Department of Mechanical Engineering

ME-303L Manufacturing Processes Lab

Experiment No. 10
Experiment Name: Part Manufacturing using EDM

Name of Student: Muhammad Umair

Registration No.: 04-3-1-036-2022
Date of Experiment: 07-04-2025
Group: B2

Report Marks _____ out of 10

Date of Report Submission: 15-05-2025
Signature of Lab Engineer:
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Table Of Contents

1 Abstract .................................................................................................................................. 1
2 Theory .................................................................................................................................... 1
3 Procedure................................................................................................................................ 2
4 Discussion .............................................................................................................................. 3
5 Sustainability .......................................................................................................................... 4
6 Conclusions ............................................................................................................................ 4
7 References ............................................................................................................................... 4
 List of Figures i

Figure 1:ELECTRIC DISCHARGE MACHINE ....................................................................... 2

Figure 2:EDM PROCESS SET-UP [2]...................................................................................... 4
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1 Abstract
The aim of this experiment was to explore the fundamental principles of an Electric Discharge
Machine (EDM), a non-traditional manufacturing process. Its primary goal is to manufacture
workpieces that cannot be produced using conventional machining methods, employing the
Electric Discharge Machine. This method is known for its high precision and tolerance levels
within the range of a few thousandths of a centimeter. During the experiment, a highly
positively charged anode served as the cutting tool. The localized melting occurred due to the
spark generated by the high potential difference between the anode and cathode when they
were in close proximity, resulting in elevated temperatures.

2 Theory
Electric Discharge Machining (EDM) stands as a prominent non-traditional manufacturing
process, widely utilized in various industries. This technique involves the controlled erosion of
conductive materials through electrical discharges. By employing discrete electrical
discharges, metal is removed with precision, achieving localized temperatures adequate for
melting or vaporizing the metal in proximity to the discharge point.

Primarily utilized for shaping, cutting, and drilling intricate geometries in materials challenging
to machine conventionally, such as hardened steel and exotic alloys, EDM employs a formed
electrode tool to shape the finished work surface. The spark generation occurs within a narrow
gap between the tool and the work surface, facilitated by the presence of a dielectric fluid. This
fluid not only enables a path for each discharge by ionizing in the gap but also serves as a
coolant, prevents arcing, and aids in conducting the electrical discharge. The process, governed
by CNC machinery, ensures precise positioning of the tool and workpiece, crucial for accurate
machining. Two types of electrodes, namely the tool electrode (cathode) and the workpiece
electrode (anode), are utilized in EDM. The tool electrode, typically crafted from graphite or
copper, assumes the desired shape of the final product. Depending on the application, dielectric
fluids, which can be oil-based or water-based, are chosen.

Renowned for its high precision and adeptness in handling intricate designs, EDM achieves
remarkable accuracy, often within microns. Its versatility makes it applicable across various
industries, including aerospace, automotive, electronics, medical devices, and tool and die
making. Components like molds, dies, turbine blades, and intricate metal parts with tight
tolerances are commonly manufactured using EDM.

Wire EDM, employing a small diameter wire as the electrode to cut a narrow kerf in the work,
and sinker EDM, utilized for fabricating dies and molds, are two primary types of EDM
processes, each with distinct applications and advantages.
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Figure 1:ELECTRIC DISCHARGE MACHINE

3 Procedure
Following procedure was adopted while using the electrical discharge machining:
1. Initially, the component to be manufactured was designed in a 2D drawing format.
2. The workpiece was affixed onto the table of the Electrical Discharge Machining (EDM)
apparatus and underwent a cleaning process post-affixation.
3. Subsequently, the oil valve was activated to permit kerosene oil to envelop the component,
ensuring it submerged at least 20-50 mm below the oil surface. This step aimed to prevent
contact with oxygen and mitigate risks of fire and oxidation.
4. Following this, a potential difference was introduced, and the electrode material was
configured based on the thickness and composition of the component being produced.
5. The machinery was initiated, and the electrode was guided to shape the material according
to the desired specifications.
6. Upon completion of the operation, the oil was drained via the drain valve, and the machinery
was powered down.
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4 Discussion
The primary objective of this experiment was to gain a fundamental understanding of the
operational principles of Electric Discharge Machining (EDM). EDM utilizes an electric
discharge to fabricate components when the two surfaces, namely the workpiece and the tool,
are in close proximity. The dielectric material undergoes ionization to establish a pathway for
the discharge. It's imperative that the dielectric material acts as an insulator to prevent the flow
of electric current; otherwise, sparks won't be generated. In our experiment, kerosene oil served
as the dielectric material. A suitable dielectric material is crucial for the success of the
operation; air cannot be employed due to its oxygen content, posing a fire hazard. Conversely,
kerosene oil, lacking oxygen, is suitable for use as a dielectric, albeit with potential surface fire
risks. Additionally, dielectric fluid serves to dissipate heat from the tool and workpiece and
flush debris from the gap. Discharges are initiated by a pulsating direct current power supply
connected to either the workpiece or the tool. The region experiencing discharge undergoes
heating to exceptionally high temperatures, causing rapid melting and removal of a small
portion of the work surface.
Surface finish of the workpiece is chiefly influenced by two factors: discharge current,
contingent on potential difference, and discharge frequency. Higher discharge current yields a
poorer surface finish but increases material removal rate, whereas higher frequency results in
a smoother finish and greater material removal rate. Conversely, lower frequency results in a
rougher finish, presenting contrasting effects to discharge current. Consequently, harder work
materials necessitate higher potential differences for effective cutting. Machine input voltage
is supplied in the form of square waves, facilitating the stepwise operation of the machine.
Achieving finer tolerances on workpiece dimensions entails producing an arc as thin as
possible, limited by the machine's capability to a minimum of 0.02 mm. Physical contact
between the tool and workpiece should be avoided to ensure arc production, minimize tool
wear, and allow the tool's geometry to shape the workpiece, while material removal is executed
by the electric arc.
The principal advantages of EDM include its ability to machine harder workpieces that are
challenging or impossible to process using conventional methods, achieved through precise
application of higher voltages. Tool wear issues are mitigated as there is no contact between
the tool and workpiece, reducing the likelihood of surface cracks. Moreover, EDM electrodes
can be tailored to specific part geometries, facilitating integration into automated
manufacturing systems for high-volume production with minimal manual intervention.
Limitations of the process include its exclusivity to electrically conductive work materials and
its time-intensive nature, particularly for intricate shapes, due to its stepwise operation.
Mechanization can expedite production for thin workpieces but may be time-consuming for
thicker parts. Furthermore, EDM entails higher initial equipment investment and operating
costs and may induce anisotropy in workpiece materials due to localized heating. Common
applications of EDM are prevalent in mold and die making industries, with Wire EDM being
the predominant and contemporary method. This technique employs a thin wire to cut a narrow
kerf in the workpiece, with tolerances contingent on wire thickness.
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Figure 2:EDM PROCESS SET-UP [2]

5 Sustainability
Electric Discharge Machining (EDM) generates metal particles and debris, necessitating
careful disposal and environmental considerations. However, EDM is recognized for its high
material efficiency, as it can precisely remove material without generating substantial waste.
Improper disposal of these byproducts can result in environmental contamination. Additionally,
the thermal effects of EDM can generate waste heat, leading to localized environmental
impacts. To mitigate the environmental effects of EDM, manufacturers can implement practices
such as optimizing machining parameters to minimize energy consumption and adopting
efficient dielectric fluid management and recycling systems. Furthermore, advancements in
EDM technology and materials hold potential to further influence its environmental footprint
in the future.

6 Conclusions
The experiment concluded the manufacturing of parts using EDM. The desired tolerances on the
work part can be achieved by controlling the discharge current and frequency. In conclusion, the
process can be used to machine work parts with high accuracy and precision and involves lesser
waste material than conventional machining processes. As technology advances in speed, work
piece size, geometry complexity and accuracy, new machine technology and EDM wires are
helping to improve machine performance and productivity. The wire-cut electrical discharge
machining plays an important role in manufacturing sectors especially industries like aerospace,
ordinance, automobile, and general engineering. Since the speed of the cutting increases, the
time taken to finish the product will decrease. So, with the right application, cutting speeds, the
process could be done faster, and it is possible to increase the productivity of parts.
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7 References
[1] K. Smith, "Google," Engineering Product Design, 20 March 2020. [Online]. Available:
https://engineeringproductdesign.com/knowledge-base/electrical-discharge-machining/.
[Accessed 10 May 2024