Journal of Engineering Science and Technology Review 4 (2) (2011) 118-130

Review Article
JOURNAL OF
Engineering Science and
Technology Review

www.jestr.org

An overview of technology and research in electrode design and manufacturing in

sinking electrical discharge machining
Bhola Jha1,*, K.Ram1 and Mohan Rao2

1
Dep. of Industrial and Production Engineering, Dr B. R. Ambedkar National Institute Of Technology, Jalandhar-144011, Punjab,India
2
Dep. of Mechanical Engineering & Mining Machinery Engineering, Indian School of Mines (ISM), Dhanbad-826004, Jharkhand, India

Received 29 September 2010; Revised 14 December 2010; Accepted 25 January 2011

___________________________________________________________________________________________

Abstract

Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes, based on
thermoelectric energy between the workpiece and an electrode. In this process, the material is removed electro thermally
by a series of successive discrete discharges between two electrically conductive objects, i.e., the electrode and the
workpiece. The performance of the process, to a large extent, depends on the material, design and manufacturing method
of the electrodes. Electrode design and method of its manufacturing also affect on the cost of electrode. Researchers
have explored a number of ways to improve electrode design and devised various ways of manufacturing. The paper
reports a review on the research relating to EDM electrode design and its manufacturing for improving and optimizing
performance measures and reducing time and cost of manufacturing. The final part of the paper discusses these
developments and outlines the trends for future research work.

Keywords: EDM, Process parameters, MRR, Electrode design, Manufacturing

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1. Introduction

Electrical discharge machining is basically a non-

conventional material removal process. This process is
widely used to produce dies, punches and moulds, finishing
parts for aerospace and automotive industry and surgical
components [1]. This process can be successfully employed
to machine electrically conductive workpieces irrespective
of their hardness, shape and toughness [2-4]. During EDM
process, the electrode shape is mirrored in the workpiece.
The electrode dimensions are determined in such a way that Fig. 1. Electrode and the workpiece
spark gap between the surface to be generated and electrode
is maintained as shown in Figure 1. Higher gap is required In present days scenario, EDM is used as a standard
for higher removal rate but also higher gap results in poor technique for manufacturing production tooling out of
surface quality. The performance of the EDM process is hardened materials for production of dies and moulds. Due
highly dependent on the material and the design of the to rapid tool wear involved; many electrodes are often
electrodes. The electrode has two parts, i.e. electrode tool required for machining each cavity. Tool wear affects
and holder. Both these parts are often designed and machining accuracy and demand for frequent tool
manufactured into single piece. The simple electrodes are replacement adding to around 50% of tooling cost.
normally manufactured by conventional cutting methods, Alternatively use of rapid tooling technique minimizes the
but machining, casting, electroforming or metal spraying electrode development lead-time and reduces the tooling
may produce complicated shape electrodes. In die-sinking cost considerably. Therefore, design, development and
electrical discharge machining process, in general, either manufacturing of EDM electrode play a very vital role in
fixed electrodes are used to produce die cavities or a rotary EDM technology. A lot of published EDM research work
device works in conjunction with a CNC to control the relates to parameter optimization for a particular work tool
electrodes path in various EDM profiling [5-7]. interface or to determine best tool material for a particular
Manufacturing method of electrode also affects work material. Many innovative electrode material and
manufacturing time, cost and performance of EDM designs have also been tried. The objective of this review
electrode. paper is to report and review the research work carried out
by researchers in the field of EDM electrode design and
______________
manufacturing.
* E-mail address: [email protected]
ISSN: 1791-2377 2011 Kavala Institute of Technology. All rights reserved.
 Bhola Jha, K.Ram and Mohan Rao/Journal of Engineering Science and Technology Review 4 (2) (2011) 118-130

2. Different aspects of electrode design These mechanical properties affect the ease in
fabrication of the electrode [15]. According to the theory the
2.1 Principles of electrode design mechanical properties of the workpiece and the tool
The prime role of EDM tool is to convey the electrical pulse electrode have negligible influence on machining
to allow erosion of workpiece with little or no tool wear. performance. However, the thermo physical properties of the
Considerable effort has gone into the EDM tooling problem workpiece and electrode (thermal and electrical
regarding inexpensive tool materials, ease of manufacture, conductivity, thermal expansion, heat to vaporize from room
rapid workpiece erosion, coupled with low tool erosion etc temperate, melting and boiling temperature) have
[8, 9]. To improve machining efficiency, roughing, finishing considerable influence on the process performance in terms
and semi-finishing electrodes are used in EDM process. of material removal rate, electrode wear and surface integrity
EDM is mostly employed in obtaining mould cavities, of the workpiece [17].
cylindrical hole machining and 3-dimensional cavity The above mentioned desirable properties may provide
machining. In cylindrical hole machining, through holes and general guidelines for electrode material selection but due to
cavities are produced by electrodes of constant cross section. highly stochastic nature of EDM process, the basis for
However, in 3-dimensional cavity machining any cavity is selection of particular work-tool interface is empirical rather
machined with one or more electrodes with varying cross than theoretical. Empirical results regarding performance of
section. The tool design procedure is approximately same different work- tool interface is summarized in Table 1[10].
for both the cases [10]. Ding et al. [11] have discussed basic Electrode materials fall into two main categories:
principles of electrode design. Poluyanov [12] have metallic and graphite. Today, metallic electrodes are only
classified EDM tools into three groups depending upon the used in perhaps 10% of sinking EDM applications (with the
value of area of projection of electrode on the workpiece exception of small hole drilling). The primary advantage of
plane. The workpiece plane is considered perpendicular to metallic electrode materials is their electrical conductivity
direction of tool feed. A systematic diagram for these three and mechanical integrity. Mechanical integrity is especially
types of tool is shown in Figure 2. Two major factors important in both sharp corner and poor flushing conditions.
governing the tool design are material selection and The primary disadvantages of metallic electrodes are
electrode wear. difficulty in fabrication and low cutting speeds. Graphite is a
preferred electrode material for 90% of all sinking EDM
applications.
2.1.1Material selection for EDM electrode

The selection of the most appropriate electrode material is a

key decision in the process plan for any sinking EDM job.
The important variables to be considered for selection of
electrode material are material removal rate, tool wear rate,
surface roughness, machinability and material cost.
Properties of different electrode materials and their influence EDM tools with flat buttends
on EDM performance as well as on fabrication of electrodes
have been summarized in EDM handbooks [13, 14, 15].
Electrode material should have the basic properties like
electrical and thermal conductivity, a high melting
temperature, low wear rate, and resistance to deformation
during machining.
Since electric current is cutting tool, in EDM, higher
conductivity (or conversely, lower resistivity) promotes
more efficient cutting. Drozda [16] explained that the tool EDM tools with flat buttends and with different inclinations
electrode is responsible to transport the electrical current to
the workpiece. Therefore, any material to be used as a tool
electrode is required to conduct electricity. Since EDM is a
thermal process, it would be logical to assume that the
higher the melting point of the material of electrode, the
better the wear ratio will be between electrode and
workpiece. Even though EDM is often thought of as a zero
force process, every individual spark is a very violent
process on a microscopic scale, exerting considerable stress EDM tools with flat buttends and with 3-D shapes
on the electrode material. How well the material responds to
these hundreds and thousands of these attacks on its Fig. 2. Classification of EDM electrode [12]
surface will be a significant factor in determining the
electrode materials performance regarding wear, surface
finish, and ability to withstand poor flushing conditions. The Therefore, it is important that we expend considerable
mechanical properties of electrode materials most often effort to understand electrodes have a greater rate of metal
considered for electrode materials are: removal in relation to its wear [18]. Graphite does not melt
in the spark gap; rather, at approximately 6062 F (3350
Tensile strength C), it changes from a solid to a gas. Because of
Transverse Rupture Strength graphites relatively high resistance to heat in the properties
Grain Size and application. Studies reveal that graphite spark gap (as
Hardness compared to copper), for most jobs it is a more efficient

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electrode material. Graphite has certain properties quite cut or used to produce another part. Vartanian & Rosenholm
different than metal based electrode materials: [19] have pointed out that for many years there have been
discussions about the relative merits of the different EDM
Graphite has an extremely high melting point. Actually, electrode materials. The major debates are about copper
graphite does not melt at all, but sublimes directly from a versus graphite. The EDM users in different parts of the
solid to a gas at a temperature thousands of degrees world have been using different electrode materials for
higher than the melting point of copper. This resistance doing exactly the same jobs. Normally, copper is mainly
to temperature makes graphite an ideal EDM electrode used in Europe or Asia for historical reasons. Graphite is the
material. chosen material by the majority of EDM users from the
Graphite has significantly lower mechanical strength USA. Most EDM jobs that can be done with copper can also
properties than metallic electrode materials. It is not as be executed with graphite. The end result might be the same,
hard, strong, or stiff like metallic electrode materials. but the cost to accomplish the job can be vastly different. In
However, since the EDM process is one of relatively low practical terms the choice of the electrode material will
macro mechanical forces, these property differences are depend mainly on the tool size, the workpiece requirements,
not often significant. type of EDM machine and methods of making the
Due to the significant differences between metallic electrodes. Other important factors shall be considered when
electrodes and graphite, there are certain properties, selecting the electrode material:
unique to graphite. These properties are-
Workpiece material removal rate [mm3/min]: A correct
Particle Size: Generally, the smaller the particle size, the choice of EDM parameters to the pair tool /workpiece
better the mechanical properties of the graphite, resulting in electrode materials will increase its value.
finer detail, better wear, and better workpiece surface finish. Electrode resistance to wear: The volumetric and corner
wears in electrode are very important in finish EDM
Density: Since graphite is a porous material, its density must operations of fine details. Minimization of those wears
be closely controlled. Generally, higher density is preferable. requires choosing proper parameters and electrode
material.
Flexural Strength: Flexural strength is a measure of the Workpiece surface roughness: Good workpiece surface
strength. Generally, graphite with the smallest particle size quality is obtained by the proper choice of electrode
has the highest flexural strength. material, good flushing conditions and adequate EDM
parameter settings.
Hardness: Hardness is generally a function of the particle Tool electrode material machinability: Copper and
size, porosity, and binder material. Hardness can be very graphite are the most commonly used. However, it is
important to the success of machining and grinding important to select an electrode material where the macro
operations. Graphite is widely used due to its significant and micro geometry can be easily machined. It promotes
production advantages over metallic electrode materials. the reduction of machining time and costs.
Electrode material cost: On average, fine graphite is about
Speed: Graphite is faster than copper in both roughing and three times more expensive than copper. The choice shall
finishing, usually by a factor of 2:1. be done considering the company facilities (e.g, machine-
tools, CAD/CAM software technology etc). It also
Machinability: Graphite machines and grinds an order of includes the know-how on machining copper and graphite
magnitude faster than copper, and can also have more detail electrodes, the complexity of the electrode and its
easily machined into it. Graphite doesnt have to be de- difficulty to be redressed and the knowledge on EDM
burred like any metallic does, further reducing electrode parameters.
fabrication costs.

In fact, there is a vast range of materials used for 2.1.2 Electrode wear in EDM
manufacturing electrodes like brass, tungsten carbides,
electrolytic copper, copper-tungsten alloys, silver-tungsten The tool wear process is quite similar to the material
alloy, tellurium-copper alloys, copper-graphite alloys, removal mechanism as the tool and workpiece are
graphite etc. The five commonly used electrodes are: copper, considered as a set of electrodes in EDM [1]. EDM electrode
brass, tungsten, zinc, and graphite. In addition, some wear may be categorized into four types- (a) Volumetric (b)
electrode materials are combined with other metals in order Corner (c) End and (d) Side [10]. Corner wear directly
to cut more efficiently. Tungsten has a melting point similar influence shape of the cavity. Heaviest electrode wear occurs
to graphite, but tungsten is highly difficult to machine. at the corners. Jeswani [20] have analyzed the electrode
Metallic electrodes usually work best for machining materials erosion by dimensional analysis. An empirical relation was
which have low melting points as aluminum, copper, and developed relating the material eroded from tool electrode to
brass. As for steel and its alloys, graphite is preferred. The the energy pulse, density, thermal conductivity, specific heat
general rule is: metallic electrodes should be applied for low and latent heat of vaporization of electrode material.
temperature alloys and graphite electrodes should be applied Crookall et al. [21] have explained the effect of debris
for high temperature alloys. However, exceptions also exist. concentration on erosion rate. They have reported that
For example, despite higher melting points for cobalt, increased debris resulted in increased erosion. Also use of
tungsten, and molybdenum, metallic electrodes like copper distilled water as dielectric results in lower erosion rates in
are recommended due to the higher frequencies needed to comparison to kerosene as dielectric. Mohri et al. [22] have
EDM these materials. During unsupervised CNC cutting, the investigated the tool wear mechanism and claimed that tool
copper electrode can be sized automatically by using a sizing wear is affected by the precipitation of carbon from the
plate. The copper electrode can then be reused for a finishing hydrocarbon dielectric on the electrode surface during
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sparking. They also reported that the rapid wear on the

electrode edge was due to the failure of carbon to precipitate
at difficult-to-reach regions of the electrode tool. Dauw [23]
has developed a geometrical simulation of EDM describing
the development of electrode wear and part geometry. It was
also considered as an off-line process planning technique as
the simulation algorithm is largely based on MRR, TWR and
spark gap. However, the simulation of discharge location
and spark gap, which are dependent on the distribution of
debris concentration, was reported by Kunieda and Kiyohara
[24] yielding a more realistic representation of the sparking
phenomenon. Kunieda et al. [25] have introduced a reverse
simulation of EDM obtaining the shape of the electrode
based on the desired workpiece shape. Marafona and Wykes
[26] have introduced a wear inhibitor carbon layer on the
EDM electrode surface by adjusting the settings of the
process parameters prior to normal EDM conditions.
Although, the thickness of the layer have made a significant Fig. 3. Electrodes shapes for basic types of flushing methods.
improvement on the tool wear rate but it had little effect on
the MRR. Saha [27] has investigated the erosion rates of few Mohan et al. [34] have investigated the effect of tube
work- tool interfaces with similar as well as dissimilar electrode hole diameter on the performance measures. They
metals. It was found that the distribution of energy per pulse found that electrode tube hole diameter significantly affects
between the electrodes, dielectric and plasma and hence their the MRR, TWR and SR. The decrease in hole diameter has
erosion rates depends on electrode material pair and their produced a better MRR, SR and higher TWR.
polarity.
Minimization and compensation of electrode wear has 2.3 Different 3-D form tool designs
always been one of the major motives in electrode design
process. Researchers have proposed several methods for Generally 3-D form tools are employed in EDM process
compensating electrode wear in EDM. Orbiting of the which are found costly, take more time for their
electrode relative to the workpiece is the most common manufacturing and associated with high wear rate
machining strategy proposed by researchers for particularly when subjected to cutting of complex shapes [1,
compensating the tool wear. It involves the electrode tool 36, 37]. Research on 3D solid form tool with different
making a planetary motion producing an effective flushing geometries revealed that best tool shape for higher MRR and
action, thus improving part accuracy and process efficiency lower TWR is circular in shape, followed by triangular,
[28]. rectangular, and square cross sections [38]. Yan and Wang
[35] compared the performance of solid electrode and tube
electrode. They observed that both the MRR and TWR
2.2 Relation of electrode design with EDM performance considerably increase for tube type electrode in comparison
measures to solid type electrodes. The same researchers compared the
performance of a stationary electrode, a rotational electrode,
Majority of researchers use material removal rate (MRR), and a rotational electrode with an eccentric through-hole in
tool wear rate (TWR) and surface roughness (SR) as terms of machining characteristics [32]. Higher MRR and
performance indices. Electrode design affects the spark gap TWR were reported for rotational electrode with an
between EDM electrodes. Spark gap differs for different eccentric through-hole. This was possibly attributable to the
electrode geometries and also for different surface finish superior debris disposal effect.
condition required. Higher spark gap results in higher 3D tools when applied for complex shapes together with
voltage setting and improved flushing conditions resulting in high penetration depths was found to introduce flushing
higher MRR and rough surface. difficulties. This in turn restricts the removal of debris
Flushing condition may also be improved by suitable causing abnormal discharge so that only 60% useful
electrode design. MRR is highly affected by types of machining time is obtained [39]. Flushing conditions may be
dielectric and method of flushing [29]. Flushing is useful to improved by increasing the electrode gap but it results in
remove debris from discharge zone even if it is difficult to lower metal removal rates [40]. Bayramoglu and Duffill [41]
avoid concentration gradient and inaccuracy [30, 31]. Better investigated the machining characteristics of 3D form and
flushing conditions result in both increases in material cylindrical tools. They reported that CNC EDM machine
removal rate and tool wear. Better flushing conditions is have the capability for developing 3D shapes using part
reported by introducing electrode rotation, tube electrode programs to generate servo-controlled tool movements on
design and electrode with eccentric hole [6, 32-34]. four axises. CNC EDM can facilitate more sophisticated tool
Electrode design also depends upon method of flushing motions and the ability to generate complex shapes with
employed. Figure 3 shows electrode designs for three basic simply shaped electrodes. With CNC EDM machines the
types of flushing methods. Wang and Yan [35] have machining can now take place in the X, Y, Z and rotational
reported the effect of flushing methods on performance C directions. However these advanced CNC capabilities
measures for Al2O3/6061Al MMC and rotating electrode. were not fully utilized by toolmakers [42]. Instead of using
They found that with side flushing, both the MRR and TWR multi-axis CNC capabilities, the design and manufacturing
is considerably less than with injection and suction flushing. of 3D shaped workpieces was largely dependent on plunging
Surface roughness value was found to be approximately the of formed tool along z-axis direction.
same for each type of flushing method.

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Table 1. Performance of work-tool interface in EDM [10] CWR: Corner wear ratio

Sr. Material Workpiece Available Performance Type of Wear ratio Machinability Best Limitations
No. of Material form Relaxation Pulse machining application and
Electrode Type type undesirable
VWR CWR
uses
R R
1 Graphite Steels Blocks, Poor Excellent R, F 100:1 5:1 Excellent Press Carbide
Rods tooling dies
2 Brass All metals Brass Fair Excellent R, F 1:1 7:1 Good Hole size Deep slots
tube,
Wire
3 Copper- All metals Short Excellent Excellent S-F, F 8:1 3:1 Fair Machining Large areas
tungsten Bars, of carbides,
Flats, slots and
Shims, micro
Wire, machining
Tubes
4 Copper All metals Bars, Excellent Good R, F 2:1 1:1 Good Hole Deep slots
Wire, with close
Tube tolerance
5 Tungsten All metals Wire, Good Good S-F, F 10:1 5:1 Poor Small Irregular
and Rods slots& holes
refractory holes
metals
6 Tungsten All metals Sintered Good Good S-F, F 10:1 6:1 Poor Small Irregular
Carbide and Rods slots& holes
refractory holes
metals
7 Steel Non Rods, Poor Good S-F 4:1 4:1 Good Through Carbide
ferrous Ingots, holes
materials Forgings
8 Zinc Steel only Cast Poor Fair R, S-F 2 7:1 Good Forging Through
Shapes Die cavities holes
9 Aluminum Steel only Cast Fair R 5:1 5:1 Good Forging Through
Shapes, Poor cavities holes
Extruded
bars

Notes: R: Rough machining

F: Finish Machining
S-F: Semi-Finish Machining
VWR: Volume wear ratio

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2.4 Plate, frame and ball ended cylindrical tool design realized by layer-by-layer machining. This maintained the
original electrode shape and converted the three dimensional
Four types of tooling methods have been reported by electrode wear to a linear one. By compensating the linear
researchers for producing 3D shape cavities in workpiece as electrode wear, complicated three dimensional cavities were
shown in Figure 4 [41- 43]. successfully machined. This technique was developed for
micromolds, but the applicability for normal size molds was
also confirmed.
Like 3D form tools, ball ended cylindrical tools can be
employed for producing basic (spheres, conics and simple
2D sweeps) and intermediate (complex 2D sweeps, ruled
surfaces and fillets) sculptured (CAD obtainable shapes,
higher order polynomials) and general (3D implied shapes
indicated on drawings). Standard cylinder or ball ended
cylinder as the tool electrode is employed in contour or CNC
EDM milling technology [47, 48]. Ding and Jiang [47] have
studied special requirements on tool paths demanded by
contour EDM machining and have proposed a two-phase
tool path generation method for 4-axis contour EDM rough
milling with a cylindrical electrode. In the first phase of the
method, initial tool paths for virtual 3-axis milling were
generated in a commercial CAD/CAM system
Unigraphics, which provides users with plenty of options in
choosing suitable tool path patterns. From these tool paths,
cutter contact points between electrode and workpiece are
reversely calculated. In the second phase, considering the
special requirements of EDM, which include discharging
gap compensation, electrode wear compensation, DC arcing
Fig. 4. Design difference between 3D form tool, frame tool, plate type prevention, etc., the electrode was adjusted to an optimized
tool and ball ended cylindrical type tool.
interference-free orientation by rotating it around the cutter
contact points obtained in the previous phase. This new
orientation together with the reference point of electrode is
Plate type tools can only be applied with basic shapes
output as new tool path. The whole algorithm has been
(spheres, conics and simple 2D sweeps) and intermediate
integrated into unigraphics, machining simulations and tests
shapes (complex 2D sweeps, ruled surfaces and fillets).
have been conducted for 4-axis contour EDM rough
When applied for complex shaped deep cavities, plate tools
machining. Being a special application of conventional
results in poor dielectric flow causing the debris to
EDM, contour or CNC EDM machining of free-form
accumulate and be suspended in the gap. With simple plate
surfaces is a new technology emerged in recent years. Due to
tooling, however, good flushing conditions can be achieved
its special machining properties, although the electrode
even in the most difficult circumstances [44]. The
moves in the same way as a cutter in mechanical milling,
application of plate type tools results in high MRR, high
tool paths generated for milling cannot be used directly in
relative electrode wear, good dimensional accuracy and
contour EDM machining. Discharge gap compensation,
better surface finish.
electrode wear compensation and many other factors have to
Application of frame type tool in EDM is a novel
be considered in the tool path generation process. Chang and
technique for generation of linear, circular and curved
Hong [48] have investigated a buffered digital differential
contours without using any complex shaped electrodes.
analyzer algorithm in a computerized numerical controller
Bayramoglu and Duffill [43] have discussed the brief
performs milling electric discharge machining of a curve
advantages of using frame type tools. Compared to form
constructed from a sequence of segments using a traditional
type tools, frame type tools are easy to produce and
computer-aided manufacturing system. The proposed
inexpensive. With application of frame type tool, the
algorithm interpolates more than one segment in a sampling
machining time reduces considerably. In EDM process
interval and supports the effective machining of a parametric
surface finish depends upon generator setting and tool
curve when the electrode crosses the connection between the
surface area [45]. Smaller machining surface results in better
short segments. The accuracy of the speed and the trajectory
surface finish. The total machining area of frame type tool is
of motion were ensured without the time function of the
smaller than for 3 D form tool. Therefore application of
parameter specified by two terms of a Taylor expansion,
frame type tool results in better surface finish. Also, catering
such as in a real-time parametric curve interpolator. The
for dimensional changes in frame type tools could be carried
proposed algorithm is compared with the referenceword
out under NC control rather than employing different tools
interpolation and real-time polynomial interpolation used in
for roughing, semi finishing and finishing operations as in
a milling EDM to confirm improvements of erosion speed.
case of 3D form tool. Therefore, frame type tools are less
After the parametric curve has been converted into the
expansive. Like plate type tools, frame type tools are only
segments using a fixed parameter increment under
suitable for basic shapes (spheres, conics and simple 2D
constrained chord error and the memory size, the buffered
sweeps) and intermediate shapes (complex 2D sweeps, ruled
digital differential analyzer algorithm interpolates more than
surfaces and fillets). Yu et al. [46] have presented a new
one segment using a simple digital differential analyzer in
method, called uniform wear method, for 3D micro-EDM.
the main program during an interruption interval. The
Simple electrodes such as with round or rectangular section
algorithm selects appropriate commands in interrupt service
were applied. Uniform wear at the end of the electrode was
routine after the results obtained by the digital differential

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analyzer have been pushed into the memory, to ensure that period of time until the surface electric charge over these
the computation time of the interrupt service routine is short. electrodes is redistributed or another discharge occurs.
The algorithm guarantees the accuracy of the line-connected Therefore, finally discharge can occur at different electrodes
contour and the speed without using real-time polynomial simultaneously. Suzuki et al. [58] and Kubota et al. [59]
interpolation. The actual chord error can be maintained proposed a twin electrode discharge system for the electric
below the threshold as required, and the actual speed is discharge dressing of metal bonded grinding wheels.
similar to that determined from two terms in the Taylor Connecting the pulse generator to one of the two twin
expansion. The rates of erosion of the milling EDM with a electrodes, the grinding wheel, and the other twin electrode
high sampling rate and a high speed along short segments serially formed the discharge circuit. In this system, for each
exceed those of traditional referenceword interpolation and pulse, two discharge points can be obtained simultaneously
real-time polynomial interpolation. Standard cylinder or ball at both the gaps between the twin electrodes and the
ended cylinder as the tool electrode may be applied in EDM grinding wheel using only one pulse generator. Kunieda and
without making the male electrode necessary to yield a part Muto [56] used twin electrode discharge system as shown in
of desired shape [48-50]. Bayramoglu and Duffill [41] have Figure 6. The removal rate and energy efficiency were found
investigated the effects of tool path, pick feed and electrode higher than those of conventional EDM in which there is
rotation for flat and ball ended cylindrical electrodes. Many only one discharge point for each pulse.
methods of determining the electrode wear rate and a system
that included mechanisms of automatic measurements and
compensation of electrode deformation for such tools have
been reported in literature [49, 51-54]. Halkaci et al. [55]
have proposed a new practical method for dimensional
measurements of semi-spherical parts for the standard tool
electrodes used in electrical discharge machining. In this
proposed method, numerous coordinate data representing
sphericity of ball surface are obtained spending less time and
lower cost. The ball ended cylindrical tool used for
experimentation is shown in Figure 5 [55].

Fig. 6. Principle of Multi-spark EDM [56]

Chen et al. [60] devised a new mechanism of cutting

pipe combined with electrical discharge machining. This
new mechanism was designed with multi electrode system
controlled by planet gear system in die sinking EDM as
shown in Figure 7. The newly developed mechanism
resulted in both increase in material removal rate and
relative electrode wear ratio for SUS 304 workpiece
material. Influence of process parameters have been
investigated on MRR for developed mechanism. The largest
removal rate and the lowest electrode wear ratio were
reported when workpieces rotate at 8 rpm.

Fig. 5. Typical ball ended cylindrical tool [55]

2.6 Computer assisted EDM electrode design
The deviation from spherical form due to electrode Ding et al. [11] have introduced a computer-aided EDM
wears during machining and consequent difficult tool path electrode design system for die and mould manufacturing.
generations are disadvantages of ball ended cylindrical tools. Under this system, when electrode boundaries are selected,
the electrode tool, tool holder and a work coordinate system
2.5 Tool design for multi-spark and multi-electrode EDM are created automatically. Thus, by this system, electrode
tools and its holders can be created automatically from
Kunieda and Muto [56] proposed the multi-spark EDM workpiece design. This design system also generates a
method which was newly developed to obtain higher workpiece co-ordinate system for machining purpose. The
removal rates and lower energy consumption compared with system has been tested and proved to be able to shorten
conventional EDM. This technique is a modification of the electrode design lead time significantly. The proposed
basic EDM principle because in basic EDM, only single method begins with the detection of the uncut region in the
discharge is delivered for each electrical pulse. To set up mould insert that requires machining. The boundary of the
multiple discharge points for each pulse two types of region is then obtained and projected onto the plane that is
electrode design has been proposed by researchers. Mohri et perpendicular to the EDM direction (X-Y Plane). The
al. [57] divided a tool electrode into multiple electrically trimming and extension of the boundary curves are invoked
insulated electrodes connected to the pulse generator when necessary for ensuring that the projected boundary
through a resistor. In this case, after a discharge occurs in forms a close loop. After that, the close-loop boundary is
the gap between one of the divided electrodes and the extruded along the Z direction to create a solid that contains
workpiece, the gap voltages at other electrodes are the region that requires the EDM process. Subtraction of the
maintained at the open circuit voltage level for a certain

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part geometry from the extruded solid gives the solid model electrodes are cheaper to produce. For complex three-
of the electrode. Although the electrode created by Ding's dimensional shapes, machining, casting, electro-forming or
method has the correct shape to perform the EDM process metal spraying may produce electrodes. Fabrication of
for the uncut region in the part, the electrode may itself electrodes using rapid prototyping (RP) technology can also
contain uncut regions. In such cases, the single electrode has reduce the cost of producing electrodes with complex
to be split into multiple electrodes to avoid machinability geometry. Research and development work in EDM
problem of the single electrode. This process is tedious and electrode manufacturing is reported in following
requires an experienced engineer to ensure proper splitting. subsections.
Mahajan et al. [61] proposed the basic principles of
designing knowledge-based system for automated EDM
electrode design. This system works by taking into account,
the logic that an experienced EDM specialist would use to
design electrodes. First the overall methodology to design
EDM electrodes automatically is described on the highest
level then the details of this methodology are explained
followed by conclusions. The success of this system depends
to some extent to the radius detection software algorithm.
General methodology proposed in the research work is
shown in Figure 8. However, these rules are presented using
high-level description, and automating the electrode design
process with them would be a difficult task, which has not
been addressed in this research work.

Fig. 8. General idea of the method to design electrodes automatically

[61]

3.1 Electrode manufacturing using casting and

machining

These are conventional techniques of EDM electrode

Fig. 7. Difference between conventional and multi electrode EDM [60]
manufacturing. Casting is used for Zn based die casting
alloy, Al alloys and Zn-Sn alloys [64]. Electrode are often
die cast by standard Zn-base die casting alloys, Zn- Sn (80-
Lee and Li [62] have developed an intelligent CAD tool 20 to 50-50) alloys and aluminum alloys. These electrodes
that supports EDM electrode design. This CAD tool uses a may be re-melted for reuse [10]. However, cast electrodes
new technique that recursively splits the EDM region into have various defects like blowholes, mismatching and micro
sub-regions until machinable electrodes can be constructed. cracks. Electrodes of copper and its alloys can be machined
This proposed intelligent CAD tool has been implemented in by using conventional machines [65]. In United States, high
and integrated with a commercial CAD/CAM system. This speed machining of graphite has become an increasingly
tool has been tested with 40 different real designs to popular solution. Application of these conventional
demonstrate its capability in handling a wide variety of techniques is limited due to complex cavities.
geometric shapes. Design engineers have been invited to
evaluate its performance. Performance data revealed that at
least a 50% improvement in the efficiency of the design 3.2 Electrode manufacturing using powder Metallurgy
process can be achieved with the current implementation. (PM)

Earlier, the majority of EDM work was being done by using

3. Different aspects of electrode manufacturing mechanically formed tool electrodes. The present EDM user
is compelled to search for alternative tooling such as powder
Electrical discharge machining is used extensively in the metallurgy (PM) method of electrode fabrication which is
machining of dies and moulds with hardened material. more economical and faster to manufacture. A complex
Generally, the cost and time consumption in the die and electrode manufactured by conventional method may cost
mould machining by EDM is the manufacturing of around 100 times more than a simple square electrode.
electrodes, which can account for over 50% of the total Therefore, conventional method is suitable for less complex
machining cost [63]. The cost of manufacturing electrodes is shaped electrodes or for complex shaped electrode in few
generally determined by the complexity of the geometry and numbers. However in the powder metallurgy, a large number
the accuracy demanded. The electrodes for electrical- of EDM tool electrodes can be manufactured from a single
discharge machining are generally fabricated using die and punch assembly. This results in an overall reduction
conventional machining methods. Uniformly dimensioned of EDM tooling cost for mass production of EDM

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electrodes. Therefore, powder metallurgy turns out to be a was coated by silver nearly 10 m thick onto the surface
viable alternative to produce tool electrode in which the and then electroformed of copper with thickness of 180
desirable properties of different materials can be combined. m.It was claimed that these electrodes are suitable for
Moreover, the thermal, electrical, mechanical and micro finishing cut in EDM die-sinking. Stucker et al. [78] have
structural properties like density and pore shape of PM attempted to apply a composite of ZnB2/Cu mixed with an
electrodes can be effectively controlled by the process adhesive to prepare a rapid prototyping model by selective
variables such as compacting pressure and sintering laser sintering (SLS), and then to make an EDM electrode
temperature. An example is an alloy of Cu-W made through after the removal of the adhesive by heating. Zaw et al. [67]
PM where tungsten particles are uniformly embedded in compared the performance of different EDM electrodes
highly conductive copper matrix. The electrodes made by made by conventional methods, PM route and rapid
using powder metallurgy technology from special powders prototyping. Yarlagadda et al. [79] have discussed the use of
have been used to modify EDM surfaces in recent years, to rapid prototype patterns made by the stereo lithography
improve wear and corrosion resistance. technique for the manufacture of EDM electrodes. The use
Samuel and Philip [66] have carried out theoretical and of other techniques such as silicone rubber casting and
experimental study into the effect of PM electrode on electroforming in the making of the EDM electrode has also
various aspects of EDM. They have established that such been described. Their research work deals with the viability
electrodes are technologically practicable and by varying of using an electroformed shell of copper, backed with a
compaction and sintering variables, EDM related properties suitable material, as an EDM electrode and it was concluded
can be controlled. Zaw et al. [67] have investigated that electroformed copper electrodes possess an excellent
compounds of ZrB2 and Ti Si with copper at various potential for use. Noguchi and Nakagawa [80] have
composition of EDM electrode. Either solid-state sintering developed a new powder casting process suitable for making
or liquid phase sintering manufactured these electrodes. metallic rapid tools by powder sintering. Allan et al. [81]
Performance of newly sintered material is compared with have applied electroforming combined with different RP
conventional electrode materials such as copper, Copper- technologies for the production of complex EDM electrodes
tungsten and RT produced from selective laser sintering. with fairly reasonable time scale. In their study, the electrode
Beri et al. [68] have investigated the usefulness of life, wear of electrodes, and eroded cavity depth against wall
electrodes made through powder metallurgy in comparison thickness has been discussed. It was found that application
with conventional copper electrode during electric discharge of filled thin-walled electroforms as EDM electrodes is
machining. It was found that Cu-W electrode (made through possible. Zhao et al. [82] have manufactured an electrical
PM) gives high surface finish where as the Cu electrode is discharge machining metal prototype directly using the
better for higher material removal rate. selective laser sintering (SLS) process. It was found that the
In spite of sintering constraint, PM manufactured wear rate of the electrode approaches to that of a general
electrodes have proved to be best alternative method of electrode, and the surface roughness of the cavity is
electrode manufacturing due to ease of production and acceptable at the same machining conditions. The preferable
control of properties. surface finish of a cavity can be acquired using roughening
or semi-finish machining parameters with this kind of
electrode. Dimla et al. [83] have described a collaborative
3.3 Electrode manufacturing using rapid prototyping research program aimed at investigating the use of quick
and rapid tooling EDM electrodes obtained via appropriate rapid prototyping
techniques in finishing laser-sintered tools. Two methods
Rapid prototyping is a motivating innovative additive were employed in obtaining the EDM electrodes: copper
technology for quickly creating physical models and coating of stereo lithography models and copper coating of
functional prototypes directly from CAD models. Rapid direct metal laser sintered (bronze) models. The amount of
tooling, is generally, related with fast tooling production copper deposited on both electrodes models was proved
using prototypes made by rapid prototyping. Technologists problematic as the electroplating process was unable to
involved in rapid tooling processes development are now deposit enough copper in the inner cavities of the electrodes.
devoting much of their efforts in reducing lead-times and Consequently, the electrodes were not found suitable for the
development costs. Rapid prototyping (RP) technology envisaged EDM process. Ferreira et al. [84] have
offers great advantages like improved quality, shortening investigated the application of indirect rapid tooling (RT)
time to market, and reduction in the cost of fabrication of technology to manufacture EDM copper electrodes from
complex shaped EDM electrodes [67, 69]. investment casting, with wax prototypes made by Thermo
Between 1991 and 1996, several attempts were made to Jet 3D printing, a rapid prototyping (RP) technique. The
develop applications and techniques for rapid prototyping reverse engineering (RE) method was utilized to transform
EDM tooling [70-76]. Arthur and Dickens [72] have the point cloud data of an object surface, obtained from 3D
investigated manufacturing parameters and discovered that digitizing, in a 3D CAD surface model dataset. Based on a
when the copper plating layer on the electrode prototype is case study, some functional conclusions were made for the
above 175 m thick than it can help in preventing the application of RT in manufacturing EDM electrodes aided
electrode prototype from breaking during EDM. Arthur et al. by 3D digitizing and RE, validating the accomplishment by
[77] have investigated wear and fracture mechanism of the integration of these technologies and methodologies in
stereolithography SL-EDM electrodes. Such electrodes EDM manufacturing processes. Kechagias et al. [85] have
present wear and failure mechanisms that are detrimental. reviewed the published research work on RT electrodes.
Arthur et al. [74] used RP parts as electrodes for EDM. They They tabulated the results of the performance of such
have found a direct generation route with rapid prototype electrodes. Hsu et al. [86] have investigated an effective
parts as EDM electrodes. Thin-coated stereo lithography method for manufacturing electrical discharge machining
models were successfully used in machining hardened tool electrodes using the rapid prototyping system based on
steel up to a depth of 4 mm. The photo-polymer electrode electroless plating (nickel plating) and electroforming

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(copper). This method was shown to finish the development reasonably good conductivity has not been
of die-sinking electrical discharge machining electrodes, sufficiently investigated.
shorten the electrode manufacturing process, and decrease Generally, tool makers use thumb rule or trial and
the manufacturing duration as well as the cost of electrodes. error method for EDM tool design. Therefore,
Test results indicated that no crack was found on the scientific investigation of design of circular as well
electrode and promising electrical discharge machining as non circular electrodes is identified as an
effects. important area of research. Results of
Although many variations of RT electrodes were investigations may be extended for fabrication of
developed and extensive research was performed, until now tools with complex cavities.
the results of RT electrode performance have shown that Like material removal mechanism, electrode wear
they do not meet the desirable standards for use as an mechanism (ERM) is also a complex phenomenon.
alternative to conventional CNC or high speed machining Simplified assumptions and approaches in
(HSM) milling electrodes [85]. theoretical modeling, have led to large
disagreement with results. Therefore, there is no
sound theoretical basis for selecting a suitable tool
3.4 Electrode manufacturing using some other material and design for a work material. Selection
techniques of suitable work-tool interface is mainly based on
empirical results.
Researchers have also tried some innovative techniques for Most of research work in EDM relates to use of 3D
fabrication of EDM electrode. Tsai et al. [87] have proposed form tool. Alternate types of tools like frame type
a new method of blending the copper powders contained and plate type are yet to be tried for work-tool
resin with chromium powders to form tool electrodes. Such interfaces.
electrodes are created at low pressure (20 MPa) and Application of plate, frame and ball ended
temperature (200 C) in a hot mounting machine. The results cylindrical tool design seems to have a lot of
showed that using such electrodes have facilitated the potential for commercial applications. Their
formation of a modified surface layer on the workpiece after applications depend upon exploitation of CNC
EDM, with remarkable corrosion resistant properties. Kadir EMD capabilities allowing servo controlled tool
Dursun and Can Cogun [88] have investigated the movement along four axes. However, market
performance of electrodes formed by using copper wire survey shows that these capabilities are not fully
bunches (WBEs). WBEs are proved to be economical as being exploited by toolmakers. The reason for the
compared to conventional solid electrode. The use of WBE same needs to be explored and thoroughly
electrode for rough machining decreases machining cost and investigated.
time. It decreases both the number of electrodes required and Even in 3D form tools, not much published work is
delay in starting machining due to preparation of electrode. available corresponding to use of different tool
Shibayama and Kunieda [89] have described improvement cross-sectional geometries like rectangular,
of machining characteristics of EDM of deep slots using a triangular etc. on performance measure like MRR,
tool electrode which has micro holes for jetting dielectric EWR etc. Therefore, effect of different tool
liquid over the working surface. The electrode was made by geometries on MRR, EWR, surface roughness etc.
the diffusion bonding of two copper plates, over an interface has to be explored for more work materials.
on which micro grooves for jetting the dielectric fluid were In case of non circular electrode design, effects of
formed using electrolyte jet machining. Use of the newly profile parameters of a particular profile (like
developed tool electrode was found to shorten the processing inscribed angle in case of triangular electrode) on
time and improve machining accuracy significantly performance measures of EDM process are yet to
compared with the conventional solid electrode. Since the be investigated sufficiently.
holes are micro in size, the outlet shapes are not replicated Hollow tube and eccentric drilled holes type
onto the bottom surface of the slot machined.
electrodes are reported to have a positive impact on
MRR due to improved flushing conditions. Such
4. Remarks and future trends designs need investigations for more work
materials to evaluate their case to case effects.
The objective of the review article has been aimed to report
Multi spark EDM and multi electrode EDM are
the work carried out by various researchers in the field of
relatively new techniques for MRR improvement
EDM electrode design and manufacturing, and to bridge the
and are still under experimental stage. More
gap between the untouched areas. After an elaborate scrutiny
empirical validation using different workpiece
of the published work, the following remarks emerge from
materials is required before the method is
the existing published work.
recommended for commercial applications.
Although EDM electrodes formed by powder
Most of the published work on EDM tool design
metallurgy route is a recommended alternative
relates to parametric optimization, improving
method for electrode manufacturing due to ease of
performance measures and selection of suitable
production and control of properties but there is
work-tool interface. There is not much published
limited published work on investigating
work on EDM electrode design.
performance of such electrodes. Most of the
In addition, published works in tool design include
published work relates to electrode formed by
a few materials like copper and its alloys, graphite
conventional techniques probably because of their
etc. Use of new materials like cermets which has
easy availability. PM electrodes should be
low tool wear rate, high corrosion resistance and

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investigated thoroughly for many work-tool

interfaces. 5. Summary
Although extensive research work has been
performed on variations of rapid tooling electrodes Design and manufacturing of electrode play an important
but still they do not meet desirable standards for role in EDM technology. The present review paper reports
use as an alternative to conventional CNC or high research and development work carried out by various
speed machining electrodes. This is due to evident researchers in the same field. After elaborate scrutiny of the
disadvantages like poor surface roughness and published work, future direction for the EDM research have
dimensional inaccuracy. Future research work may been indicated as a novel contribution to the archival
be directed for minimizing such disadvantages for literature.
making RP electrode as a feasible alternative.
There is negligible published work available on List of abbreviations
comparative study of various electrode designs and
electrodes manufactured by different techniques EDM: Electrical Discharge Machining
with same/different work materials. So, there is a MRR: Material Removal Rate
lot of scope for future research work in this field. CNC: Computed Numerically Controlled
Researchers have investigated innovative ways of CAD/CAM: Computer Aided Design/ Computer
EDM electrode manufacturing using diffusion Aided Manufacturing
bonding, wire bunch electrodes, electrodes with TWR: Tool Wear Rate
micro holes etc. However, there is limited SR: Surface Roughness
published literature regarding performance of such PM: Powder Metallurgy
electrodes. Such electrodes should be investigated RP: Rapid Prototyping
thoroughly for many possible work material- RT: Rapid Tooling
electrode material combinations before their
commercial application.

______________________________
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