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Design and Development of Die Sink Electrical
Discharge Machine for Melting Point and
Removal Rate of Materials
Mudasser Waqas
Dept. of Mechanical, Mechatronics
and Manufacturing Engineering,
University of Engineering &
Technology (UET) Lahore,
Faisalabad Campus
Faisalabad, Pakistan
mudasserwaqas11@gmail.com
Zeeshan Ali
Dept. of Electrical Engineering,
University of Engineering &
Technology (UET) Lahore,
Faisalabad Campus, Faisalabad,
Pakistan
zeeshan.uetians@gmail.com
Adnan Hussain
Dept. of Mechanical, Mechatronics
and Manufacturing Engineering,
University of Engineering &
Technology (UET) Lahore,
Faisalabad Campus
Faisalabad, Pakistan
Mohammad2adnan123@gmail.com
Muzzamil Waqas
Dept. of Electrical
Engineering, Government
College University,
Faisalabad Campus
Faisalabad, Pakistan
muzzamiljutt88@gmail.com
Abstract— In this world of advanced technology, unconventional
Micro-EDM technology has shown extraordinary interest in the
development of microstructure. This work presents the development
of the Die Sink EDM machine and investigates the relation and effect
of melting point of the electrode materials on Material Removal Rate
(MRR) by machining on brass and steel. Unlike traditional Lathe
and Milling Machines, the Die Sink EDM machine is an
environmentally friendly thermal process that generates sparks to
melt workpiece materials at high temperature. The removal of
workpiece materials depends on the melting point of the electrodes.
In addition, the Flow System was used to remove debris from the
dielectric fluid and to act as an insulator to cool the workpiece.
Overall, it is concluded that the materials with higher melting points
took longer to process than materials with lower melting points.
Moreover, electrode materials with high material removal rate
(MRR) provided more Surface Roughness.
Keywords— Micro-EDM, Die Sink EDM, Material Removal Rate,
Lathe machine, Milling Machine, Flow System, Surface Roughness
I.
INTRODUCTION
The Electrical Discharge Machining (EDM) process
began when the English scientist Joseph Priestly noticed the
erosiveness of electric discharges around 1770. The first
attempt to machine diamonds and metals was made in 1930,
and the process of "arc or spark machining" was labeled [1]-
[3]. During the 2nd World War, Russian scientists B.R. and
N.I. Lazarenko conducted research, minimized the usage of
electrical contacts, and found solutions for expensive
materials. They utilized an RC circuit and loaded some energy
into the condenser. In 1943, B.R. Lazarenko suggested that
"the effect of wear on electrical power contacts must be
converted into a good result for the processing of the metal
workpiece, and to achieve an improvement of the effect of
wear for electrical contact usage"[4]-[6].
In 1943, a commission was formed to examine how
tungsten electrical contacts could be prevented from
degenerating by sparks. In this regard, they observed that if the
electrode had been immersed in a dielectric fluid, the erosion
would have been even more decisive. This led them to design
the EDM machine. The machine of B.R and N.I Lazarenko was
called the RC machine type.
Electrical removal of the material has had devastating
effects, and a controlled method of cutting the material has
been devised. The RC was shown during the 1950s and
provided the necessary electrode distance between tool and
workpiece, the first robust and reliable pulse-time control, and
a simple servo-control circuit [7]-[10].
One of the main aspirations of EDM is that it does not
depend on hard materials. At present, material hardness is not
an important consideration for EDM. In a condenser bank,
Material extraction is done through a tiny space with a straight
polarity between the tool electrode (cathode) and the
workpiece (anode) [11], [12]. The selection of tools varies with
different methods of EDM. Graphite, tungsten, brass, and
copper are acknowledged as the best workpiece material [13],
[14].
Material such as brass has low thermal conductivity and
melting point compared to steel material, which makes this
material absorb less heat in Inter Electrode Gap (IEG).
Therefore, it is more likely that the material removal rate in the
machining of brass is higher. The melting point is the reverse
of the material removal rate [15]-[17].
Fig.1 represents the machining process between an
electrode and a die-electrical workpiece. Workpiece removal
is a chemical and physical process. The sink is sometimes
called the EDM form of the cavity. The tool electrode goes
directly to the workpiece until the space is narrow enough to
ionize the dielectric fluid. Short-term discharges are created in
the dielectric gap between the tool and the workpiece in
deionized water. With a temperature of about 10,000 C, the
material is removed from the workpiece by the erosive effect
of electric shocks [18]-[21]. The tool does not make direct
contact with the working part. The problems of mechanical
load, vibration, and vibration during machining can be
eliminated by giving a low-frequency signal to the electrode
[22]-[25].
2023 International Multi-disciplinary Conference in Emerging Research Trends (IMCERT) | 979-8-3503-4770-8/23/$31.00 ©2023 IEEE | DOI: 10.1109/IMCERT57083.2023.10075169
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Fig. 1. Die-Sink Electric Discharge Machine.
The main drawbacks of this approach are its low Material
Removal Rate (MRR) and poor surface quality. In recent years,
a number of strategies have been used to solve these problems,
using powdered dielectric solutions, vibration-assisted
machining, and material-changing methods. This study reveals
that the efficiency of the fundamental EDM process is
increased by introducing different electrode materials and
work technologies [26]-[29].
A.
Process Mechanism
The general premise of the EDM process is that the
electrode material is fused and vaporized by the intense electric
funnel formed by the inter-electrode gap (IEG). Due to the high
thermal energy of the spark, the material melts, and the molten
material is sprinkled with dielectric [30]-[32] The strategy is
to periodically restore the funnel between the workpiece and
the electrode and immerse them in dielectric fluid [33]-[35].
The temperature is sufficiently high for soft and hard materials.
It can reach temperatures up to 20,000C [36]. The volume of
material to be removed during spark is
to
in
size [37], and the work process for material displacement is
approximately 2-400 per minute [38]. The accuracy of EDM's
components is sufficient. In addition, the EDM form
replication approach may also be defined as reflective of a
tool's electrode condition. The input current increases and the
TWR grows [39], which means the machined surface area is
more Ra-estimated, which is harder with more input current
values.
B.
Process Characteristics
The EDM process has the following characteristics:
a)
This process can machine any electrically conductive
material as required, with little attention paid to its
hardness and other physical properties.
b)
Unlike other traditional machines, this method can be
used to create complex shapes on workpieces.
c)
The specific shape of the electrode can be duplicated in
the workpiece with an elevated level of accuracy.
d)
The thermal properties of the workpiece play an
important role in the MRR during the EDM procedure.
II.
WORKING PRINCIPAL
As shown in Fig. 2, two terminals, a cathode and anode,
and components such as power, fitting, tank, etc., are used to
form the EDM system. The power supply can affect the inter-
electrode gap of the two electrodes (IEG). The dielectric
functions as a load carrier. After completing the circuit, a
funnel is produced between the two terminals that cause the
electrodes' material to melt. The material is removed at a
controlled rate as fine particles in the workpiece. The dielectric
discharges material from the fusion cavity when the electrode
is pushed upwards in due course [40].
Fig. 2. Schematic of EDM.
a)
During the procedure, the workpiece and instrument
are never in contact, and a little gap between the
electrodes isolates them.
b)
The electrode should also be conductive to finish the
circuit for current flow.
III.
OPERATING METHODOLOGY
A.
Design of the Pulse Generator
The core of the electric discharge machine is the pulse
generator design. The entire operational mechanism is based
on the HFP generator. The pulse generator has a vital role in
the machining process.
Fig. 3 shows the Proteus Circuit of the Pulse Generator.
At first, an Arduino controller with a low-voltage pulse is
produced. Arduino is a genuinely dependable controller,
allowing the desired frequency pulse to be generated by
programming. The Arduino creates a low voltage 5V pulse.
This 5V pulse is sufficient to enable the 12V DC to pass
through the optocoupler output terminals.
We have an optocoupler PC817C that can easily operate
80V on the output terminals. The voltage we supply to the
optocoupler output is merely 12V, which makes it impossible
to burn. This 12V from the output of the optocoupler is applied
at the gate terminal of MOSFET.
-
+
Voltmeter
Ammeter
DC Pulse Generator
Servo controlled feed
Fixture
Work piece (+)
Filter
Reservoir
Pump
Flow meter
Pressure gauge
Tool holder
Dielectric fluid
Tool (-)
Filter
Workpiece
Tool
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Fig. 3. Proteus Circuit for the controller generating pulses of different
frequencies
Fig. 4. PCB design of the 12V power supply for activating the gate terminal of
the MOSFET
Fig. 4 represents the PCB design of the 12V Power Supply
which will activate the gate Terminal of MOSFET. We use
IRFP450 MOSFET for creating the high voltage pulse to
perform the machining process. Table I compares the
properties of four MOSFETS.
The selection of the MOSFET depends upon the
machining process. The large current flows when the high
voltage pulse generates in the case of these MOSFETs—the
rate of machining with high current rating MOSFETs
increases.
TABLE I. THE MOSFET PROPERTIES
MOSFET
Drain-
Source
Voltage
Gate-Source
Voltage
Continuous
Drain
Current
IRFP450
500V
20V
14A
IRF640
200V
20V
18A
IRFP260
200V
20V
46A
IRF540
100V
20V
28A
We use the 60V & 30A power supply for the machining
process. Some of the distinguishing features of the DC power
supply are as follow.
Precise variable voltage control knob for adjusting the
power supply voltage.
Highly accurate variable current limiting knob for limiting
the power supply's current.
The short circuit is always risky due to the fault in
manufacturing, wear and tear, and when voltages exceed
the threshold. Fig. 5 shows the high voltage and current
power supply, where short circuit protection is integrated
into the power supply.
Fig. 5. Variable high voltage and current power supply
When the MOSFET door terminal produces the pulse, the
high-voltage pulse can be used for electrodes to work the
machining via the drain and spring terminal. It will generate
sparks between the electrodes in the die electric medium. Fig.
6 illustrates the generated pulses from the MOSFET through
an oscilloscope.
Fig. 6. Oscilloscope displaying the voltage pulse for the electrodes
Fig. 7 verifies the accuracy and quality of pulses produced
by our pulse generator; the complete pulse generator circuit is
simulated first in the software design protective circuit.
Figure. 7. Simulation of the DC pulse generator circuit
After the successful simulation in Proteus, we design the
pulse generator. Fig. 8 shows the final look of the pulse
generator.
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Fig. 8. Pulse generator of the electric discharge machine.
B.
Design of the flow system
Fig. 9 shows the Flow diagram of the Dielectric Flow
system in the Electrical Discharge Machine. The flow system
is a vital part of the Electric discharge machining process.
During the machining, the material removes from the
workpiece appears in the form of debris and contaminates the
dielectric fluid. Moreover, the temperature of the dielectric
fluid also increases [41]. Both of these conditions are not
conducive to machining.
To overcome this and improve the machining process, we
install the flow system in the machine, which simultaneously
decreases the temperature of the dielectric fluid and removes
the debris from the fluid.
Fig. 9. Flow diagram of the dielectric flow system.
The working of the flow system is as follows.
Dielectric fluid, deionized water, is stored in the supply
tank.
From the supply tank, the dielectric fluid passes through
the heat exchanger to remove the heat from the fluid due
to the previous machining process.
Pump 1 pumps the fluid that passes through the heat
exchanger.
Valve 1 operates for filling the storage tank, and in the
meantime, valve two remains close.
When the storage tank is filled, valve1 closes, and valve
2 starts operating and pours the dielectric fluid on the
workpiece during the machining.
After the machining process, the dielectric fluid pass
through the filter, which removes the debris from the
dielectric fluid.
The whole process of the flow system is controlled
through Arduino, which commands the flow system to
operate during the machining.
C.
Mechanical System feed rate control mechanism
The gap between the workpiece and the electrode should
be in micrometers to start machining. This is achieved by
setting the MS 1-3 pins of the A4988 driver high.
TABLE II. THE STEP OF THE X, Y, AND Z RAILS
MS1
MS2
MS3
Microstep Resolution
LOW
LOW
LOW
FULL STEP
HIGH
LOW
LOW
HALF STEP
LOW
HIGH
LOW
QUARTER STEP
HIGH
HIGH
LOW
EIGHTH STEP
HIGH
HIGH
HIGH
SIXTEENTH STEP
Table II helps to calculate the step of the X, Y, and Z rails
are as follows.
X & Y axis calculation
Pitch of the lead screw = 8mm Steps in one revolution
= 3200
In one step lead screw move = 8000/3200 = 2.5μm
Z-axis calculation
Pitch of the lead screw = 2mm Steps in one revolution
= 3200
In one step lead screw move = 2000/3200 = 0.625μm
Fig. 10 shows the complete design of the Electrical
Discharge Machine.
Fig. 10. Die sink electric discharge machine
IV.
RESULTS
We use three materials to evaluate the relation between the
melting point of material and Material Removal Rate in the
machining process of the Die Sink Electrical Discharge
Machine.
Steel
Iron
Brass
The main reason behind the selection of these three
materials is that they are readily available, and their
thermodynamic properties are suitable for machining.
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The melting point of the material is the significant
thermodynamic property that plays its role in the machining
process. When the spark occurred, the heat energy released
melts the material. As shown in Table III, cast iron has a much
higher melting point than others and has a lower wear rate. It
will act as a tool material in this process.
TABLE III. THE MELTING POINT OF DIFFERENT MATERIALS
Sr. No
Material
Melting Point (degrees)
1
Iron
1538
2
Steel
1370
3
Brass
940
A.
Material Removal Rate
The material removal rate is the most crucial property
which defines the efficiency of the die-sinking electrical
discharge machine. The formula for calculating the material
removal rate is given in Equation (1).
MRR =
(1)
where Wi is the Initial Weight of the workpiece, and Wf is the
final Weight of the Workpiece in grams, p represents the
density of the material in g/mm3, and t represents the time in
minutes [42].
The weight of the workpieces measured on the weight
scale model before and after the machining process. 92SM-
202A DR weight scale model is used for this purpose. Then
using the density of material and time of the machining, we
calculate the material removal rate of the workpiece .
Fig. 11. The Machining on steel piece.
Fig. 12. Thermal Analysis of Steel piece in Solidworks.
Fig. 11 shows the machining process on steel to calculate
the material removal rate. Although this material's melting
point is higher, it showed a good surface finish due to the low
material removal rate.
MRR =
=
263
/min (2)
The steel piece model is designed in Solidworks to do a
thermal analysis of steel. This way, we analyzed the effect of
temperature on the steel model during machining. Fig. 12
illustrates the thermal analysis of a steel plate.
Now under the same condition, Fig. 13 represents the
machining of the brass piece for two minutes.
Figure. 13. Machining on Brass Piece
The material removal rate of brass is given below
MRR =
= 464
/min (3)
3D model of the Brass piece is made in Solidworks to do
its thermal analysis. Fig. 14 shows the temperature distribution
of brass piece during the machining time.
Fig. 14. Thermal Analysis of Brass Piece in Solidworks
Surface Roughness is higher on brass material as
compared to steel. The debris removes from the dielectric
medium through the flow system.
V.
CONCLUSION
The machining is performed on steel and brass using the
iron electrode. Since it is very clear from table III that the
melting point of the brass is far lesser than the steel, we observe
that the material removal rate of the brass is almost double as
compared to the piece of steel material during the same
machining time of 2 minutes. However, the surface roughness
was higher in the machined brass than in the steel. Therefore,
the die sinks electric discharge machine can perform more
efficiently on the materials with low melting points and
provides a good surface finish. The materials with a high
melting point can also be machined with the die sink electrical
discharge machine with the same accuracy, but the time of
machining increases as the melting point of the metal
increases.
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