Precision Engineering
journal homepage: www.elsevier.com/locate/precision
Review
a r t i c l e
i n f o
Article history:
Received 13 September 2014
Accepted 3 November 2014
Available online 11 November 2014
Keywords:
Electrical discharge machining
Dielectric uids
Die sink
EDM characteristics
a b s t r a c t
Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM
process is based on thermoelectric energy between the work piece and an electrode. In electrical discharge machining (EDM), a process utilizing the removal phenomenon of electrical discharge in dielectric,
the working uid plays an important role affecting the material removal rate and the properties of the
machined surface. Choosing the right dielectric uid is critical for successful operations. This paper
presents a literature survey on the use of dielectric uids and also their effects in electrical discharge
machining characteristics.
2014 Elsevier Inc. All rights reserved.
Contents
1.
2.
3.
4.
5.
6.
7.
8.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.
Sinking EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.
Wire EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.
Micro EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.
Powder mixed EDM (PMEDM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.
Dry EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Research trends in EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.
Functions of a dielectric uid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.
Types of dielectric uid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1.
Mineral oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.
Kerosene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3.
Mineral seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4.
Transformer oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDM with water based dielectrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.
Pure water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.
Water with additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powder additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDM with gaseous dielectrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low-viscosity dielectric oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1. Introduction
The electrical discharge machining (EDM) is one of the major
manufacturing processes widely applied in die and mold making
industry to generate deep and three-dimensional complex cavities
in many different classes of materials under roughing and nishing
operations [1]. This technique has been developed in the late 1940s
[2] where the process was based on removing material from a part
by means of a series of repeated electrical discharges between tools
called the electrode and the work piece in the presence of a dielectric uid [3]. The electrode is moved toward the work piece until the
gap is small enough so that the impressed voltage is great enough
to ionize the dielectric [4]. Short duration discharges are generated
in a liquid dielectric gap, which separates tool and work piece. The
material is removed with the erosive effect of the electrical discharges from tool and work piece [5]. However, it was only in early
1940 that electrical discharge machining started to become a wellknown manufacturing process when Boris and Natalie I. Lazarenko
discovered the decisive role of the dielectric uid [6]. Since then,
EDM has experienced a dramatic evolution. EDM process can be
classied according to the type of dielectric uid used. Dielectric
uid is an extremely important function regarding the quality of the
machined parts. Since different dielectrics have different cooling
rates and compositions, the choice of dielectric plays an important
role in the EDM process. Dielectric media, circulated between the
electrode and work piece, must be carefully selected and applied
to maintain peak performance and control of the electrical spark.
Another key factor is the dielectric media ltration system, which
helps maintain consistent gap performance and dielectric cleanliness. The four basic functions of dielectric oil (specic to sinker
EDMs and specially designed wire EDMs) are: insulation, ionization,
cooling, removal of waste particles. Different kinds of dielectric
uid are available for machining the parts in EDM. Die sink EDM
generally operates with hydrocarbon oil, while wire, micro-EDM
and fast drilling usually work with deionized water [7]. It has
already been observed that pure kerosene, which is used as the
dielectric liquid in most of the conventional EDM systems, creates
several problems while machining, such as degradation of dielectric properties, pollution of air, and adhesion of carbon particles
on the work surface. All these phenomena obstruct the stable discharge between the two electrodes, i.e., tool and work piece and
further result in lower machining efciency. Investigation should
be made to search out the alternative to kerosene dielectric with
other types of dielectrics since the properties of dielectric are the
effective machining parameter, which may overcome the abovementioned problems. This paper will present a review on the use
of different kinds of alternative dielectric uid and their effects for
die sink EDM characteristics.
2. Types of EDM
The EDM process is most widely used by the mold-making tool
and die industries, but is becoming a common method of making
prototype and production parts, especially in the aerospace, automobile and electronics industries in which production quantities
are relatively low. It is also used for coinage die making, metal disintegration machining, etc. There are different types of EDM available
which is briey discussed below.
2.1. Sinking EDM
In the sinking EDM process, a mirror image of tool shape occurs
on the surface of work piece. In this process, copper or graphite is
generally used as electrode material. The numerical control monitors the gap conditions (voltage and current) and synchronously
controls the different axes and the pulse generator. The dielectric liquid is ltrated to remove debris particles and decomposition
products. In this process electrical energy turns into thermal energy
through a series of discrete electrical discharges occurring between
the electrode and work piece immersed in a dielectric uid [8]. The
thermal energy generates a channel of plasma between the cathode
and anode. When the pulsating direct current supply is turned off,
the plasma channel breaks down. This causes a sudden reduction in
the temperature allowing the circulating dielectric uid to implore
the plasma channel and ush the molten material from the work
piece surface [9].
2.2. Wire EDM
Wire-cut EDM (WEDM) is one of the most favorable variants
owing to its ability to machine conductive, exotic and high strength
and temperature resistive (HSTR) materials with the scope of generating intricate shapes and proles [10]. It uses a thin continuously
traveling wire feeding through the work piece by a micro-processor
eliminating the need for elaborate reshaped electrodes, which are
required in the EDM. The wire-cut EDM process uses a thin copper
wire of diameter about 0.10.3 mm as the electrode and the work
piece is mounted on a controlled worktable, enabling complex two
dimensional shapes can be cut on the work piece by controlled the
movement of the XY worktable [11]. Wire EDM process is widely
applied not only in tool and die-making industry, but also in the
elds of medicine, electronics and the automotive industry [12].
2.3. Micro EDM
The recent trend in reducing the size of products has given
micro-EDM a signicant amount of research attention. Micro-EDM
is capable of machining not only micro-holes and micro-shafts as
small as 5 m in diameter but also complex three-dimensional (3D)
micro cavities [13]. Micro EDM process is basically of four types:
micro-wire EDM, die-sinking micro-EDM, micro EDM drilling and
micro-EDM milling. In micro-wire EDM, a wire which has a diameter down to 0.02 mm is used to cut through a work piece. In
die-sinking micro-EDM, an electrode is used containing microfeatures to cut its mirror image in the work piece. In micro EDM
drilling, micro-electrodes (of diameters down to 510 m) are used
to drill micro-holes in the work piece. In Micro-EDM milling,
micro-electrodes (of diameters down to 510 m) are employed
to produce 3D cavities by adopting a movement strategy similar to
that in conventional milling [9].
2.4. Powder mixed EDM (PMEDM)
The mechanism of PMEDM is totally different from the conventional EDM [14]. A suitable material in the powder form is mixed
into the dielectric uid of EDM. When a suitable voltage is applied,
the spark gap lled up with additive particles and the gap distance
setup between tool and the work piece increased from 2550 to
50150 mm [15]. The powder particles get energized and behave
in a zigzag fashion Fig. 1. These charged particles are accelerated
by the electric eld and act as conductors. The powder particles
arrange themselves under the sparking area and gather in clusters. The chain formation helps in bridging the gap between both
the electrodes, which causes the early explosion. Faster sparking
within discharge takes place causes faster erosion from the work
piece surface.
2.5. Dry EDM
In this process a thin walled pipe is used as tool electrode
through which high-pressure gas or air is supplied. The role of the
gas is to remove the debris from the gap and cooling of the inter
electrode gap. The technique was developed to decrease the pollution caused by the use of liquid dielectric which leads to production
of vapors during machining and the cost to manage the waste [9].
3. Research trends in EDM
The researches have classied the numerous EDM research
interests referred in the papers into four different major areas as
shown in Fig. 2. Many researchers have worked in this eld about
the study of various aspects of EDM process. In this section, discussion is only about different types of dielectric uid and their effects
for die sink EDM characteristics.
3.1. Functions of a dielectric uid
The sinker EDM process has primarily used oil for the dielectric uid. The dielectric uid in a sinker EDM serves a number of
functions [18]:
(1) The dielectric uid works as a medium through which controlled electrical discharges occur.
(2) The dielectric uid works as a quenching medium to cool and
solidify the gaseous EDM debris resulting from the discharge.
(3) The dielectric uid works as a medium used to carry away the
solidied EDM debris from the discharge gap to the lter system.
(4) The dielectric uid works as a heat transfer medium to absorb
and carry away the heat generated by the discharges from both
the electrode and the work piece.
3.2. Types of dielectric uid
3.2.1. Mineral oils
According to Wikipedia Mineral oil or liquid petroleum is a byproduct in the distillation of petroleum [18].
3.2.2. Kerosene
Kerosene was one of the rst popular dielectric oils. Its primary benet is that it has very low viscosity and ushes very well.
Unfortunately, it has many drawbacks:
(1)
(2)
(3)
(4)
In the old days, there were numerous EDM res and explosions
attributed to the use of kerosene [18].
3.2.3. Mineral seal
Mineral seal oil takes its name from the fact that it originally
replaced oil derived from seal blubber for use in signal lamps and
lighthouses. Mineral seal is petroleum based product that has many
fundamental mechanisms affecting such combinations will promote the applications of PMEDM to feasibly produce superior
surface nish and properties of components using EDM. Silicon powder was used by Pecas and Henriques [34] to assess
improvement through quality surface indicators and process time
management over a set of different processing area. The result
shows that 2 g/l of Si concentration, smooth and high reective craters were achieved with average surface roughness (Ra)
depends on the area and varies between 0.09 mm for 1 cm2 and
0.57 mm for 64 cm2 electrode. The polishing time has a greater
effect on decreasing the surface roughness. Yih-fong and Fu-Chen
[42] investigates the effect of powder properties on surface quality (SQ) of SKD-11 (die steel) work piece using Al, chromium (Cr),
copper (Cu), and SiC powders. The smallest particle (7080 nm)
generates best surface nish and Al powder produces the best
surface nish. Furutani et al. [43] studied a deposition method
of lubricant during nishing EDM to produce parts for ultrahigh
vacuum such as space environment using PMEDM. Smoother surface can be obtained by adding aluminum powder to the mixture
of molybdenum disulde (MoS2 ) powder and working oil and it
has smaller friction coefcient than that with normal working
oil.
8. Conclusion
Many researchers have worked in this eld about the study of
various aspects of EDM process. The contribution of EDM to industries such as cutting new hard materials make EDM technology
remains indispensable. The review of the research trends in EDM
in different kinds of alternative dielectric uid and their effects in
the characteristics of die sink EDM is presented. As we know hydrocarbon oils results better in die sink application, but machining in
distilled water also resulted in a higher MRR and a lower wear ratio
than hydrocarbon oils when a high pulse energy range was used.
With distilled water, the machining accuracy is poor but the surface nish is better. The best machining rates have been achieved
with the tap water. Machining with water as dielectric has the possibility to achieve zero electrode wear while using copper tool is
connected to the negative polarity. Work piece surface roughness
is also dependent on the type of dielectric uid. Surface roughness
produced with deionised water is generally lower than that with
hydrocarbon oils.
Many authors have studied the feasibility of adding organic
compounds to deionised water. Performance of such operation is
found to be higher in terms of material removal rate than that
obtained with hydrocarbon oils. The feasibility of adding organic
compound such as ethylene glycol, polyethylene glycol 200, polyethylene glycol 400, polyethylene glycol 600, dextrose and sucrose
to improve the performance of deionized water have also been
studied. It has been found that deionised water with organic compounds has an advantage over hydrocarbon dielectrics during
discharges using long pulse duration and high pulse duty factor
current.
PMEDM can also improve machining efciency in roughing
operations. Electrically conductive powder reduces the insulating
strength of the dielectric uid and thus increases the spark gap
between the tool and the work piece. EDM process becomes more
stable and improves MRR and SQ also.
Electric discharge machining can also be achieved with gaseous
dielectrics such as air and oxygen. It is found that gaseous dielectric
can provide higher material removal rates than that with hydrocarbon oil.
During micro-EDM, lower viscosity dielectric oils can improve
the efciency. The low-viscosity dielectric oil inuence the machining cycle time more than the hydrocarbon oils. As the role of
dilectricin EDM is highly complex, much research is needed to come
out with newer hybrid dielectrics which will give quality machined
surface at commercially viable prices.
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