Analysis of Various Machining Parameters of Electrical Discharge Machining (EDM) on Hard Steels using Copper and Aluminium Electrodes

Full Text (PDF, 447KB), PP.1-14

Views: 0 Downloads: 0


Ashwani Kharola 1,*

1. Institute of Technology Management (ITM), Defence R&D Organisation (DRDO), Mussoorie-248169, Uttarakhand, India

* Corresponding author.


Received: 21 Nov. 2014 / Revised: 2 Jan. 2015 / Accepted: 3 Feb. 2015 / Published: 8 Mar. 2015

Index Terms

EDM, Die-Sinking, MRR, TRR, Surface roughness


EDM is a non-contact machining process widely used for shaping electro-conductive materials regardless of their hardness. In EDM material removal takes place by a series of recurring electrical sparks between the tool electrode and workpiece. In this study the effect of variation of discharge current on various machining parameters including Metal removal rate (MRR), Tool removal rate (TRR) and Surface roughness has been considered. A total of 32 experiments were conducted on four different workpieces i.e. Die Steel-D3, En-8, En-19 and Stainless steel (SS-AISI-440C) with the help of Copper and Aluminium electrodes. In this study Die-Sinking EDM has been employed and the results are shown with the help of graphs.

Cite This Paper

Ashwani Kharola,"Analysis of Various Machining Parameters of Electrical Discharge Machining (EDM) on Hard Steels using Copper and Aluminium Electrodes", IJEM, vol.5, no.1, pp.1-14, 2015. DOI: 10.5815/ijem.2015.01.01


[1] A.K.M. Asif Iqbal and Ahsan Ali Khan, "American Journal of Engineering and Applied Sciences", 3 (2): 396-402, 2010", ISSN 1941-7020, 2010.

[2] Trias Andromeda, Azli Yahya, Nor Hisham, Kamal Khalil, Ade Erawan, "Predicting Material Removal Rate of Electrical Discharge Machining (EDM) using Artificial Neural Network for High I-gap current", International Conference on Electrical, Control and Computer Engineering, Pahang, Malaysia, June 21-22, 2011.

[3] M.M.Pawade and S.S.Banwait, "An Exhaustive Review of Die Sinking Electrical Discharge Machining Process and Scope for Future Research", World Academy of Science, Engineering and Technology, Vol:7 2013-06-26.

[4] Jesus Doval Gandoy, Ramon Pasandin, Bernardo Fernandez, "Electrical Discharge Machining for sharpening diamond disks", IAS 2004, 0-7803-8486-5/04, 2004 IEEE.

[5] Kuldeep Ojha, R.K. Garg, K.K. Singh, "MRR Improvement in Sinking Electrical Discharge Machining: A Review", Journal of Minerals & Materials Characterization & Engineering, Vol. 9, No. 8, pp. 709-739, 2010.

[6] H.K.Kansal, P.Singh, P.Kumar, "Technology and Research developments in Powder mixed electric discharge machining (PMEDM)", Journal of Materials Processing Technology, 184, 32-41, 2007.

[7] H.Ramasawmy and L.Blunt, "Effect of EDM process parameters on 3-d surface topography", Journal of Materials Processing Technology, 148, 155-164, 2004.

[8] S.Mahendran, R.Devarajan, T. Nagarajan, and A. Majdi, "A review of micro-EDM", Proceedings of the International Multiconference of Engineers and computer scientists (IMECS), Vol. 2, March 17-19, 2010, Hong Kong.

[9] G Krishna Mohana Rao, S.Satyanarayana, M Praveen, "Influence of Machining Parameters on Electric Discharge Machining of Maraging Steels-An Experimental Investigation", Proceedings of the World Congress on Engineering 2008 Vol. II, WCE 2008, July 2 - 4, 2008, London, U.K.

[10] G.Kibria, B.R.Sarkar & B.B.Pradhan and B. Bhattacharyya, "Comparative study of different dielectrics for micro-EDM performance during micro hole machining of Ti-6Al-4V alloy," International Journal of Advanced Manufacturing Technology, 48: pp. 557–570, 2010.

[11] W.Koenig, D.F.Dauw, G. Levy and U.Panten, "EDM-future steps towards the machining of ceramics", Ann. CIRP: 37 (2), pp. 625–631, 1998.

[12] Samad Dadvandipour, "On the Experimental Study of Electric Discharge Machining (EDM) of P20 Type Tool Steel", SAMI 2013, IEEE 11th International Symposium on Applied Machine Intelligence and Informatics, January 31 - February 2, 2013, Slovakia.

[13] Yoshio Mizugaki, "Contouring Electrical Discharge Machining With On-Machine Measuring and Dressing of a Cylindrical Graphite Electrode", 0-7803-2775-6196, 1996, IEEE.

[14] Y.FTzeng. and N.H.Chiu, "Two-Phase Parameter Design for the Optimisation of the Electrical Discharge Machining Process Using a Taguchi Dynamic Experiment. "International Journal of Advanced Manufacturing Technology, Vol.21, No 12 ,2003, pp. 1005-1014.

[15] P.M George, B.K. Raghunath , L.M. Manocha and Ashish M. Warrier, "EDM machining of carbon-carbon composite- A Taguchi approach", Journal of Materials Processing Technology, Vol. 145, Issue 1, 2004, pp 66-71.

[16] S.R.Nithin Aravind, S.Sowmyi and K.P.Yuvara, "Optimization of Metal removal rate and surface roughness on wire EDM using Taguchi method", IEEE-International Conference On Advances In Engineering, Science And Management (ICAESM -2012) March 30, 31, 2012.

[17] Krishna Kumar Dadsena, S. Sivasankar, and C. R. Jeyapaul, "A Study on Electrical Discharge Machining of ZrB2-SiC Composite using Grey Entropy Analysis", 978-1-4673-5630-5/13/2013 IEEE.

[18] Chen Jian, Sun Zhong-ming and LU Guo-dong, "Simulation for Electrode Wear Predication in Die-Sinking EDM Based on Geometry Model", 2013 Fifth Conference on Measuring Technology and Mechatronics Automation.

[19] K.H. Ho, S.T. Newman, "State of the art electrical discharge machining (EDM)", International Journal of Machine Tools & Manufacture, 43, 1287-1300, 2003

[20] Ahmet Hascalik, Ulas Caydas, "Electrical Discharge Machining of Titanium Alloy (Ti-6AI-4V)", Applied Surface Sciences, 253, 9007-9016, 2007.

[21] E.I. Shobert, "What happens in EDM", E.C. Jameson (Ed.), Electrical discharge machining: Tooling methods and applications, Society of manufacturing engineers, pp. 3-4, 1983, Dearbern, Michigan.

[22] G. Boothroyd, A.K. Winston, "Non-conventional Machining Processes", Fundamentals of machining and machine tools, Marcel Dekker Inc., pp. 491, 1989, New York.

[23] M.P. Jahan, M. Rahman, Y.S. Wong, "A Review on the conventional and micro-electro discharge machining of tungsten carbide" International Journal of Machine Tools & Manufacture, 51, 837-858, 2011.

[24] Nikhil Kumar, Lalit Kumar, Harichand Tewatia, Rakesh Yadav, " Comparative study for MRR on Die-Sinking EDM using electrode of copper and graphite", International Journal of Advanced Technology & Engineering Research (IJATER), Vol. 2, Issue 2, ISSN: 2250-3536 May 2012.

[25] V.N. Gaitonde, S.R. Karnik, M. Faustino, J. Paulo Davim, "Machinability analysis in turning tugsten copper composite for application in EDM electrodes", International Journal of Refractory metals and hard materials, 28, 221-227, 2010.

[26] Han-Min Chow, Lieh-Dai Yang, Chin-Tien Lin, Yaun Feng Chen, "The use of SiC Powder in water as dielectric for Micro-slit EDM machining", Journal of Material Processing Technology, 195, pp. 160-170, 2008.

[27] K.S. Banker, S.P. Parmar, B.C. Parekh, "Review to performance improvement of Die-sinking EDM using powder mixed Dielectric fluid", International Journal of research in Modern Engineering and Emerging Technology", Vol. 1, Issue 3, ISSN:2320-6586, April 2013.