EDM (Electrical discharge machining), commonly referred to as spark erosion machining, is a manufacturing technique that uses an electric spark to remove material from hard metals and machine shapes that are challenging to create with a conventional cutter. As previously stated, there are a few rules that must be followed in any manufacturing process, and lubrication is among the most crucial ones. The purpose of this research is to examine if EDM has a lubricating function, as well as its importance and function within the EDM process.
Understanding EDM
To begin with, it will be worthwhile to describe both what EDM is and how it functions in relation to lubrication. EDM is a latest technique of machining that uses electrical sparks for the purpose of cutting or eroding material from a work-piece. It is especially crucial for hard-to-machine materials that conventional methods might not work well on. EDM was thus divided into two categories.
- Wire EDM:In this method, the material is shaped with the thin wire that acts as an electrode that melts and erodes the material.
- Die-Sinking EDM:It employs a shaped electrode with the necessary geometry to wear and abrade the material in a cavity-like manner.
Both types depend on dielectric fluid; this fluid commonly associated with EDM lubrication.
The Role of Dielectric Fluid
Some of the functions of the dielectric fluid used in EDM include but not limited to the following. The dielectric fluid acts as a coolant and also as a lubricant. In this way, the understanding of the functions of the compound can assist to explain how EDM lubricate the parts.
Cooling the Workpiece
EDM is generally a high energy process and is associated with high temperatures due to electric discharge. Failure to do so will result to either the work piece or the tool electrode getting burnt. The dielectric fluid assists in cooling down this heat so that both components become maintainable in their respective temperatures that enhance their durations.
Spark Control
The dielectric fluid also plays a role of insulating between the electrode and the workpiece so that subsequent electrical discharge is not made continuously. It makes it possible to pop only where it is useful, regulating the material removal process and achieving accuracy.
Removing Debris
EDM uses materials to cut the required shape hence it results in formation of numerous metallic shavings. The rest of the abrasive particles are washed away in the fluid and do not cause any harm to the machining process. It’s important to pick up this debris because it contributes to the wanted dimension tolerance and the visual appeal of the surface of the finished part.
Lubrication
Though it is not its initial function, the dielectric fluid does offer some lubricating properties. As a result, it provides lower resistance to the movement of the electrode across the workpiece, making it easier to work on it and at the same time minimizing on the amount of wear that such movement may cause.
Types of Dielectric Fluids
EDM dielectric fluids may differ and their composition does not the dielectric properties of the fluid but have lubrication properties.
Here are some common types:
Hydrocarbon-based Fluids
Hydrocarbon fluids are used extensively because of their good cooling properties and efficiency in removing debris. Another is that they help in offering a certain amount of cooling because they produce a thin layer between the electrode and the workpiece which minimizes contact.
Synthetic Fluids
Coolant fluids which include deionized water with additives more effective than hydrocarbons for cooling because of the environmental effects that the latter brings. They can offer as much lubrication as is required to reduce the possible health and safety hazards.
Gaseous Dielectrics
Other lower dielectrics utilized in EDM are the gaseous dielectrics such as compressed air even though they are rarely utilized. These gases give very little lubrication but can be useful circumstances in precision turning processes.
Benefits of EDM Lubrication
Some of the advantages of the dielectric fluid in the EDM process:
Extended Tool Life
There is a decrease in friction for the same electrode, it means less wear and tear hence more operating time or seldom replacement of tools for the same.
Improved Surface Finish
Lubrication has an important function of improving the surface finish on the workpiece to the specified quality that may not require further finishing.
Enhanced Machining Precision
The sample’s dielectric fluid also helps reducing friction and heat that improve the level of accuracy needed for components with precise measurements.
Reduced Energy Consumption
Optimal lubrication is good for the shaper’s performance because it creates good operating conditions that in turn reduce the energy required in the machining process.
Considerations for Effective EDM Lubrication
In order to enhance the benefits brought by EDM lubrication some of the following should be taken into consideration:
Fluid Selection
Hence, final selection of the dielectric fluid suitable for the required machining and the properties of the working material are paramount. Keep the parts clean for effective work where the fluids are applied as lubricants, coolants, and for debris removal.
Fluid Maintenance
Maintain the dielectric fluid for a proper performance of the equipment. This is particularly done to avoid contamination of the fluid, separation of the solid material from the fluid, and controlling the concentration of the fluid for it to be effective.
System Configuration
The dielectric fluid’s flow velocity and pressure are two examples of how the configuration of an EDM machine can impact lubrication. The efficiency of these parameters and the way operating operations are carried out are improved when they are made easier to use.