influence of electrical process parameters

8/10/2019 Influence of Electrical Process Parameters

1/8

Review

A review on inuence of electrical process

parameters in EDM process

T. Muthuramalingam a,*, B. Mohan b

aDepartment

of

Production

Technology,

M.I.T.

Campus,

Anna

University,

Chennai,

IndiabDepartment

of

Mechanical

Engineering,

CEG

Campus,

Anna

University,

Chennai,

India

1. Introduction

Electrical discharge machining (EDM), otherwise known as

thermal

erosion

process,

is

one

of

the

non-conventional

machining processes, where tool and workpiece do not come

into contact with each other during the machining process. The

progression of events constituting the process of material

erosion

from

the

work

surfaces

by

an

electrical

discharge

machining

can

be

explained

in

the

following

way.

If

an

appropriate voltage is developed across the tool electrode

(normally cathode) and the workpiece (normally anode), the

breakdown of dielectric medium between them happens due to

the growth of a strong electrostatic eld. Owing to the electric

eld, electrons are emitted from the cathode toward the anode

on

the

electrode

surfaces

having

the

shortest

distance

between

them. These electrons impinge on the dielectric molecules of

the

insulating

medium,

breaking

these

dielectric

uid

mole-

cules into positive ions and electrons. These secondary

electrons travel along on the same ionization path. This event

causes an increase in the electric eld strength across the work

surfaces

and

liberates

a

large

number

of

electrons.

It

creates

an

ionized

column

in

the

shortest

spark

gap

between

the

tool

electrode and the workpiece, thereby decreasing the resistance

of the uid column and causing an electrical discharge in the

shortest distance point between the tool and the workpiece. The

a r ch i ve s o f c i vi l a n d m e ch a ni c al e n gi n ee r in g x x x ( 2 01 4 ) x x x x xx

a

r

t

i

c

l

e

i

n

f

o

Article history:

Received 12 July 2013

Accepted 16 February 2014

Available online xxx

Keywords:

EDM

EWR

Discharge

MRR

Surface

a

b

s

t

r

a

c

t

Since the thermal energy produced in electrical discharge machining process is due to the

appliedelectrical energy, it is veryimportant to enhance theelectrical processparameters to

improve theprocess efciency. Thepresent study discusses about havingan overview of the

EDM process, modeling of processparameters, and inuence of process parameters such as

input electrical variables, pulse shape, anddischargeenergy onperformance measures such

as material removal rate, surface roughness and electrode wear rate. This study also

discusses about controlling the electrical process parameters, and empirical relationships

between processparameters and optimization of process parameters in EDM process. From

the review results, it has been observed that the efcacy of the machining process can be

improved by electrical process parameters, and only less attention has been given for

enhancing such parameters.

# 2014 Politechnika Wrocawska. Published by Elsevier Urban & Partner Sp. z o.o. All

rights reserved.

* Corresponding author. Tel.: +91 9994872013; fax: +91 4422232403.

E-mail addresses: [email protected], [email protected] (T. Muthuramalingam), [email protected] (B. Mohan).

ACME-201; No. of Pages 8

Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,Archives of Civil and Mechanical Engineering (2014), http://dx.doi.org/10.1016/j.acme.2014.02.009

Available online at www.sciencedirect.com

ScienceDirect

journal homepage: http://www.elsevier.com/locate/acme

http://dx.doi.org/10.1016/j.acme.2014.02.009

1644-9665/# 2014 Politechnika Wrocawska. Published by Elsevier Urban & Partner Sp. z o.o. All rights reserved.
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2/8

enormous thermal energy melts and vaporizes the materialfrom

the

workpiece,

which

creates

a

small

crater

over

the

work

surface. There happened a collapse of the ionized column with

the termination of the electrical energy by means of the

switching circuit and then surrounding dielectric uid occupies

its

place.

The

melted

debris

is

removed

by

the

ushing

process.

The conduction of dielectric medium can be determined by the

current,

duration

and

pulse energy

[1].

Fig.

1

explains

the

formation of ionized column in the shortest distance of work

surfaces using the EDM process [1].

2. State of art in EDM process

Since the electrical discharge machining process is of with

non-linear

nature,

it

requires

a

lot

of

improvements

on

it.

Many authors have discussed about the research works for

improving process efciency of the EDM process. The funda-

mentals of EDM process mechanism and research works

carried out from the inception to the development of the die-

sinking EDM process within the past decade have been

discussed

by

Ho

and

Newman

[2]. It

has

been

reported

and

discussed

about

the

EDM

researches

relating

to

improve

the

process performance measures, optimizing the process vari-

ables, and monitoring and control of the sparking process.

Abbas et al. presented the recent research trends to improve

the performance characteristics involved in all the aspects ofelectrical discharge machining process. They discussed about

the need for controlling the process parameters to enhance the

machining process efciency of the EDM process [3]. The

development of new technologies for improving the surface

quality of workpiece is a signicant research area in EDM

process.

Kumar

et

al.

presented

a

review

on

the

phenomenon

of surface modication by EDM and future trends of its

applications [4]. It has been observed that most of the research

works concentrated on surface modication using the powder

mixed

dielectric

medium

in

EDM

process.

The

study

of

the

impact of the electrical process parameters on surface

modication of the workpiece has been taken up by very

few researchers.

3. Enhancing the performance of pulsegenerator

Since the electrical energy is supplied to the EDM process

informing the DC pulses, the pulse generator needs to be

upgraded

to

improve

the

performance

measures

in

the

machining process. The lower energy pulses enhance thesurface nish of the workpiece whereas the higher energy

pulses improve the material removal rate.

Jahan

et

al.

conducted

a

detailed

experimental

investiga-

tion

to

nd

out

the

inuence

of

major

operating

parameters

on

surface quality of tungsten carbide with both transistor and

RC-type generators in EDM process [5]. It has been proved that

RC pulse generator has produced a smoother surface nish

than the transistor pulse generator due to its lower discharge

energy

distribution

over

the

surface

of

tungsten

carbide.

Han

et

al.

designed

and

developed

a

modied

transistor

pulse

generator with pulse frequency of 1 MHz to produce higher

material removal rate than the RC pulse generator in the

electrical discharge machining process [6]. They found that thetransistor

pulse

generator

has

provided

two

or

three

times

higher machining speed than the conventional RC pulse

generator while machining tungsten workpiece with brass

electrode.

A

pulse

generator

based

on

xed

pulse

width

modulation

has been developed by Yan and Liu to generate the high

frequency

4.4

MHz

and

short

duration

pulse

control

signals

to

reduce surface roughness of the workpiece tungsten carbide in

the EDM process [7]. From the experimental results, it has been

observed that the very low discharge energy pulse applied

between

tool

and

electrode

has

improved

the

surface

quality

of

workpiece during the machining process. Yan and Chiang

discussed about the development and application of a newpower supply in wire electrical discharge machining process

[8].

A transistor-controlled power supply composed of a low

energy discharge circuit has been designed to provide the

functions of high frequency and lower energy pulse control.

The experimental results have shown that the low peak

current has been resulted in better surface nish in EDM

process.

Muthuramalingam

and

Mohan

discussed

about

effect

of

uniform

distribution

for

improving

the

surface

quality

using

iso current pulse generator in EDM process [9]. Fig. 2 shows the

surface quality of workpiece made by three different pulse

generators. It has been observed that the iso current pulse

generator could produce better surface nish than theconventional pulse generators such as RC pulse generator

and transistor pulse generator.

Han et al. designed and developed a new transistor type

pulse generator with high frequency response to produce

higher erosion rate of the workpiece in the electrical discharge

machining

process

[10]. From

the

experimental

results,

it

has

been observed that the modied transistor pulse generator has

produced 24 times higher material removal rate than the RC

pulse generator in the EDM process. Yan and Lai presented the

development

of

a

ne-nish

power

supply

with

high

frequen-

cy in EDM process [11]. This power supply has been composed

with full bridge circuit, two snubber circuits and a pulse control

circuit. It has been found that the proposed power supply has

Fig. 1 Basic mechanism involved in EDM.

a rc h iv es o f c i vi l a n d m e ch an i ca l e n gi ne e ri n g x xx ( 2 01 4 ) x xx x x x2


http://dx.doi.org/10.1016/j.acme.2014.02.009http://dx.doi.org/10.1016/j.acme.2014.02.009


3/8

produced

lower

discharge

energy

and

thus

contributed

to

lower surface roughness. Muthuramalingam and Mohan

developed a semiconductor based pulse switching circuit to

produce lower energy discharge pulses during nishing levelof

the

process

for

enhancing

the

EDM

performance

character-

istics [12]. Casanueva et al. attempted to establish a new EDM

impulse generator based on high frequency switched DC-to-

DC series-parallel resonant converter [13]. It has been claimed

that

the

capacitance

effect

has

affected

the

overall

impedance

of the EDM arrangement and thus altered the machining

characteristics

of

EDM

process.

4. Inuence of pulse shape on performancemeasures

Studying the variation of the EDM process response char-acteristics due to change in shape of the generated pulse is one

of

the

research

aspects

in

the

EDM

process.

The

discharge

pulse shape affects the average spark energy which is

delivered on the surface. Since the machining characteristics

in EDM process depend on the electrical energy, the pulse

shape which has an effect on the machining characteristics

such as material removal rate, surface quality and electrode

wear

rate

as

shown

in

Fig.

3.

The

effects

of

the

voltage

excitation

of

the

pre-ignition

spark pulse on the performance measures such as material

removal rate, electrode wear rate and average surface

roughness have been discussed by Ghoreishi and Tabari

[14]. Based on the results, it is clear that applying voltageexcitation of the pulse has produced an effective pulse which

in turn increased material erosion and surface quality. The

inuence of the current impulse on machining tungsten

carbide

and

SKD

die

steel

with

electrolytic

copper

tool

electrode in the EDM process has been investigated by Tsai

and Lu [15]. From the experimental results, it has been found

that the material removal rate and tool wear rate have beenaffected

by

the

energy

density.

Muthuramalingam

and

Mohan

discussed about inuence of discharge current impulse on the

performance measures in EDM process [16].

Son et al. investigated the inuences of electrical pulse

condition

on

the

machining

characteristics

in

the

EDM

process

[17]. It has been found that the duration of pulse considerably

affects

the

machining

characteristics

such

as

material

removal

rate, tool wear rate and surface accuracy. It has also been

realized that the shorter EDM pulse could be efcient to make a

precision part. Liu et al. described the inuence of the EDM

discharge

pulse

shape

on

the

machining

characteristics

such

as material removal mechanism of Si3N4TiN [18]. The surface

texture of machined workpiece has been investigated withdifferent form of discharge pulse such as relaxation and iso

current

pulse.

It

has

been

proved

that

uniform

discharge

energy has produced good surface topography.Janardhan and

Samuel analyzed the effect of machining parameters on

material removal rate and average surface roughness using

the pulse train data acquired at the spark gap with the help of

MATLAB software package [19]. It has been observed that the

material

erosion

rate

has

been

increased

with

decrease

in

the

pulse

off

time

in

EDM

process.

Yeo

et

al.

proposed

a

new

pulse

discriminating technique for monitoring electrical discharge

machining process [20]. This system has employed the current

pulse as the main detecting parameter as it has been

considered to be a better representation of the spark energyinside the plasma channel as compared to the voltage. There

should be less arcing effect to enhance the surface nish for an

ideal EDM process. Muthuramalingam and Mohan discussed

and proved that the uniform duration pulse shape for the

discharging phenomenon in EDM process has improved the

surface

quality

of

the

workpiece

with

less

arcing

effect

[21].

5. Inuence of electrical process parameterson

performance

measures

There are many research works that have been conducted to

nd the inuence of process parameters especially electrical

Fig. 2 Surface topography of machined surface using different pulse generators.

Fig. 3 Relation between pulse shape and machining

characteristics in EDM process.

a rc h iv e s o f c i vi l a nd m ec h an ic a l e ng i ne e ri n g x xx ( 2 01 4 ) x x x xx x 3




4/8

process parameters on EDM process. Most of the researchworks

reveal

that

the

discharge

current

and

machining

time

have the most inuencing nature on the EDM performance

measures. Fig. 4 shows the SEM images of EDM surface while

machining AISI 202 stainless steel with tungsten carbide tool

electrode.

Gostimirovic et al. investigated the effects of electrical

process

parameters

on

the

performances

of

die-sinking

electrical discharge machining process with RC pulse generator

while machining manganese-vanadium tool steel workpiece

using graphite tool electrode. They found that the discharge

current

and

pulse duration

have

highly

inuenced

the

material

removal rate of the EDM process [22]. Mohan et al. analyzed the

effect of EDM process parameters such as electrode material,polarity, pulseduration, current and rotation of the electrode on

the

material

removal

rate,tool

wear

rate

and

surface

roughness

[23]. It has been found that the material removal rate and tool

wear rate have been increased with the discharge current during

machining process. Nowicki et al. analyzed the effects

individual electrical discharge on the crater volume of the

workpiece in EDM process [24]. They found that the crater

surface

exhibits

strong

interaction

with

the

electrical

discharge

spark.

Mohan

et

al.

investigated

the

surface

roughness

of

the

SiC/6025Al composite surface using electrical discharge ma-

chining process with brass as the tool electrode [25]. From the

experimental results, it has been observed that increasing peak

current has resulted in higher surface roughness during themachining process.

Seo et al. discussed about the drilling process of a

functionally graded 1535 vol.% of silicon carbide particulate

reinforced Al359 metal matrix composite byelectrical discharge

machining process to assess the machinability and workpiece

quality

[26].

It

has

been

observed

that

the

peak

current

and

pulse

on time have increased the material removal rate. It has also

been reported that increase in percentage SiC particles has

increased the material removal rate and electrode wear rate.

Puertas

et

al.carried

out

a

study

on

the

inuence

of

the

factors

of

current intensity, pulse time and duty cycle over the material

removal rate, surface quality and electrode wear rate [27]. They

modeled the relationship between the input parameters and

response

parameters

in

the

die-sinking

EDM

process

using

response surface methodology. It has been concluded that the

lower values of the current intensity and the machining time

have to be used in order to obtain a good surface nish. The use

of the dimensional analysis for investigating the effects of the

electrical and the physical parameters on the material removal

rate

of

a

die-sinking

EDM

process

has

been

described

by

Yahya

and Manning [28]. From the experimental results, it has beenfound that the material removal rate has been increased with

discharge current, gap voltage and pulse on time.

Huang

et

al. made

an

attempt

to

unveil

the

inuence

of

the

process

parameters

on

the

machining

performances

in

the

EDM

process [29]. It has been found that the pulse on time and spark

gap have the most signicant nature to affect the performance

measures such as surface roughness and white layer depth

using numerical analysis. Kuppan et al. reported about the

experimental

investigation

of

small

deep

hole

drillingof

Inconel

718

with

electrolytic

copper

tool

electrode

using

the

electrical

discharge machining process [30]. The experimental results

have shown that the material removal rate has been increased

with the increase in the peak current and duty factor. Patel et al.investigated

the

feasibility

of

fabricating

micro holes in

SiCpAl

composites using electrical discharge machining with a rotary

tube electrode [31]. They have investigated the material removal

rate, electrode wear rate and hole tapper as the responses for the

study.

The

experimental

results

have

revealed

that

pulse on

duration has signicantly affected the response characteristics

involved

in

EDM

process.

Pelicer

et

al.

focused

on

investigating

the inuence of EDM process parameters and electrode

geometry on feature micro accuracy on tool steel for mold

fabrication purposes [32]. A set of designed experiments with

varying

process

parameters

such

as

pulse current,

open

voltage

and pulse duration have been carried out in H13 steel using

different shaped copper electrodes. It has been concluded thatthe triangular shaped electrode would produce highly inef-

cient

output,

since

the

fast

wearing

nature

of

the

electrode

edges. Wang et al. carried out a series of experiments to

investigate the impacts of machining polarity, electrode

rotation speed and nominal capacitance on the material

removal rate and tool wear rate with poly crystalline diamond

[33]. It has been demonstrated that favorable machining

performance

of

EDM

process

on

the

workpiece

could

be

achieved

in

tool

with

negative

polarity

as

compared

to

the

positive polarity.

Tosun et al. presented an investigation on the effect and

optimization of machining parameters on kerf and material

removal rate in wire EDM process with Taguchi method [34].Theexperimental studies have been conducted under varyingpulse

duration, gap voltage, wire speed and ushing pressure with

AISI 4140 steel as workpiece material. Based on the ANOVA

method, the high effective parameter on both kerf and material

removal rate has been found as pulseduration.Ji et al. presented

a

new

process

of

machining

SiC

ceramics

using electrical

discharge milling process [35]. The effects of tool polarity, pulse

duration, voltage and peak current on the process performances

such as material removal rate, electrode wear rate and surface

roughness

have

been

investigated.

It

has

been

found

that

the

negative polarity tool electrode with longer pulse duration has

produced high material removal rate and surface roughness.

Rebelo et al. presented an experimental study on the effect of

Fig.

4

SEM

images

of

surface

using

EDM

process.





5/8

electric

discharge

machining

parameters

on

material

removal

rate and surface quality with high strength copperberyllium

alloys [36]. They found that the plasma diameter has been

decreased with pulseduration and discharge current during the

machining process.

Yu et al. examined the use of electrical discharge machin-

ing

on

machining

poly-crystalline

silicon

[37]. The

effects

of

different WEDM process parameters on machining character-istics have been explored. From the experimental results, it

has been indicated that the pulse on time has the great

inuence

on

the

cutting

speed

in

Wire

EDM

process.

Batish

et

al.

investigated

the

effect

of

process

parameters

and

mechanism of material deposition in electric discharge

machining on surface properties of EN31, H11 and high carbon

high chromium die steel materials [38]. It has been discussed

about material transfer mechanism involved in EDM process.

It

has

been

found

that

die

steels

have

been

machined

effectively

with

copper

tool

electrode

using

EDM

process.

Patel et al. presented a detailed experimental investigation of

machining characteristics such as surface integrity and

material removal mechanisms of advanced ceramic compos-ite

Al2O3SiCwTiC with EDM process [39]. It has been

concluded that the surface roughness and material removal

rate have been increased with pulse duration in EDM process.

6. Inuence of discharge energy onperformance measures

In view of the fact that when the discharge energy is converted

into the thermal energy to melt and vaporize the material in

EDM

process,

it

is

unavoidable

to

discuss

the

inuence

of

the

pulse energy on the machining characteristics in such a

process.Jahan et al. conducted an experimental investigation with

the

view

of

obtaining

ne

surface

nish

in

die-sinking

EDM

process of tungsten carbide using different tool electrodes

such as tungsten, copper tungsten and silver tungsten [40]. It

has been found that the surface nish has been inuenced by

the discharge energy during machining process. It has been

realized that the lower discharge energy has produced good

surface

nish.

Yeo

et

al.

discussed

about

the

machining

of

zirconium

based

bulk

metallic

glass

by

EDM

process

with

different tool electrodes such as copper, brass and tungsten

rod electrode [41]. The experimental results have shown

that the usage of lower input energy has produced the

lower surface roughness and electrode tool wear. Khanraet al. investigated the inuence of energy input on the

workpiece surface during the machining in the EDM process.

In this experimental investigation, a well-polished mild steel

(C 0.18%) plate has been used for machining byEDM [42]. It has

been observed that the energy input has inuenced the debris

particle

size

in

the

EDM

process.

Popa et al. showed the importance of optimizing the

process parameters that could inuence the quality of the EDM

process [43]. They formulated the equation of crater depth in

terms

of

discharge

energy

in

EDM

process.

From

the

relation,

it

has been observed that the crater depth has been increased

with the discharge current owing through the workpiece and

tool electrode. Kojima et al. described about the spectroscopic

measurement

of

arc

plasma

diameter

in

EDM

[44]. They

found

that the arc plasma has been increased with increasing

discharge current. It has been veried that crater diameter and

depth decrease with increasing gap width due to the increased

plasma diameter. The arc plasma diameter has been increased

with increasing spark gap and thus claried the reason for

lower

material

removal

rate

and

smoother

surface

nish

with

longer spark gap. Wong et al. developed a single spark pulsegenerator using resistancecapacitance arrangement to study

the erosion characteristics in the EDM process from the crater

size

[45].

The

volume

and

size

of

the

craters

have

been

found

to

be

more consistent at lower energy discharge sparks than the

higher energy discharge sparks. The higher energy pulse leads

to the micro surface crack on the work surface. Guu et al.

aimed to investigate the machining characteristics of manga-

nesezinc ferrite magnetic materials using electrical discharge

machining

process

[46]. The

experimental

results

have

indicated that the morphology of debris revealed the mecha-

nism of material removal. It has been observed that the better

machined surface has been obtained by setting processparameters

at

low

pulse

energy.

Nowicki

et

al.

made

an

attempt to machine supercial layer of the workpiece using

brush EDM process by modifying the spark energy [47]. The

theoretical modeling of the EDM process based upon the heat

transfer

equations

has

been

established

by

Singh

[48]. In

the

study, the input energy equation has been developed as a

function

of

pulse

duration,

current,

polarity

of

electrode

and

properties of the workpiece and tool electrodes. This model

has been helpful to calculate the optimal process parameters

for obtaining optimum discharge energy.

7.

Monitoring

and

control

of

the

EDM

process

The

EDM

process

parameters

have

to

be

monitored

during

the

machining process so that the controlling of those parameters

can be done to obtain the required response parameters. The

main action of monitoring and controlling the process is to

observe and measure process parameters to reduce the

deviation of performance measures from the expected level.

An

adaptive

control

system

for

process

monitoring,

identication

and

control

in

the

wire

electrical

discharge

machining process has been developed by Yan [49]. It has been

realized that the wire breaking has been controlled by

adjustment of pulse interval of each pulse cycle of supply.

Caydas et al. developed an adaptive neuro-fuzzy inferencesystem model for the prediction of the surface roughness of

machined surface using wire EDM process as a function of

process parameters such as open circuit voltage, pulse

duration and wire feed rate [50]. From the experimental

results, it has been found that the proposed control system has

improved

the

surface

quality

in

EDM

process.

Yilmaz et al. introduced a used friendly intelligent system

based on the knowledge of the skilled operators for the

selection of the EDM process parameters for machining AISI

4340

stainless

steel

[51]. The

system

has

been

provided

with

a

compact selection tool based on expert rules and enabled an

unskilled user to select necessary parameters which lead to

lower electrode wear rate and better surface quality. Zhou and





6/8

Han

developed

an

adaptive

control

system

which

directly

and

automatically has regulated the tool down time for improving

the process performance in EDM process [52]. It has been

observed that this adaptive system would improve the

machining rate, due to the automatic adjustment of spark

gap. Yan and Chien developed a new pulse discriminating and

control

system

for

process

monitoring

in

EDM

process

[53].The

effects of pulse interval, machining feed rate and workpiece onthe variation of the proportion of normal spark, arc and short

circuit in the total spark have been discussed. The experimen-

tal

results

have

indicated

that

the

developed

control

system

has

signicantly

reduced

the

arc

discharge

in

EDM

process

to

achieve stable machining.

Chang designed a proportional derivative controller of the

spark gap between an electrode and a workpiece to analyze the

non-linearity involved in EDM process [54]. They concluded

that

this

non-linearity

has

reduced

the

effective

discharge

in

electrical

discharge

machining

process.

Behrens

and

Ginzel

proposed a neuro-fuzzy based gap width controller for a highly

efcient removal mechanism in EDM process [55]. The

experimental results have indicated that the proposedcontroller

has

enhanced

EDM

process

to

achieve

the

better

surface nish of workpiece. Kao and Shih monitored the

discharge current in electrical discharge machining using high

speed data acquisition with high frequency response [56].

From

the

experimental

results,

it

has

been

found

that

decrease

in air gap between tool and workpiece has improved the

material

removal

rate

in

EDM

process.

Tong et al. designed an experimental system with a macro/

micro dual feed spindle to improve the machining perfor-

mance of servo scanning micro EDM process, which utilized an

ultrasonic

linear

motor

as

the

macro

drive

and

a

piezoelectric

actuator as micro feeding mechanism [57]. Based on LabVIEW

software package, a real time control system has beendeveloped to control coordinately the dual-feed spindle to

drive

the

tool

electrode.

Fenggou

and

Dayong

presented

a

method to automatically determine and optimize the process

parameters on the EDM sinking process with the application of

articial neural network [58]. The experimental results have

proved that automatic determination of current value would

be the efcient method on improving EDM performance.

8. Modeling of EDM process parameters

The process parameters modeling helps to analyze the

inuence process parameters on the machining character-istics in any of the machining process. This section is

discussed about the mathematical modeling of process

parameters and simulation models in the EDM process.

8.1.

Theoretical

modeling

of

EDM

process

Since the two electrical conductors such as tool electrode and

workpiece are separated by a dielectric medium, the EDM

arrangement can be modeled as a capacitor. Liu et al.

constructed

a

plate

capacitor

model

for

electrical

discharge

machining process [59]. The correlation actions of process

parameters and energy distribution have been discussed

based on the eld electron emission theory. It has been

observed

that

machining

time

plays

a

major

role

to

improve

the process efciency. Das andJoshi developed a comprehen-

sive mathematical model to predict the spark erosion rate

involved in EDM process [60]. They found that the plasma

current and plasma radius have been increased with pulse

duration. Salonitis et al. developed the thermal based model

for

the

determination

of

the

material

removal

rate

and

average

surface roughness achieved as a function of the processparameters in the EDM process [61]. Spadlo et al. developed a

thermo model for brush electrical discharge alloying process

[62].

It

has

been

realized

that

material

removal

depends

on

the

discharge

current

pulse

owing

through

the

dielectric

medi-

um.

8.2.

Optimization

of

EDM

process

Most

of

the

research

works

have

been

carried

out

to

optimize

the

electrical

process

parameters

in

EDM

process.

Marafona

and Wykes described an investigation into the optimization of

material removal rate in the electric discharge machining

process with copper tungsten tool electrode [63]. From theexperimental

results,

it

has

been

proved

that

large

current

intensity would result in higher material removal rate.

Matoorian et al. presented the application of the Taguchi

robust design methods to optimize the precision and accuracy

of

the

EDM

process

for

machining

of

precise

cylindrical

forms

on hard and difcult-to-machine materials [64]. They found

that

the

current

intensity

of

the

EDM

process

affects

the

material removal rate greatly. Muthuramalingam and Mohan

developed Taguchi-DEAR methodology based optimization of

electrical process parameters [65]. Tzeng and Chen described

about

the

application

of

the

fuzzy

logic

analysis

coupled

with

Taguchi methods to optimize the precision and accuracy of the

high speed electrical discharge machining process [66]. Themost important factors affecting the precision and accuracy of

the

high

speed

EDM

process

have

been

identied

as

duty

cycle

and peak current. Kuriakose and Shunmugam developed a

multiple regression model to represent relationship between

the input and output process variables [67]. They have done

the multi objective optimization method based on non-

dominated sorting genetic algorithm to optimize the EDM

process

parameters.

9. Conclusion

The present study discussed about the review of contributionof electrical process parameters for efcient EDM process in

various aspects such as state of art, inuence of the discharge

energy, modeling of EDM process parameters, pulse genera-

tors, pulse shape, monitoring the parameters and optimiza-

tion of EDM process parameters. The review has been carried

out

in

all

aspects

and

types

of

EDM

process

such

as

die-sinking

EDM, wire EDM and micro EDM. The following conclusions can

be mainly made based on the literatures:

(i)

Most

of

the

literatures

have

discussed

about

inuence

of

process parameters on the performance measures,

modeling and optimization of process parameters in-

volved in the electro erosion process.





7/8

(ii)

It

has

been

found

that

peak

current

and

pulse

duration

are

dominating the performance measures in EDM process.

(iii) It has been observed that only less attention has been

given for enhancing the electrical process parameters in

EDM process in terms of pulse modication, monitoring

and adaptive controlling of the process parameters.

(iv)

It

has

also

been

observed

that

only

very

few

literatures

are

available describing the hybrid modern manufacturingtechniques such as electro chemical discharge machining

(ECDM).

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removal rate in wire electrical discharge machining based on



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Please cite this article in press as: T. Muthuramalingam, B. Mohan, A review on inuence of electrical process parameters in EDM process,hi f i il d h i l i i ( ) h //d d i / /j
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