Electric Moduge Machine: The Physics Of The Electric Discharge Machine

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Abstract
Electric discharge machine developed in late 1940’s has been accepted worldwide as a standard process in manufacturing and is capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, nitrated alloy, carbides, heat resistant steels etc. EDM has become an important and cost-effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The work piece material selected in this experiment is EN-41 alloy steel taking into account its wide usage in industrial applications. In today’s world EN-41 alloy steel contributes to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are current, pulse on time and duty cycle. Taguchi method is applied to create an orthogonal array of input variables using the design of experiment (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as material removal rate (MRR), tool wear rate (TWR) is …show more content…

It is thus a thermal erosion process. The sparks are created in a dielectric liquid, generally water or oil, between the work piece and an electrode, which can be considered as the cutting tool. There is no mechanical contact between the electrodes during the whole process. Since erosion produced by electrical discharges, both electrode and work piece have to be electrically conductive. Thus, the machining process consists in successively removing small volumes of work piece material, molten or vaporized during a discharge. The volume removed by a single spark is small, in the range of 10-6-10-4 mm3 but this basic process is repeated typically 10,000 times per

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