Material is removed by a rapid series of recurring electrical spark discharges between a shaped tool (cathode) and a conductive workpiece (anode) immersed in a dielectric fluid (like kerosene or deionized water). The intense heat melts and vaporizes the material.
EDM operates on the thermoelectric phenomenon. When a voltage (50-400 V) is applied across a small gap (0.01-0.5 mm) between an electrode (copper/graphite) and a conductive workpiece in a dielectric fluid, the dielectric breaks down. A plasma channel forms, reaching 8000-12000°C, melting and vaporizing material. The dielectric flushes away debris. EDM is specifically suited for mold and die making. However, the rapid heating/cooling creates a "recast layer" (2-10 µm thick) containing micro-cracks and tensile residual stresses, reducing fatigue life by up to 40% in critical components.
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Advancements in Non-Conventional Machining: A Strategic Overview 1. Introduction Non Conventional Machining Process Ppt
Materials like Nimonic alloys, tungsten carbide, and stainless steel are incredibly difficult to machine conventionally.
Material is removed via atom-by-atom electrochemical dissolution.
– Bullet points explaining tool wear, hardness limitations, and heat generation. Material is removed by a rapid series of
Uses a high-velocity stream of gas and abrasive particles.
These processes remove material at the atomic level through chemical dissolution or reverse-galvanic cell action. Electrochemical Machining (ECM)
Can machine any electrically conductive material, regardless of its hardness. Electrochemical Machining (ECM) When a voltage (50-400 V) is applied across a small gap (0
Creating precision diesel fuel injection nozzles and complicated die shapes. 5. Conclusion
Combines electrochemical dissolution with conventional grinding wheel action. 3. Chemical Processes
High setup costs due to the mandatory vacuum chamber environment. 5. Chemical and Electrochemical Machining Processes