Electrical Discharge Machining (EDM): Types, Technologies and Applications

Muhammad Pervej Jahan (Editor)
Department of Architectural and Manufacturing Sciences, Western Kentucky University, USA

Series: Manufacturing Technology Research
BISAC: TEC007000

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Edited by I Leslie Rubin, Robert J Geller, Abby Mutic, Benjamin A Gitterman, Nathan Mutic, Wayne Garfinkel, Claire D Coles, Kurt Martinuzzi, and Joav Merrick

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Electrical Discharge Machining (EDM) is one of the earliest and most widely used non-conventional machining processes. In recent years, the use of EDM has increased significantly in industries, mainly due to the extensive use of hard and difficult-to-cut materials, i.e. hardened steels, carbides, titanium alloys, nickel super alloys and so on. The EDM process is being used extensively for many important applications in die and mold, aerospace, automotive, micro-electronic and biomedical industries. As a result, extensive research has been carried out on various aspects of EDM. Taking those facts into consideration, this book aims to provide a comprehensive overview of the various types, technologies and applications of EDM.

The book starts with chapters on the two major types of EDM: die-sinking EDM and wire-EDM. Subsequently, several EDM-based hybrid machining processes, such as: ultrasonically aided EDM, powder-mixed EDM, and simultanous micro-EDM/ECM have been discussed in detail. This book includes chapters on the detail of EDM surface and modeling and simulation of the EDM process. This book also contains chapters on the novel and innovative applications of EDM as well as machining of newer materials, such as: shape memory alloy, reaction-bonded silicon carbide, metal metrix composites, silicon based semiconductors, and non-conducting polymers. It is a useful resource for students and researchers who are planning to start their research on the area of EDM and related processes. It can also serve as a reference for students, academics, researchers, engineers, and working professionals in non-traditional manufacturing processes related industries.
(Imprint: Nova)

Preface
pp. vii-viii

Contributors
pp. ix-xii

Chapter 1
Die-sinking Electrical Discharge Machining
(M.P. Jahan, Department of Architectural and Manufacturing Sciences, Western Kentucky University, Bowling Green, KY, USA)
pp. 1-32

Chapter 2
Wire Electrical Discharge Machining
(D. Ghodsiyeh and M. Moradi, Department of Mechanics and Aerospace, Politecnico di Torino, Torino, Italy)
pp. 33-66

Chapter 3
EDM Modelling and Simulation
(U. Maradia, K. Wegener, Institute of Machine Tools and Manufacturing, ETH Zurich)
pp. 67-122

Chapter 4
Surfaces in Electrical Discharge Machining
(Bülent EKMEKCÝ, Nihal EKMEKCÝ, Hamidullah YAÞAR, Department of Mechanical Engineering, Bülent Ecevit University, Zonguldak, Turkey)
pp. 123-150

Chapter 5
Ultrasonically Aided Electrical Discharge Machining
(Daniel Ghiculescu, Polytehnic University of Bucharest, Bucharest, Romania)
pp. 151-208

Chapter 6
Hybrid Micro-EDM/ECM and its Applications for Fabrication of Complex 3D Micro-structures
(Minh Dang Nguyen, Mustafizur Rahman, Yoke San Wong, Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore)
pp. 209-254

Chapter 7
Orbital Electro Discharge Machining
(Harshit K. Dave, Harit K. Raval, Keyur P. Desai, Sardar Vallabhbhai National Institute of Technology, Surat, India)
pp. 255-272

Chapter 8
Micro-Electrical Discharge Machining Employing Powder Mixed Dielectrics
(Golam Kibria, Department of Mechanical Engineering, Aliah University, Kolkata; IndiaIshwer Shivakoti, Department of Mechanical Engineering, Sikkim Manipal Institute of Technology (SMIT), Sikkim, India; and B. Bhattacharyya, Production Engineering Department, Jadavpur University, Kolkata, India)
pp. 273-314

Chapter 9
Application of Micro-EDM in Patterning Conducting Polymer
(Mohammed Muntakim Anwar, Kenichi Takahata, John D Madden, Electrical and Computer Engineering, University of British Columbia, Vancouver, Canada)
pp. 315-328

Chapter 10
Fabrication of Micro-grinding Tool by Block-EDM
Asma Perveen, Mechanical Engineering Department, Bursa Orhangazi University, Bursa, Turkey; and Mustafizur Rahman, Yoke San Wong, Mechanical Engineering Department, National University of Singapore, Singapore)
pp. 329-356

Chapter 11
Electrical Discharge Machining Characteristics and Optimization of Newer Materials
(S. Gopalakannan, Department of Mechanical Engineering, Adhiparasakthi Engineering College, Melmaruvathur, Tamilnadu, India)
pp. 357-382

Chapter 12
Electro-Discharge Machining for Non-Metal Based Fabrication Process
(Tanveer Saleh, Department of Mechatronics Engineering, International Islamic University, Malaysia)
pp. 383-424

Chapter 13
Micro Electrical Discharge Machining of Reaction-Bonded Silicon Carbide
(Pay Jun Liew, Manufacturing Process Department, Universiti Teknikal Malaysia, Melaka, Malaysia; and Jiwang Yan, Department of Mechanical Engineering, Keio University, Japan)
pp. 425-456

Chapter 14
Electrical Discharge Machining of Shape Memory Alloys
(M. P. Jahan, Pegah Kakavand, Department of Architectural and Manufacturing Sciences, Western Kentucky University, Bowling Green, KY, USA)
pp. 457-490

Index
pp. 491-493

"This book provides an extensive overview of an important non-conventional manufacturing process named “Electrical Discharge Machining (EDM)”. The contents in the book cover both the fundamentals of the EDM process and recent research and development in the area of EDM. The book accumulated many important topics on varisous aspect of EDM and EDM-based hybrid manufacturing processes in a comprehensive collection, that could help the educators, researchers, engineers, technologists, and students working on EDM.

The first two chapters cover the basics of two common types of EDM process named die-sinking EDM and wire EDM. The chapters include the history, principle, system component, parameters, variations, and applications of two major types of EDM processes. These two chapters would be very useful for graduate students who are planning to start their research in the EDM field. The following chapter focuses on the mathematical modeling and simulation of the EDM process from different perspective such as EDM gap phenomena, single and multiple discharges, temperature distributions and material removal mechanism. As EDM is an electro-thermal process, one of the major concerns of the EDM process is the surface generated during the machining. This book includes a chapter providing in-depth discussion on the surface topography, sub-surface microstructures, residual stress, hardness, micro-cracks and other surface characteristics produced from the EDM process and ways to improve the surface quality.

This book also covers the recent research and development done in the EDM field. One of the growing area of research is the EDM and micro-EDM based hybrid manufacturing processes. The objective of the research in hybrid machining is to compensate the difficulties of a single process and to improve the overall machining performance and efficiency. This book provides a detail and in-depth discussion on various types of EDM-based hybrid machining processes, such as ultrasonically aided EDM, powder-mixed EDM, micro-EDM and micro-grinding, and simultanous micro-EDM/ECM processes. The chapters on each hybrid machining process include a comprehensive review of research works conducted on that specific process. This book also discusses the important industrial applications of the EDM process as well the machinability of emerging novel materials by the EDM process. For example, the book presents interesting applications of EDM and Micro-EDM processes in machining of conducting polymer (i.e. Polypyrrole), metal matrix nano composites (MMNCs), reaction bonded silicon carbide, and silicon based semiconductor materials, and shape memory alloys. The chapters on machining of innovative materials would motivate and guide future researchers to explore new applications of the EDM process.

Finally, this book provides a comprehensive and in-depth overview of the EDM process, its types, varities and applications. This book can serve as an important reference material for students, academics, and researchers working in the area of EDM." - Dr. Elsayed A Orady, Professor of Manufacturing, Industrial and Manufacturing Systems Engineering Department (IMSE), College of Engineering and Computer Science (CECS), University of Michigan - Dearborn (UMD)

This book can be used as a research book for final year undergraduate engineering and technology course as well as a topic on manufacturing for Masters and Doctoral level course. In addition, this book can serve as a reference book for students, researchers, engineers, teachers and working professionals in non-traditional manufacturing processes related industries. This book would be very useful for the students and researchers who are planning to start their research on the area of EDM and related processes. Therefore, the scientific interest in this book is evident for universities, research centers, as well as industries.

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