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Preface ................................................. xi 1 Description and Development of Electrical Discharge Machining (EDM) ....................... 1 Definition of EDM .......... .............................. .... 1 Development of EDM ...................................................... 7 Comparison of Die-sinker and Wire-cut Machines ............. 17 Acceptance of the EDM Process ....................................... 21 2 The EDM System ........ ............................... 23 Die-sinker Machines ...................... .................................. 23 EDM Assem blies .............................................................. 26 Wire-cut Machines ........... ............................. ... 46 3 The EDM Process ......... .............................. 61 lonization .............................................. 61 Overcut ........................................................................... 6 9 Material Removal ............................................................. 75 4 The EDM Sparking System ........................................ 87 Sparks Occur Between the Closest Points ........................... 87 Movement of Spark Over Electrode Surface ....................... 87 Types of EDM-power Supplies ........................................... 88 Pulse-power-supply Waveform ........................................ 90 EDM-spark-ON and -OFF Time ........................................ 92 Direct-current (DC) Sparking ............................................. 92 Electrical Circuit for EDM Sparking .................................... 94 EDM-DC-power Source ...................................... 94 Spark-ON/OFF-time Waveform ........................................ 98 5 The EDM-power Supply (Generator) ........................... 103 The Power-supply Assembly ......................................... 103 Resistor-capacitor (R-C) -type EDM-power Supply............. 114 Transistor Power Supply Missing Sparks ........................... 119 R-C-power Supply Missing Sparks ................................... 120 Summary ....................................................................... 12 1 Gap-initiation Voltage .................................................... 132 Voltage and Ammeter .................................................... 134 Summary....................................................................... 135 7 Electrode Servo Systems ............................................ 137 Die-sinker-servo System .................................................. 137 Wire-cut Servo System .................................................... 149 Summary....................................................................... 151 8 EDM Dielectric Systems........................................... 153 EDM Dielectric Fluid ....................................................... 153 Dielectric Fill-drain Systems ............................................ 159 Filtration ........................................................................ 170 9 lonization and Electrode Wear ................................... 177 Spark Occurs within Ionized Column ............................... 177 Determining the Sparking Gap ....................................... 177 Electrode Polarity ........................................................... 179 Electrode Wear .............................................................. 180 No-wear Machining ....................................................... 184 Electrode Material .......................................................... 187 Electrode Corner-wear Comparison ................................ 189 Wire-cut-EDM Electrodes ................................................ 191 Data for Wire Selection .................................................. 195 Summary....................................................................... 196 10 EDM Chips ............................................................. 197 Chip Formation ........................................................... 198 Results of Chips Remaining in Sparking Gap................. 198 Using Dieledric Fluid for Chip Removal ........................ 200 Fluid-flow Paths ........................................................... 200 Side Sparking and Sidewall Taper ................................. 212 Smoke and Gas Collection in Filter Vessels ................... 216 Tapered Walls and Electrode Misalignment ................... 217 External Flow for Chip Removal .................................... 218 Vibration for Chip Removal .................................. ...... 221 Electrode Orbiting ....................................................... 224 Wire-cut Chip Removal ........................................ 226 11 Spark Energy Transmission ...................................... 233 Power Supply and Machine Electrical Connection .......... 233 Electrical Connections ................................................ 241 Wire-cut Electrical Inductance and Connections ............ 246 12 The EDM Surface ........................................ 249 Spark Energy .............................................................. 249 Electrode Surface Imperfections .................................... 252 Variation in Spark-cavity Size ........................................ 252 Equal Spark-energy Power Supplies .............................. 254 EDM Surface Finishes ........................................ 255 EDM Metallurgy ........................................ .. 256 EDM Surface Considerations ........................................ 259 Machining Heat-treated Material .................................. 260 13 DC Arcing .............................................................. 263 Normal Sparking Pulse ................................................ 263 Actual Flow of Spark Electricity ..................................... 263 Electrical Inductance .................................................... 265 DC-arc Description ........................................ 268 14 Different Types of EDM ........................................ 275 Electrical Discharge Grinding ....................................... 275 Multi-electrode and Multi-lead EDM ............................. 282 Wire-cut Multiple-workpiece and -electrode Machining.. 290 Micro-hole EDM Drilling .............................................. 291 Electrical Discharge Texturing (EDT) .............................. 297 15 Electromagnetic Radiation ....................................... 305 Detecting EDM Electromagnetic Radiation ..................... 305 Placement of EDM Machines ........................................ 306 Machine Grounding and Shielding ............................... 307 Glossary ...................................................................... 309 Bibliography ................................................................. 317 Books ................................................. 317 Magazines ......... ......................................... ............... 3 18 Resources ...................................................................... 3 19 Index ........................................................................... 321