Module-3: ADVANCED MATERIAL REMOVAL PROCESSES

Lecture No-10 Die-Sinker EDM and its Systems Die-Sinker EDM is known by different names such as Ram EDM, sinker EDM, vertical EDM and plunge EDM. The process is generally used for producing blind cavities. In die-sinker EDM, the electrode and workpiece are submerged in an insulating liquid such as oil or other dielectric fluids. The electrode and workpiece are connected to a suitable power supply. An electrical potential is generated between the tool and the workpiece through the power supply. As the electrode approaches workpiece, the dielectric break down starts taking place in the fluid. Due to this activity, a plasma channel starts forming and sparks jump from the electrode to the workpiece leading to material removal from the workpiece. The principle of die-sinking EDM is shown in Fig. 3.10.1 and the schematic of die-sinker EDM process is shown in Fig. 3.10.2 The main components of Die-sinker EDM are: Power supply. Dielectric system. Electrode Servo system.

Power Supply The power supply provides a series of DC electrical discharges and controls: Current Pulse voltage Pulse duration Duty cycle Electrode polarity Pulse frequency

Dielectric and its Circulation System The dielectric fluids used in EDM operations are of different types. The most popular dielectric fluids are hydrocarbon oil (kerosene in particular). The other fluids used are transformer oil, paraffin oil; silicon based oil, or de-ionized water. The selection of an appropriate dielectric fluid depends upon its various chemical and fluidic properties (such as flash point, dielectric strength, viscosity, specific gravity and color) The dielectric system performs the following tasks:

It induces clean dielectric into the cutting zone Flushes away debris Cools the workpiece and electrodes

In order to provide circulation of the dielectric fluid to the work piece, the EDM machine tool is equipped with a well-designed dielectric circulation system. It consists of following two parts: 1. Pump : Its main purpose is to circulate the dielectric fluid on-to the workpiece

2. Filter and suction unit: This unit filters out the material debris and any other foreign parts from the dielectric. Servo System The servo system is commanded by signals from gap voltage sensor system in the power supply and it controls the in-feed of the electrode to precisely match the required rate of material removal. At times stepper motor can be used instead of a servomotor. As soon as the gap voltage sensor system determines bridging of some pieces of electrically conductive materials between the electrode and work-piece, the servo system immediately reacts and reverses the direction. The process is restored when the gap is flushed by the dielectric fluid. When the gap becomes clear, the in-feed resumes and cutting process continues. Electrodes The electrodes for EDM process are usually made of brass, copper, graphite and coppertungsten alloys.

Design considerations for EDM process

In EDM process, fine openings and deeper slots need to be avoided. Very fine surface finish values should not be specified. As the MRR of EDM process is low, the rough cutting should be done by some other machining process and EDM machine should me made used for the finishing operations only.