Electric Discharge Machining and Its Parameters: A Review
Keywords:
EDM, Dry EDM, WEDM, Die sinking EDM, MRR, TWR.Abstract
Electric discharge machining (EDM) is a thermal erosion process which is used to machine extremely hard materials that are difficult to machine like alloys, tool steels, tungsten carbide etc. The efficiency of traditional cutting process is limited by the mechanical properties and complexities of the workpiece material. In recent years EDM researchers have work to improve the EDM process parameters such as Electrical parameters, Non-Electrical parameters, Tool electrode base parameters and Powder base parameters. This paper reviews the electric discharge machining process and its parameters
References
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[34] Webzell S. That first step into EDM. In: Machinery. Kent, UK: Findlay Publications Ltd, Nov 2001: 41.
[35] Anonymous. History and development. In: The Techniques and Practice of Spark Erosion Machining. Gloucester, UK: Sparcatron Limited, 1965: 6.
[36] Jameson EC. Description and development of electrical discharge machining (EDM). In: Electrical Discharge Machining. Dearbern, Michigan: Society of Manufacturing Engineers, 2001: 12.
[37] Houman L. Total EDM. In: Jameson EC (Ed.). Electrical discharge machining: Tooling, methods and applications. Dearbern, Michigan: Society of Manufacturing Engineers, 1983: 5-19.
[38] Nipanikar SR. Parameter optimization of electro discharge machining of AISI D3 steel material by using Taguchi method. Journal of Engineering Research and Studies Jul-Sep 2012; 3(3): 7-10.
[39] Pawade MM, Banwait SS. A brief review of die sinking electrical discharge machining process towards automation. American Journal of Mechanical Engineering 2013; 2: 43-49.
[40] Kumar S. Current research trends in EDM: A review. Research Journal of Engineering Science 2013; 2(2): 56-60.
[41] Liu HS, Yan BH, Chen CL et al. Application of micro-EDM combined with highfrequency either grinding to micro-hole machining. International Journal of Machine Tools & Manufacture 2006; 46: 80-87.
[42] Ferraris E, Reynaerts D, Lauwers B. Micro-EDM process investigation and comparison performance of Al3 O2 and ZrO2 based ceramic composites. CIRP Annals-Manufacturing Technology 2011; 60: 235-38.
[43] Choudhary SK, Jadoun RS. Current advanced research development of EDM: A review. International Journal of Research in Advent Technology Mar 2014; 2(3): 273-97.
[44] El-Taweel TA. Multi-response optimization of EDM with Al-Cu-Si-tic P/M composite electrode. International Journal of Advanced Manufacturing Technology 2009; 44(1): 100-13.
[45] Han F, Wang Y, Zhou M. High speed EDM milling with moving electric arcs. Int J Mach Tools Manuf 2009; 49: 20-24.
[46] Xu MG, Zhang JH, Zhang QH et al. Material removal mechanisms of cemented carbides machined by ultrasonic vibration assisted EDM in gas medium. Journal of Materials Processing Technology 2009; 209: 1742-46. [47] Prihandana GS, Mahardika M, Hamdi M et al. Effect of low-frequency vibration on workpiece in EDM processes. Journal of Mechanical Science and Technology 2011; 25(5): 1231-34.
[48] Yan BH, Tsai HC, Huang FY. The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium. International Journal of Machine Tools & Manufacture 2005; 45: 194-200.
[49] Zhang QH, Zhang JH, Deng JX et al. Ultrasonic vibration electrical discharge machining in gas. Journal of Materials Processing Technology 2002; 129: 135- 38.
[50] Zhang QH, Du R, Zhang JH et al. An investigation of ultrasonic-assisted electrical discharge machining in gas. Int J Mach Tools Manuf 2006; 46: 1582-88.
[51] Fujiki M, Ni J, Shih AJ. Tool path planning for near-dry EDM milling with lead angle on curved surfaces. Journal of Manufacturing Science and Engineering 2011; 133: 510051-59.
[52] Syed KH, Palaniyandi K. Performance of electrical discharge machining using aluminium powder suspended distilled water. Turkish J Eng Env Sci 2012; 36: 195-207.
[53] Jeswani ML. Electrical discharge machining in distilled water. Wear 1981; 72: 81-88.
[54] Muniu JM, Ikua BW, Nyaanga DM et al. Study on effects of powder-mixed dielectric fluids on electrical discharge machining processes. International Journal of Engineering Research & Technology 2013; 2(10): 2449-56.
[55] Goyal S, Singh RK. Parametric study of powder mixed EDM and optimization of MRR & surface roughness. International Journal of Scientific Engineering and Technology 2014; 3(1): 56-62.
[56] Balasubramanian P, Senthilvelan T. Optimization of machining parameters in EDM process using cast and sintered copper electrodes. Procedia Materials Science 2014; 6: 1292-302.
[57] Thareja P, Mahapatra PB, Sharma DD. Metamorphosis in teaching of ‘Materials’: A case study aligning manufacturing requirements. Proceedings of National Conference on Advances in Materials and Manufacturing Technology, 2010. Available from: http:// ssrn.com/abstract=1567511.
[2] Jha B, Ram K, Rao M. An overview of technology & research in electrode design & manufacturing in sinking electrical discharge machining. Journal of Engineering Science & Technology Review 2011; 4(2): 118-30.
[3] Balasubramanian P, Senthilvelan T. Optimization of machining parameters in EDM process using cast & sintered copper electrodes. Procedia Materials Science 2014; 6: 1292-302.
[4] Ho KH, Newman ST. State of the art electrical discharge machining (EDM). International Journal of Machine Tool & Manufacture 2003; 43: 1287-300.
[5] Pawade MM, Banwait SS. A brief review of die sinking electrical discharge machining process towards automation. American Journal of Mechanical Engineering 2013; 2: 43-49.
[6] Kumar S. Current research trends in EDM: A review. Research Journal of Engineering Science 2003; 2(2): 56-60. [7] Choudhary SK, Jadoun RS. Current research development in dry electric discharge machining (DEDM): Review article. International Journal of Engineering Technology & Advanced Engineering Aug 2014; 4: 832-39.
[8] Saini PK, Verma M. Experimental investigation of wire EDM process parameters on MRR of Ti-6al-4v alloy. International Journal of Innovative Technology & Exploring Engineering Oct 2014; 4(5).
[9] Choudhary SK, Jadoun RS. Current advanced research development of ED: A review. International Journal of Research in Advent Technology Mar 2014; 2(3): 273-97.
[10] Kumar N, Kumar L, Tewatia HC et al. Comparative study For MRR on diesinking EDM using electrode of copper & graphite. International Journal of Advanced Technology & Engineering Research May 2012; 2(2): 170-74.
[11] Syed KH, Palaniyandi K. Performance of electric discharge machining using aluminium powder suspended distilled water. Turkish J Eng Env Sci 2012; 36: 195-207.
[12] Choudhary SK, Jadoun RS. Current research issue, trend & applications of powder mixed dielectric electric discharge machining (PM-EDM): A review. International Journal of Engineering Science & Research Technology Jul 2014; 3(7): 335-58.
[13] Ojha K, Gary RK, Singh KK. MRR improvement in sinking electric discharge machining: A review. Journal of Minerals & Materials Characterization & Engineering 2010; 9(8): 709-39.
[14] Singh A, Grover NK, Sharma R. Recent advancement in electric dicharge machining: A review. International Journal of Modern Engineering Research Sep-Oct 2012; 2(5): 3815-21.
[15] Ghoreishi M, Atkinson J. A comparative experimental study of machining characteristics in vibratory. Journal of Materials Processing Technology 2002; 120: 374-84.
[16] Jilani ST, Pandey PC. Experimetnal investigations into the performance of water as dielectric in EDM. International Journal of Machine Tool Design and Research 1984; 24: 31-43.
[17] Gough PJC. Electrode manufacturing: Conventional and new techniques. Proceedings of the First Electrical Machinery Symposium (EM85), Birmingham, UK, 1985: 64-81.
[18] Carter GA, Jergas I. Choice of electrical discharge machining tooling. In: Jameson EC (Ed.). Methods and Applications. Dearborn, MI: Society of Manufacturing Engineers, 1983: 57-61.
[19] Puri AB, Bhattacharyya B. An analysis and optimization of the geometrical inaccuracy due to wire lag phenomenon in WEDM. Int J Mach Tools Manuf 2003; 43(2): 151-59.
[20] Bojorquez B, Marloth RT, Es-Said OS. Formation of a crater in the work piece on an electrical discharge machine. Eng Fail Anal 2002; 9: 93-97.
[21] McGeough JA. Electro discharge machining. Advanced Methods of Machining. London: Chapman & Hall, 1988: 130.
[22] Huntress EA. Electrical discharge machining. Am Machinist 1978; 122(8): 83-98.
[23] Singh J, Walia RS, Satsangi PS et al. FEM modeling of ultrasonic vibration assisted workpiece in EDM process. IJMSE Nov 2011; 1(1): 816.
[24] Prihandana GS, Mahardika M, Hamdi M et al. Effect of low frequency vibration on workpiece in EDM Process. Journal of Mechanical Science and Technology 2011; 25(5): 1231-34.
[25] Jahan MP, Wong YS, Rahman M. Evaluation of the effectiveness of low frequency workpiece vibration in deephole micro-EDM drilling of tungusten carbide. Journal of Manufacturing Process 2012; 14: 343-59.
[26] Singh J, Walia RS, Satsangi PS et al. Hybrid electric discharge machining process with continuous & discontinuous vibration on workpiece. IJMSE Feb 2012; 2(1): 22-33.
[27] Teimouri R, Baseri H. Experimental study of rotary magnetic field-assisted dry EDM with ultrasonic vibration of workpiece. Int Journal of Advanced Manufacturing & Technology 2013; 67: 1371-84.
[28] Maroju NK, Kanmani S, Vamsi KP et al. Vibration assisted conventional & advanced machining: A review. Procedia Engg 2014; 97: 1577-86.
[29] Singh B, Pabla BS, Saroha M. Investigating the effects of process parameters on MRR in WEDM using Molybdenum wire. IJEBEA 2014; 14(304): 1-5.
[30] Ram Prasad AVS, Ramji K, Datta GL. An experimental study of wire EDM on Ti6Al-4V alloy. Procedia Materials Science 2014; 5: 2567-76.
[31] Mohammadi A, Tehrani AF, Abdullah A. Investigation on the effects of ultrasonic vibration on material removal rate and surface roughness in wire electrical discharge turning. Int J Adv Manuf Technol 2014; 70: 1235-46.
[32] Chander S, Tiwana JS. Optimization of material removal rate & surface (Ti-4.5Al-2V) using Taguchi method. IJETAE Apr 2015; 5: 87-94.
[33] Kalpajian S, Schmid SR. Material removal processes: Abrasive, chemical, electrical and high-energy beam. In: Manufacturing Processes for Engineering Materials. New Jersey: Prentice Hall, 2003: 541.
[34] Webzell S. That first step into EDM. In: Machinery. Kent, UK: Findlay Publications Ltd, Nov 2001: 41.
[35] Anonymous. History and development. In: The Techniques and Practice of Spark Erosion Machining. Gloucester, UK: Sparcatron Limited, 1965: 6.
[36] Jameson EC. Description and development of electrical discharge machining (EDM). In: Electrical Discharge Machining. Dearbern, Michigan: Society of Manufacturing Engineers, 2001: 12.
[37] Houman L. Total EDM. In: Jameson EC (Ed.). Electrical discharge machining: Tooling, methods and applications. Dearbern, Michigan: Society of Manufacturing Engineers, 1983: 5-19.
[38] Nipanikar SR. Parameter optimization of electro discharge machining of AISI D3 steel material by using Taguchi method. Journal of Engineering Research and Studies Jul-Sep 2012; 3(3): 7-10.
[39] Pawade MM, Banwait SS. A brief review of die sinking electrical discharge machining process towards automation. American Journal of Mechanical Engineering 2013; 2: 43-49.
[40] Kumar S. Current research trends in EDM: A review. Research Journal of Engineering Science 2013; 2(2): 56-60.
[41] Liu HS, Yan BH, Chen CL et al. Application of micro-EDM combined with highfrequency either grinding to micro-hole machining. International Journal of Machine Tools & Manufacture 2006; 46: 80-87.
[42] Ferraris E, Reynaerts D, Lauwers B. Micro-EDM process investigation and comparison performance of Al3 O2 and ZrO2 based ceramic composites. CIRP Annals-Manufacturing Technology 2011; 60: 235-38.
[43] Choudhary SK, Jadoun RS. Current advanced research development of EDM: A review. International Journal of Research in Advent Technology Mar 2014; 2(3): 273-97.
[44] El-Taweel TA. Multi-response optimization of EDM with Al-Cu-Si-tic P/M composite electrode. International Journal of Advanced Manufacturing Technology 2009; 44(1): 100-13.
[45] Han F, Wang Y, Zhou M. High speed EDM milling with moving electric arcs. Int J Mach Tools Manuf 2009; 49: 20-24.
[46] Xu MG, Zhang JH, Zhang QH et al. Material removal mechanisms of cemented carbides machined by ultrasonic vibration assisted EDM in gas medium. Journal of Materials Processing Technology 2009; 209: 1742-46. [47] Prihandana GS, Mahardika M, Hamdi M et al. Effect of low-frequency vibration on workpiece in EDM processes. Journal of Mechanical Science and Technology 2011; 25(5): 1231-34.
[48] Yan BH, Tsai HC, Huang FY. The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium. International Journal of Machine Tools & Manufacture 2005; 45: 194-200.
[49] Zhang QH, Zhang JH, Deng JX et al. Ultrasonic vibration electrical discharge machining in gas. Journal of Materials Processing Technology 2002; 129: 135- 38.
[50] Zhang QH, Du R, Zhang JH et al. An investigation of ultrasonic-assisted electrical discharge machining in gas. Int J Mach Tools Manuf 2006; 46: 1582-88.
[51] Fujiki M, Ni J, Shih AJ. Tool path planning for near-dry EDM milling with lead angle on curved surfaces. Journal of Manufacturing Science and Engineering 2011; 133: 510051-59.
[52] Syed KH, Palaniyandi K. Performance of electrical discharge machining using aluminium powder suspended distilled water. Turkish J Eng Env Sci 2012; 36: 195-207.
[53] Jeswani ML. Electrical discharge machining in distilled water. Wear 1981; 72: 81-88.
[54] Muniu JM, Ikua BW, Nyaanga DM et al. Study on effects of powder-mixed dielectric fluids on electrical discharge machining processes. International Journal of Engineering Research & Technology 2013; 2(10): 2449-56.
[55] Goyal S, Singh RK. Parametric study of powder mixed EDM and optimization of MRR & surface roughness. International Journal of Scientific Engineering and Technology 2014; 3(1): 56-62.
[56] Balasubramanian P, Senthilvelan T. Optimization of machining parameters in EDM process using cast and sintered copper electrodes. Procedia Materials Science 2014; 6: 1292-302.
[57] Thareja P, Mahapatra PB, Sharma DD. Metamorphosis in teaching of ‘Materials’: A case study aligning manufacturing requirements. Proceedings of National Conference on Advances in Materials and Manufacturing Technology, 2010. Available from: http:// ssrn.com/abstract=1567511.
Published
2019-01-07
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