With the gap setting held constant, the process gradually erodes the surface.
When enough metal has been removed to change the gap distance, the
microprocessor senses this and signals the servo mechanism to advance the
ram head sufficiently to maintain the proper gap width and the process
continues.
114

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Servo mechanism-EDM
If the ram were allowed to move forward unchecked,
there would be direct contact between electrode and
workpiece, causing an electrical short circuit.
This is prevented by a servo mechanism in which the
potential is monitored and compared with a reference.
If the potential is greater than the reference, the ram
advances; if it is less, the ram retracts. The movement
may be accomplished by a hydraulic cylinder or a directdrive servomotor.
As the work is machined by spark erosion, the distance
between electrode and workpiece increases. The
potential goes up, and the ram advances until the
potential matches the reference. Thus, the servo
mechanism maintains a constant gap.
Erosion continues until a preset depth is reached. At this
point, the electrode is retracted from the workpiece.
115

EDM-servo system
EDM machines require an automatic system for proper spacing of an
electrode from the workpiece.
This maintains efficient sparking. Such a system must be versatile
enough to work with electrodes as small as (0.025 mm) in diameter,
to very large electrodes that weigh several Kg.
This automatic operation is accomplished by the EDM-servo system.
Requirements for an EDM-servo system are:
the electrode must not touch the workpiece, and
the electrode must advance toward and retract from the workpiece
to maintain the voltage between the electrode and workpiece.

116

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SPARKING VOLTAGE

EDM-servo systems make use of the electrical characteristics of the

dielectric fluid for their operation
The dielectric fluid during EDM changes from an insulator into an
electrical conductor, causing the voltage between the electrode and
workpiece to drop from the open circuit to sparking voltage. This
normally occurs in a range of 2050 VDC.
117

SERVO-REFERENCE VOLTAGE

As the machining-voltage range is constant for a particular dielectric

fluid, a voltage in this range is selected as a reference for controlling
the servo system
This reference voltage is compared to the actual machining voltage
measured between the electrode and workpiece.
The difference between the reference voltage and the actual
electrode-to-workpiece machining voltage is that the difference in the
voltages is used to command the electrode-servo system to advance,
hold position, or retract from the workpiece.
118

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Metal and graphite servo-reference-voltage range

119

Electrical connections for sparking power and

servo sensing.

The servo system is controlled by wires that connect the electrode

and work piece to the electronic assembly of the power supply.
These sensing wires allow the electrode-to-workpiece voltage to be
compared to the servo controls reference voltage
120

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Two servo systems in EDM

The system used primarily depends on the size and
weight of the electrodes.
Large machines using heavy electrodes normally use the
hydraulic servo and those that use smaller electrodes
generally use the electric motor- servo drive.
Electric-motor-drive systems are preferred for wire-cut
machines because positioning- and data-feedback
devices are readily available
Mechanically, the electric-motor and hydraulic-drive
systems are simple structures. In both instances, the
electronic control commands an action to be taken.
The mechanical drive assembly advances, holds position,
or retracts the electrode.
121

Basic electric-servo system.

The electric motor is directly coupled here to a precision lead screw.The leadscrew nut is attached to the machine axis of movement.
Any rotational movement of the motor will produce a corresponding
movement in the machine axis and electrode
122

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Basic hydraulic servo system.

123

Basic hydraulic servo system

When fluid pressure is applied to one side of the hydraulic-cylinder piston, fluid enters
that side of the cylinder and exits the opposite side.
The piston and piston rod move in response to the fluid entering the cylinder.
The fluid flowing to and from the hydraulic cylinder is controlled by the servovalve,
which is electronically controlled by the servo-control unit in the power-supply
cabinet.
124

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EDM Surface topography

When inspecting an EDM surface finish, the lack of surface

directionality needs to be considered.
The surface resembles a cratered surface with all craters the
same size (Fig. ).
There is no "lay" or directionality to the surface as in
conventional machining. Because the crater size depends on
spark energy, and spark energy varies widely, the EDM
surface finish surface can range from 0.2 to 12.5 m
125

Each discharge creates a crater

An AFM view
126

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25-03-2015

EDM Surface-Metallurgical and Chemical Effects

Because of the rapid quenching by the dielectric

and the heat sink effect of the workpiece, the
surface layer affected by the EDM process is quite
thin--less than 0.1 mm for roughing settings and
0.01 mm for finish settings
127

WORKPIECE METAL - Layers formed by EDM process.

The EDM process changes not only the surface of the work metal, but
also the subsurface.
Three layers (total thickness may be 0.05-0.1 mm mm only) are
created on top of the unaffected work metal (figure).
The spattered surface layer
The recast (white) layer (2 to 50 micrometer)
heat affected zone(25 micrometer)

128

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Layers formed by EDM process.

The spattered EDM surface layer is created when expelled molten metal and small
amounts of electrode material form spheres and spatter the surface of the workmetal.
This spattered material is easily removed by polishining.
The next layer is the recast (white) layer. The action of EDMing has actually altered
the workmetal's metallurgical structure and characteristics in the recast layer.
This layer is formed by the unexpelled molten metal solidifying in the crater. The
molten metal is rapidly quenched by the dielectric. Microcracks can form in this very
hard, brittle layer.
If this layer is too thick or is not reduced or removed by polishing, the effects of this
layer can cause premature failure of the part in some applications. Microcracks occur
in the recast layer and can act as initiation points for failure(reduced fatigue strength)
The recast layer is characterized by a rapidly quenched structure. The structure is
usually brittle and extremely hard(65 HRC) It may be porous and contain micro cracks.
This can be removed by abrasive methods or shot peening operations
129

Layers formed by EDM process-heat affected zone

The last layer is the heat affected zone which has only been heated,
not melted. Heating, cooling and diffused material are responsible for
this zone. HAZ may contain thermal residual stress and grain
boundary cracks.
The depth of the recast layer and the heat affected zone is determined
by the heat sinking ability of the material and the power used for the
cut. This altered metal zone influences the quality of the surface
integrity
The recast layer is characterized by a rapidly quenched structure,
while the heat-affected zone has an annealed or tempered structure.
130

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Schematic diagram of layers on an EDMd

component

131

A typical specification for

EDM application could include the following items
total thickness of the re-deposited and re-solidified layers:
0.025 mm;
total thickness of the re-deposited, re-solidified, and
changed material characteristic layers: 0.05 mm);
electrode material present in re-deposited layer: none;
cracks in re-deposited and re-solidified layers: acceptable
(depending on the end use); and
cracks in parent material: not acceptable.
In many instances the EDM surface finish may be used without additional
finishing operations, such as in plastic-injection molds or in press tooling.
But for structural components, it is a common practice to do polishing (abrasive
methods) to remove recast layer. Shot peening is also used to remove a small part
of the recast layer and to improve the fatigue properties.
132

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Process capability of EDM

Accuracy-0.025 to 0.1mm (Best possible:
2.5m)
Taper in deep holes: 0.005 to 0.05mm/cm
Aspect ratio:100:1 (special care of flushing)
Crater diameter: 5 to 12 m and crater
depth:0.25 to 1.25 m
Surface finish (usual case):08 to 3.5m (may go
up to 12 microns)
Best Finish using ideal CNC EDMsetting:0.18 to
0.25m
133

MRR and Finish for EDM

134

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Dielectric Fluids
The dielectric fluid performs several functions:
It is a spark conductor that must ionize under
an applied voltage.
It is a coolant for work and electrode.
cooling for the vaporized material that becomes
the EDM chip upon solidification;
It is a flushing medium that carries away the
EDM-spark debris (EDM chips) resulting from
the process.
135

Desirable properties of dielectric

low viscosity,
High flash point,
generation of stable spark (spark gap control by
acceptable dielectric strength)
low cost.
Because of small working gaps at finish spark settings, a low-viscosity
dielectric is especially important.
Low viscosity also helps in settling of the swarf, thus keeping the
dielectric fluid clean.

The most common dielectric fluid is petroleumbase oil (hydrocarbon oils dedicated for EDM
process) . Also used are kerosene, silicone oils, and
water-base dielectrics.

136

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Dielectric Fluids
Spark-ON time determines how long spark
electricity will flow after the ionization point is
reached. When spark electricity is turned OFF,
electricity stops flowing.
The spark is then extinguished and the dielectric
fluid is once again an insulator. This characteristic
is most important, since the dielectric-fluidionization point controls each spark.
These changes, from insulator, to conductor, to
insulator, take place for each spark. It is required
for this action to occur as often as 500,000 times
per second (500 kHz).
137

Dielectric Fluids
Deionized water has some desirable
characteristics
fire safety,
low cost,
low viscosity, and
absence of carbon to react with the work.

138

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Dielectric Fluids
Petroleum products are often referred to as
hydrocarbon fluids, since they break down into
hydrogen, carbon, and other by-products
when they are heated during sparking.
Deionized water has the impurities removed that
would make it electrically conductive. The heat of
sparking breaks down this water into hydrogen and
oxygen.
Usually, die-sinker machines use hydrocarbon fluids
as dielectric fluids, and wire-cut machines use
deionized water.
139

Deionized water
Deionized water absorbs materials that make
the water electrically conductive during the
sparking process.
As water absorbs materials, the dielectric
characteristics of the water change.
This also changes the waters ionization point
and it affects the reliability and repeatability
of the sparking process
Thus deionized water is not an acceptable
dielectric fluid for Die sinking EDM process
140

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Deionized water-Wire EDM

In most instances, wire-cut-machining operations are not
performed with the workpiece submerged.
Instead, a high-velocity flow of fresh deionized water
surrounds the electrode and covers the workpiece in the
sparking area.
It then returns immediately to the collection system for
reprocessing.
This process ensures that the deionized water passing
through the sparking area will stay within the acceptable
range of electrical characteristics required for precise
EDM operations.
141

HYDROCARBON FLUIDS
Hydrocarbon fluids maintain their dielectric
characteristics during the sparking process
when sparking heat breaks the fluid down,
and the machining process adds debris.
This electrical integrity under such conditions
makes hydrocarbon fluids the dielectric fluid of
choice for submerged machining (RAM EDM).

142

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RESULTS OF CHIPS REMAINING IN SPARKING

GAP

If chips are not removed from the sparking gap, the spark electricity is forced
to pass through the chips on the workpiece surface.
As it does so, the electricity re-machines the chips into smaller ones, which
requires spark energy and reduces the size of chips being removed from the
workpiece surface.
This smaller than normal amount of workpiece material being removed
creates inefficient EDM operations.
As chips are free to move about the workpiece surface, variances are caused
in the electrode- to-workpiece voltage that cause unstable servo operations.
143

Flushing -INSIDE THE CAVITY

Flushing - Flowing dielectric through the gap to remove

the debris caused by machining with EDM.
As the cut progresses through the work metal a cavity
starts to form. The deeper this cavity becomes, the
harder it is for fresh dieletric fluid to get into the cavity
to remove debris and quench the work piece and
electrode .
In order to get smooth, even flow of dielectric through
the gap flushing becomes an essential part of the EDM
process.
144

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Pressure flow through the electrode and

workpiece

145

Flushing- Fluid-pressure flow through electrode

146

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Workpiece pressure flow for chip removal.

147

Flushing -INSIDE THE CAVITY

Good flushing allows the work piece particles and eroded electrode particles to be
removed from the gap. Flushing also allows fresh dielectric into the gap.
It is the volume of oil moving through the gap that performs particle removal.
Flushing at higher pressure may actually prevent the flow of particles out of the gap
and the dielectric renewal in the gap. High pressure also tends to wear the electrode.
The ideal pressure is usually between 0.2 to 0.3 bar .
The balance of volume and pressure is important. Roughing operations where the gap
is large would require high volume and low pressure for good oil flow. Finishing
operations where the gap is smaller may necessitate higher pressure to improve the
oil flow.
148

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Various methods for dielectric flushing

(a) suction through electrode, (b) suction through workpiece, (c)

pressure throughelectrode, (d) pressure through workpiece, (e) jet
flushing, (f) periodic cycling of electrode

149

Flushing-general rules
There are three rules for good EDM ing
(1)Flush ! (2)Flush !! and (3) Flush !!!
Changing from very poor to very good flushing conditions
can improve efficiency and thus reduce machining time
by a factor of six (6) !
Through-the-tool flushing is preferred to side flushing
Many small flush holes are preferable to a few large
ones. Besides giving better fluid distribution, smaller and
more-easily-removed spikes (the column of metal left
from a flush hole) result
A steady flow of dielectric fluid over the entire electrodeworkpiece interface is desirable
150

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MAKING EDM WORK

The EDMer's job is to control the machining
parameters and predict the results.
Varying the on-time and/or off time will change
the duty cycle and the frequency .
These changes plus varying the peak current
will affect the metal removal, electrode wear
and finish.

151

Effect of pulse current (energy)

Effect of pulse current (energy) on removal rate and

surface roughness.
152

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Effect of pulse on-time (energy)

Effect of pulse on-time (energy) on removal rate and surface roughness.

153

Basic die-sinker-EDM machine.

154

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Die-sinker major assemblies.

155

C-frame, die-sinker machine.

156

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Bridge-style, die-sinker machine

157

EDM applications

158

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Materials That Can Be EDMed

Any material that conducts electricity can be
EDMed, either hard or soft.

EDM is particularly used to cut Stellite, Inconel, Hastelloy, Nitralloy, Waspaloy,

Nimonic, Udimet, tool steels, tungsten carbide and titanium alloys.
159

EDM applications
Although the application of electrical discharge
machining is limited to the machining of
electrically conductive workpiece materials, the
process has the capability of cutting these
materials regardless of their hardness or
toughness.
Nonconductors such as glass, ceramics, or plastics
cannot be machined using EDM techniques, but
the machining of hardened steel using EDM
eliminates the need for subsequent heat treatment
with possible distortion.
160

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EDM applications
The EDM process is most widely used by the
mold-making and tool and die industries, but it
is increasingly being applied to make prototype
and production parts, especially in the
aerospace and electronics industries, in which
production requirements are relatively low.
Stamping ,extruding, heading, drawing, forging,
and die casting dies, as well as molds for
plastics, can be done with EDM techniques.

161

EDM applications
Electrical discharge machining is particularly well suited
for parts that are made from materials that are difficult
to machine and/or contain small or odd-shaped holes, a
large number of holes, or holes having shallow entrance
angles, intricate cavities, or intricate contours.
Miniature parts and parts made from material too thin or
fragile to withstand conventional, mechanical cutting
forces are also good applications.
Round or irregular-shape holes as small as 0.05 mm (in
diameter can be produced with length-to-diameter ratios
of about 20:1.
Narrow slots as small as 0.05 to 0.30 mm wide are cut
routinely.
162

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Electric Discharge Machining-Applications

163

Electric Discharge Machining-Applications

This satellite structural component was
wirecut from solid CAL-4V titanium
WHEN?
VERY THIN WALLS

WHY?
NO CONTACT
NO FORCE
NO DEFORMATION
Wire + Sinker EXAMPLES?
- SURGICAL TOOLS
- SATELLITE COMPONENTS
- INERTIAL GUIDANCE
- MICROWAVE HORNS
- HONEYCOMB
164

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Electric Discharge Machining-Applications

WHEN?
RECESSED CUTS
KEYWAYS
BOTTLING INDUSTRY

165

Electric Discharge Machining-Applications

166

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Electric Discharge Machining-Applications

WHEN?
FRAIL/FRAGILE CANT TAKE STRESS OF MACHINING
WATCH PARTS
LEAD FRAME DIE
PRINTER HAMMER
167

Electric Discharge Machining-Applications

Medical applications
DENTAL FIXTURES
-MEDICAL CLAWS
168

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Electric Discharge Machining-Applications

169

Wire electrical discharge machining (Wire EDM)

170

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Wire EDM schematic.

Wire EDM schematic.

171

Wire EDMed components

172

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Wire electric discharge machining (Wire EDM)

In wire electric discharge machining (wire EDM), a
wire (about 0.05-0.30 mm diameter) is used as an
electrode and deionized water as dielectric.
A nozzle is employed to inject the dielectirc in the
machining area in wire EDM.
Electrodes (wire and workpiece) are connected to a
pulsed DC supply.
Heat generated due to sparking results in the
melting of workpiece and wire material, and
sometimes part of the material may even vaporize
like in conventional EDM.
173

Wire electric discharge machining (Wire EDM)

A constant gap between tool (wire) and work
piece is maintained with the help of a computer
controlled positioning system.
This system is used to cut through complicated
contours specially in difficult-to-machine
materials.
This process gives a high degree of accuracy
and a good surface finish.

174

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Open-style wire-cut machine

175

wire EDM machine

176

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Enclosed-style wire-cut machine.

The enclosed wire-cut machine is a self-contained module, designed to

protect electronic /electrical components from exposure to dielectric fluid.
Access to the work area and wire-feed unit is gained through sealed doors. 177

Wire-cut machine major assemblies

178

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wire electric discharge machining

Schematic illustration of wire electric discharge

machining
179

Wire-cut machine major assemblies

There are four basic elements of this machine
tool,
the power supply system,
the dielectric system,
the positioning system,
and the wire drive system.

180

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Power Supply System

EDWC machines are equipped only with pulse
generators, where peak current and on-time are the
major variables controlling spark energy.
Wire EDM power supply uses pulse frequency which
is about 1 MHz.
It results in reduced crater size or better surface
finish.
The wire has a limited current capacity, so that the
current rating rarely exceeds 30 A. The potential
difference between the wire electrode and the WP
is usually set between 50 and 60 V.
However, because of very small wire size, it usually
cannot carry current more than 20A.
181

Dielectric System
Water is a likely substitute for hydrocarbon oils
as dielectric in EDM.
It is an attractive proposition because of its
availability, desirable thermal properties, low
viscosity and pollution-free working.
It gives higher MRR and better surface finish
under the identical machining conditions.
Deionized water has low viscosity, no fire
hazard, high cooling rate and high MRR. That is
why water is used as dielectric in most of the
wire EDM systems.
182

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Dielectric-fluid and Filtration Unit

The wire-cut dielectric system must filter the sparking by-products

from the water after it returns to the storage reservoir.
Additives are sometimes used as antirust compounds or ethylene
glycol-based compounds to make the dielectric slippery.
In addition to the filtration, the water must be processed to remove
any dissolved materials before it is usable as an EDM dielectric.
183

Deionized-water dielectric assembly.

Used water from the machine tool is returned to the dielectric-unfiltered reservoir.
A partition in the dielectric tank separates the unfiltered water from the filtered and
deionized water.
Water is pumped from the unfiltered reservoir through the filter to remove the solid
EDM debris.
The water is then pumped through the resin tank and into the filtered and deionized
water reservoir.
The filtered and deionized storage tank includes a sensor to monitor the electrical
conductivity of the deionized water
184

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Positioning System
Usually positioning system is a computerized
numerical control (CNC) two-axes table.
However, it operates in an adaptive control
mode so that in case wire approaches very near
to the workpiece, or the gap is bridged by debris
and causes a short circuit, the positioning
system should be capable to sense it.
Instantaneously, it should move back to reestablish proper cutting conditions in the gap

185

multi-axis, wire-cut servo system.

186

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Multi-axis, wire-cut servo system

The axes are identified as X axis, Y axis, U axis, V axis, and Z axis.
In operation, the X and U axes are parallel in the direction of
operation, the Y and V axes are parallel in their operation, while the Z
axis is perpendicular to the X-U and Y-V axes.
The U and V axes offset the electrode wire from the vertical position.
Z-axis operation may be manually operated or computer controlled.
187

Moving-workpiece-and-electrode wire-cut design.

188

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Wire Drive System

This system serves two purposes, viz continuously delivers fresh wire, and always
keeps the wire under appropriate tension so that it moves in the machining zone as a
straight wire.
The latter requirement is important from the point of view of quality of the machined
surface. For example, it helps to minimize taper, streaks as well as vibration marks.
It also minimizes the wire breaks during machining.
On the way while moving to the machining zone, wire is guided by sapphire or
diamond wire guides .
As it moves towards the take up spool, the wire passes through a series of tensioning
rollers
189

Wire Drive System

The tensioned wire is used only once, traveling from a take-off spool to
a take-up spool while being guided to provide an accurate narrow kerf.
190

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Wire Drive System

Stratified wire used in wire EDM.

Large diameter (0.15-0.30 mm) wires, used in wire EDM, are made of copper or brass while small
diameter wires are usually made of molybdenum steel.
The most widely used wire is brass wire. It has most of the qualities needed for wire EDM, that is, high
tensile strength, high electrical conductivity, and good wiredrawing ability to close tolerances.
Layered wires are also recommended, but are more expensive; however, they cut faster than brass.
One example is steel/copper/graphite wire, with a steel core for tensile strength, a copper layer for
electrical conductivity, and graphite on the surface for attaining high machining speeds. Zinc-coated
brass, with molybdnum-core, is also available
Wire is discarded after it has been used once because the sparking takes place at its leading surface,
hence, it no longer remains round
Wire diameters range from 5 to 300 m. It travels at a constant velocity ranging from 0.2 to 9 m/min.
191

Cutting Speed
In EDWC, the cutting speed is generally given in
terms of cross-sectional area cut per unit time.
Typical examples are 18,000 mm2/h for 50 mm
thick tool steel and 45,000 mm2/h for 150 mm
thick aluminum block.
This rate indicates a linear cutting speed of 6
mm/min and 5 mm/min, respectively.
192

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PROCESS CHARACTERISTICS
This process produces accurate matte finish. Thousands of
tiny craters on the machined surface help in retaining the
lubricating oil and result in increased die life.
Surface finishes range from to 0.2 Im to 1.25 m Ra Surface
finish of the order of 0.1m can be achieved in finish pass
Normal accuracy is about 0.013 mm
Special measures such as m0ultiple passes and precise
temperature control are used for a higher accuracy of
0.005 mm
Work thickness capacity of 150 mm is average with some
machines capable of up to 420 mm
With todays systems, machining rate for definite materials
has gone up from 12.50 cm2/hr to about 40 cm2/hr.

193

Flushing and Dielectrics.

Good flushing is as important in wire EDM as in
vertical EDM.
Nozzles should be as close as possible to the
work.
Workpieces with large variations in thickness
prevent this and are especially troublesome.

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Overcut

As in EDM, an overcut exists in wire EDM that

makes the kerf larger than the wire diameter
This overcut is in the range 0.020 to 0.050mm
Once cutting conditions have been established for
a given cut, the overcut remains fairly constant and
predictable

195

Typical products cut by EDWC

. (From AGIE Charmilles Group, Charmilles)

The special features of wireEDMmake it ideal for making components for

stamping ing dies, tools for lathes, electrodes for vertical EDM, broaches,
and extrusion dies
Because the kerf is so narrow, it is often possible to fabricate punch and die
in a single cut
Wire EDM also has many applications in metallurgy, such as the removal of
core samples from castings to determine variation in chemistry; the
sectioning of welds for metallography, and the making of mechanical
property specimens
Other tools and parts with intricate outline shapes, such as lathe form tools,
extrusion dies, and flat templates, are made with electric discharge wire
cutting.
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Thank You.

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