Syllabus for Electro Discharge Machining (EDM)

Course Overview: Electro Discharge Machining (EDM) is a non-traditional machining process

that uses electrical discharges to erode material from a workpiece. This course covers the theory,
application, and practical aspects of EDM, focusing on its principles, equipment, and use for
precision machining of hard materials.

Module 1: Introduction to EDM

 Fundamentals of Non-Traditional Machining

o Overview of conventional vs non-traditional machining processes
o History and development of EDM
 Basic Principles of EDM
o Electric discharge and spark erosion
o Mechanism of material removal
o Characteristics of EDM process
 EDM Machine Setup
o Components of an EDM machine: electrodes, power supply, dielectric fluid
o Workpiece material considerations

Module 2: EDM Process Details

 Types of EDM
o Wire EDM (WEDM)
o Die-sinker EDM
o Hole-drilling EDM
 Electrode Material and Design
o Types of electrodes: copper, graphite, and others
o Electrode wear and its effect on machining
o Electrode design considerations for different applications
 Dielectric Fluid
o Role of dielectric in EDM
o Types of dielectric fluids
o Maintenance and filtration systems for dielectric fluids
 Discharge Mechanism and Energy Generation
o Spark generation and the electric circuit
o Role of voltage, current, and frequency
o Heat generation and its effects on material properties

Module 3: Process Parameters and Optimization

 Process Parameters
o Pulse on-time, pulse off-time, peak current, and voltage
 o Flushing pressure and dielectric temperature
 Effect of Parameters on Material Removal Rate (MRR) and Surface Finish
o Influence of EDM parameters on machining efficiency
o Trade-off between MRR, surface finish, and electrode wear
 Optimization of EDM Parameters
o Empirical formulas for optimization
o Adaptive control techniques
o Process monitoring and control

Module 4: EDM Applications

 Applications in Industries
o Aerospace, automotive, tool-making, and die manufacturing
o Use of EDM for intricate and complex geometries
o Micro-EDM for small-scale applications
 Materials Machined by EDM
o Hard and brittle materials (e.g., hardened steels, carbide, ceramics)
o Applications in high-performance and exotic materials
 Complex Geometries and Precision Machining
o Application of EDM for intricate cavity shapes, deep holes, and fine features

Module 5: Advanced EDM Technologies

 Wire EDM (WEDM)

o Principle of wire EDM
o Advantages and limitations of WEDM
o Applications and industries utilizing WEDM
 Micro EDM
o Micromachining techniques using EDM
o Applications in precision engineering and electronics
 High-Speed EDM and Laser-EDM Hybrid Technologies
o High-speed EDM machines and their capabilities
o Hybrid systems combining laser and EDM

Module 6: Quality Control and Maintenance

 Surface Finish and Accuracy in EDM

o Methods of measuring surface quality and dimensional accuracy
o Impact of process parameters on finish and accuracy
 Maintenance of EDM Machines
o Regular maintenance procedures
o Common issues in EDM and troubleshooting tips
 Environmental and Safety Aspects
o Waste management of dielectric fluids and electrodes
o Safety considerations in handling electrical discharges and fluids
Module 7: Future Trends and Research in EDM

 Emerging Trends in EDM Technology

o Automation and robotics in EDM
o Advances in material science and electrode development
 Research and Development in EDM
o Current research trends in improving MRR, accuracy, and surface quality
o Integration of EDM with other manufacturing technologies (e.g., additive
manufacturing, laser machining)

Recommended Textbooks and References:

1. "Fundamentals of Electrochemical Machining" by V. K. Jain

2. "Advanced Machining Processes" by Prof. K. R. R. Anjaneyulu
3. "Introduction to Nontraditional Manufacturing Processes" by Paul J. Desrochers
4. Research papers and journals on EDM (e.g., CIRP Annals, Journal of Materials
Processing Technology)

Assessment:

 Theory Exams: Covering EDM principles, applications, and optimization.

 Practical Assignments: Hands-on experience with EDM machines or simulation-based
exercises.
 Project: A project involving process optimization or the design of EDM electrodes for a
specific application.

This syllabus is designed to give students both theoretical knowledge and practical skills in using
EDM for precision machining and advanced manufacturing techniques.

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Overview of conventional vs non -traditional machining process

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Overview of Conventional vs Non-Traditional Machining Processes

Machining is a process used to remove material from a workpiece to achieve desired dimensions
and surface finish. There are two primary categories of machining processes: Conventional
Machining and Non-Traditional (or Advanced) Machining.

1. Conventional Machining Processes

Conventional machining processes typically involve mechanical means of material removal,

such as cutting, grinding, turning, and milling. These processes require direct contact between
the cutting tool and the workpiece.

Key Features:

 Tool-workpiece interaction: Involves physical cutting or grinding action, where a

cutting tool removes material through shear force.
 Mechanical methods: Based on traditional methods that have been in use for centuries,
such as turning, milling, drilling, and grinding.
 Material removal: Material is removed by shear deformation or abrasion.
 Precision: Limited by tool wear, surface finish, and geometric constraints of the tools.
 Applications: Suitable for relatively simple geometries, and when the material being
machined is not excessively hard or difficult to process.

Common Processes:

1. Turning: A rotating workpiece is cut by a stationary tool.

2. Milling: A rotating tool removes material from a stationary workpiece.
3. Drilling: A rotating drill bit creates holes in the workpiece.
4. Grinding: A rotating abrasive wheel removes fine material to achieve high surface
finishes and close tolerances.

Advantages of Conventional Machining:

 Well-established techniques with mature technology.

 High material removal rates (MRR) for certain materials.
 Suitable for a wide range of materials (metals, plastics, etc.).
 Economical for medium to high production volumes.

Disadvantages of Conventional Machining:

 Limited to relatively soft materials unless very specialized tools are used.
 Not ideal for complex, intricate, or hard-to-machine geometries.
 Tool wear is significant, affecting accuracy and surface quality.
 High forces and temperatures generated during machining can cause material distortion
or thermal damage.
2. Non-Traditional Machining Processes (NTM)

Non-traditional machining processes, also known as advanced or unconventional machining, do

not rely on direct mechanical cutting forces. Instead, they use energy sources like electrical
discharges, lasers, chemical reactions, or abrasives to remove material. These processes are
particularly useful for hard, brittle, or complex materials where conventional machining would
be difficult or inefficient.

Key Features:

 No direct tool-workpiece contact: Many non-traditional processes avoid direct

mechanical interaction, which helps reduce wear on the tools and allows machining of
hard or delicate materials.
 Energy-based material removal: They often use heat, electricity, laser beams, water
jets, or chemical reactions to remove material.
 Precision and Complexity: Capable of achieving very high precision and machining
intricate shapes that would be difficult or impossible with conventional methods.
 Suitable for hard, brittle, or high-strength materials: Especially when conventional
tools may wear out quickly or be ineffective.

Common Processes:

1. Electro Discharge Machining (EDM): Uses electrical discharges (sparks) to erode

material from the workpiece.
2. Laser Beam Machining (LBM): Uses a high-powered laser to melt or vaporize material.
3. Water Jet Cutting (WJC): Uses a high-pressure stream of water (often with abrasives)
to cut through materials.
4. Electron Beam Machining (EBM): Uses a focused beam of high-energy electrons to
vaporize material.
5. Chemical Machining (CHM): Removes material by selective chemical etching, often
used for thin, flat parts.
6. Ultrasonic Machining (USM): Uses high-frequency vibrations of a tool to remove
material via abrasive slurry.

Advantages of Non-Traditional Machining:

 Ability to machine hard and brittle materials: Ideal for high-hardness materials (e.g.,
tungsten carbide, ceramics, and superalloys).
 Intricate shapes and fine details: Can produce complex, detailed parts that are difficult
to achieve with conventional methods.
 No tool wear: Many NTM processes (like EDM and laser cutting) do not involve
physical contact between the tool and the workpiece, reducing tool wear.
 Higher precision: Non-traditional processes can achieve superior surface finishes and
tight tolerances, especially for small or delicate parts.

Disadvantages of Non-Traditional Machining:

  Lower material removal rates: Many NTM processes have lower material removal
rates compared to conventional methods, making them less suitable for high-volume
production.
 Higher operational costs: The equipment and operating costs for NTM processes (e.g.,
lasers, EDM machines) are generally higher.
 Limited material compatibility: Some non-traditional processes are effective only for
specific materials (e.g., EDM is ideal for conductive materials, laser cutting for metals,
etc.).
 Complex setup and operation: Some NTM processes require specialized skills and
knowledge to operate effectively.

Key Differences:

Aspect Conventional Machining Non-Traditional Machining

Material Cutting (shearing, grinding, Energy-based (electrical, thermal,
Removal abrasion) chemical, etc.)
Tool-Workpiece Direct contact (cutting tool and No direct contact (except for some like
Contact workpiece) water jets)
Limited by tool wear and High precision and capability for complex
Precision
mechanical forces shapes
Materials Primarily metals, plastics, softer Hard, brittle, exotic materials, and complex
Machined materials alloys
High material removal rates for Slower material removal rates, better for
Production Rate
simple geometries intricate parts
Significant wear, which affects Minimal to no tool wear in many processes
Tool Wear
surface finish and tool life (e.g., EDM, LBM)
Relatively lower operational Higher setup and equipment costs, but cost-
Cost
costs effective for low-volume, complex parts

Conclusion

Conventional machining processes are widely used for high-volume, simpler machining tasks
involving softer materials, where high material removal rates are desired. In contrast, non-
traditional machining processes offer a more specialized approach for complex geometries,
intricate details, and hard-to-machine materials, although at the cost of slower material removal
and higher operational costs.

Both approaches have their place in modern manufacturing, and often, a combination of both
traditional and non-traditional methods is used to optimize productivity, cost-effectiveness, and
precision.

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You said:

Explain the principles of EDM

ChatGPT said:

ChatGPT

Principles of Electro Discharge Machining (EDM)

Electro Discharge Machining (EDM) is a non-traditional machining process that removes

material from a workpiece using electrical discharges (sparks) between a tool electrode and the
workpiece. This process is ideal for machining hard materials, complex shapes, and fine details
that are difficult or impossible to achieve with conventional machining methods. The key
principles of EDM revolve around the controlled use of electrical energy to erode material in a
precise manner.

Basic Working Principle

1. Electric Spark Generation:

EDM uses a series of controlled electrical discharges (sparks) between an electrode (tool)
and the workpiece. These sparks occur in a gap filled with a dielectric fluid (usually oil or
deionized water), which serves as an insulator. The sparks are created when a voltage is
applied between the electrode and the workpiece, creating an electrical breakdown of the
dielectric fluid.
2. Material Erosion:
When a spark occurs, a small portion of the workpiece material is rapidly melted and
vaporized by the heat generated by the spark. The dielectric fluid flushes away the molten
material, and the process repeats with successive sparks. The material removal happens in
tiny increments, leaving a cavity in the workpiece.
3. Electrode and Workpiece Interaction:
The electrode (tool) is typically made from materials such as copper, graphite, or
tungsten, and it is usually shaped to the desired geometry of the cavity or feature to be
machined. The workpiece, which is often made of hard or brittle materials, is positioned
relative to the electrode, and the gap between the two is carefully controlled.
4. Controlled Sparks and Gap Regulation:
EDM is a highly controlled process where the frequency, duration, and intensity of the
electrical pulses are precisely regulated. The gap between the electrode and the
workpiece must remain stable, and any fluctuation or variation in this gap can affect the
machining precision.

Detailed Breakdown of EDM Principles

1. Spark Discharge

 Spark Formation: When the voltage applied between the electrode and the workpiece
reaches a critical value, the dielectric fluid breaks down, and an electrical discharge
occurs. This results in a spark that generates a high temperature (up to several thousand
degrees Celsius) localized in the area of the spark.
 Heat Generation: The intense heat melts the material of the workpiece at the point of the
spark. The molten material either vaporizes or is ejected as tiny droplets or particles.

2. Dielectric Fluid

 Role of Dielectric: The dielectric fluid serves several functions: it insulates the
workpiece and the electrode, prevents direct electrical contact, cools the area around the
spark, and helps remove debris from the machining zone.
 Types of Dielectrics:
o Oil-based dielectric: Typically used in traditional EDM due to its higher
flashpoint and better flushing characteristics.
o Water-based dielectric: Used in some EDM applications for faster flushing and
lower electrode wear.

3. Material Removal Mechanism

 Microscopic Erosion: Each discharge melts and vaporizes a very small amount of
material from the workpiece, typically in the order of micrometers per spark. Over time,
the cumulative effect of millions of pulses leads to significant material

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