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EDM Electrode Design and Analysis to Enhance Process Performance

Article in Tikrit Journal of Engineering Sciences · December 2023

DOI: 10.25130/tjes.30.4.15

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 Abstract: Electric discharge machining (EDM)
Keywords: is regarded as one of the most energy-efficient
manufacturing processes for exceptionally
accurate processing of any electrically conductive
material, regardless of mechanical properties.
EDM is a non-contact process utilized in various
ARTICLE INFO
industries, including aerospace, industrial,
Article history: instruments, molds, dies, and medical tools; also,
Received 17 May 2023 it is beneficial for hard materials with simple or
Received in revised form 06 June 2023 proficient geometries and shapes. Although EDM
Accepted 09 Sep. 2023
is for machining "difficult to machine" metals,
Final Proofreading 16 Nov. 2023
Available online 13 Dec. 2023 such as those used in the mold and die industries,
metal properties indicate potential capability in
the domain of surface modification due to the
© THIS IS AN OPEN ACCESS ARTICLE UNDER electrical spark between the tool and the work
THE CC BY LICENSE material. This paper investigates the machining
http://creativecommons.org/licenses/by/4.0/ of Alloy steel X210 by using the most affecting
parameters and how electrode angles contribute
to responses, as MRR, Electrode wear ratio, and
Citation: Abbas AM, Khleif AA. surface finish, which the manufacturing industry
uses to make die tools, molds, automotive parts,
EDM Electrode Design and
and other products. Electrodes with angles of 0o
Analysis to Enhance Process and 90o are used to machine workpieces using
Performance. Tikrit Journal of WEDM (dk7740). Electrode Angle, peak
Engineering Sciences 2023; 30(4): 145- discharge current, pulse-on time, and pulse-off
152. time were controllable parameters in this study.
http://doi.org/10.25130/tjes.30.4.15 While all other criteria are constant, variables
have been studied. The effects of the four aspects
on the four variables were statistically analyzed
using ANOVA by MINITAB. Regression models
Ahmed Mohammed Abbas for the responses were developed. Regression
Department of Mechanical Techniques, Hawija mathematical models have been developed for
Institute, Northern Technical University, Alloy steel X210 workpieces to increase
Kirkuk, Iraq. productivity and industry results.

Tikrit Journal of Engineering Sciences Volume 30 No. 4 2023 Page 145

 Ahmed Mohammed Abbas, Ali Abbar Khleif / Tikrit Journal of Engineering Sciences 2023; 30(4): 145-152.

‫تصميم وتحليل أداء األلكترودات في مكائن القطع بالشرارة الكهربائية لتحسين عملية التشغيل‬
2
‫ علي عبار خليف‬،1‫احمد محمد عباس‬
.‫العراق‬/ ‫ الجامعة التقنية الشمالية‬/ ‫ المعهد التقني – الحويجة‬/ ‫ قسم التقنيات الميكانيكية‬1
.‫ العراق‬- ‫ بغداد‬/ ‫ الجامعة التكنولوجية‬/ ‫ قسم هندسة االنتاج والمعادن‬2
‫الخالصة‬
‫) واحدة من أكثر مكائن التشغيل كفاءة في عمليات التصنيع في استخدام الطاقة‬EDM( ‫تعتبر مكائن التشغيل بالشرارة الكهربائية‬
.‫ وبغض النظر عن الخصائص الميكانيكية للمواد‬،‫خصوصا ً تلك الصناعات التي تتطلب الدقة العالية وألي مادة موصلة للكهرباء‬
‫ العدد‬،‫ بما في ذلك صناعة الطيران‬،‫في هذه العملية التي ال تالمس العدة المشغولة فهي منتشرة وتُستخدم في كثير من الصناعات‬
‫ على الرغم من‬.‫ وهي مفيدة بشكل خاص للمواد الصلدة ذات األشكال الهندسية البسيطة أو المعقدة‬،‫ واألدوات الطبية‬،‫والقوالب‬
‫ إال أن خصائص‬.‫ في تشغيل المعادن "التي يصعب تشغيلها" مثل تلك المستخدمة في صناعات القوالب‬EDM ‫استخدام مكائن‬
.‫المعدن تشير الى االمكانية المحتملة في مجال معالجة السطح بسبب الشرارة الكهربائية التي تحدث بين األلكترود ومادة المشغولة‬
‫ باستخدام معظم المتغيرات المؤثرة وكيف يمكن أن تساهم زوايا األلكترود على‬X210 ‫في هذا البحث تم دراسة الصلب السبائكي‬
،‫ والتي تستخدمها المصانع لصنع عدد القوالب‬،‫ والخشونة السطحية‬،‫ نسبة تآكل األلكترود‬،‫ معدل ازالة المعدن‬:‫المخرجات مثل‬
‫ استخدمت مكائن سلك الشرارة‬،‫ في تشغيل العينات‬90º ‫ و‬0º ‫ أُستخدمت األلكترودات بزوايا‬.‫ وغيرها‬،‫وأجزاء السيارات‬
،‫ وتيار تفريغ النبضة‬،‫ التيار‬،‫ زاوية األلكترود‬:‫ متغيرات هذه الدراسة كانت‬.‫ لتصنيع األلكترودات‬WEDM (dk7740)‫الكهربائي‬
‫ أُجريت دراسة على هذه المتغيرات ثم أُجري تحليل تأثيرات‬،‫ في حين أن جميع المتغيرات األخرى ثابتة‬،‫وتيار توقف النبضة‬
‫ تطوير نماذج االنحدار‬.MINITAB ‫ باستخدام برنامج‬ANOVA ‫المتغيرات األربعة على المخرجات إحصائيًا باستخدام مبدأ‬
.‫ لزيادة اإلنتاجية‬X210 ‫ تم تطوير النماذج الرياضية االنحدارية لعينات الصلب السبائكي‬.‫للمخرجات‬

.‫ النمذجة‬،‫ معدل ازالة المعدن‬،‫ الخشونة‬،‫ الشكل الهندسي لأللكترود‬،‫ مكائن التشغيل بالشرارة‬:‫الكلمات الدالة‬
1.INTRODUCTION
Recent advancements in electronic products, granules in the gap are crucial for establishing
such as mobile phones, PDAs, and handheld steady machining conditions by improving
media players, have proven the need for items spark position distribution, and a dielectric that
with intricate and undercut designs. Electro- is too clean can lead to uncontrolled sparking
discharge machining (EDM) is a material [8]. This investigation presents an overview of
removal process that uses electric spark the modern technologies using the EDM
discharges to machine conductive materials [1]. process. Shukry works with electrodes made of
Alloy steel compressor and gas turbine carbon steel CK 60 for the workpiece and brass
fabrication are examples of promising for the tool, and these electrodes can have flat,
applications besides producing tools and molds conical, or spherical geometries. The material
from hard materials, such as high-hardness removal rate was shown to be most affected by
materials. The electrode (tool) and the the duty factor, i.e., the percentage of the ratio
workpiece are submerged in a fluid (dielectric) between pulse duration and total cycle time,
that carries an electrical current. During the and current in experiments. According to the
process, the anode and the cathode are placed results of this research, the electrode form
very close to one another, creating a plasma using a flat tool produced the highest MRR
stream [1, 2]. The process’s essence is compared to other electrode shapes [1].
converting electrical energy in the form of Nadeem et al. modified a standard tool design,
sparks into thermal energy. The electric spark including relief angles in the electrodes. The
occurs when the distance between the tool and workpiece and electrode were made of WC and
the electrode is close enough to create a micro- copper, respectively; when it came to relief, the
conductive ionized channel [3]. Alloy tool steel angled tool electrodes behaved better than their
is used for various purposes, from cutting tools cylindrical counterparts. The machining time
and hammers to stamping and metalworking has been cut by 49% due to the relief-angled
molds and machine parts. The enormous electrodes [4]. Electric machining of tool steel
demand for tools, tooling, dies, and molds is by Hanan et al. analyzed the effect of the tip
due to the extensive use of these items in angle and tip radius of a copper electrode tool
production. How likely a discharge is (AISI D2). Compared to other electrodes, it was
determined by how easily electricity can be discovered that the conical electrode with a
broken down within the spark gap [4, 5]. Any radius of 1 mm delivered the highest MRR,
point between the two electrodes will while the conical electrode with a radius of 0
experience a more severe electrical breakdown mm offered the lowest EWR [9]. Uhlmann et al.
if debris is present. This debris can cause explored how changing the electrodes' exterior
unstable electrical conditions; thus, flushing is shape on cylindrical tools could improve the
performed under standard machining settings efficiency of electric discharge drilling. Brass
to remove it from the cutting gap [6, 7]. Debris electrodes with helical flutes along the shank

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were compared to the standard form of a tool with a stepped cylindrical shape consisting
cylindrical rod electrode to determine which is of a (body), "shank," and "neck," and a
more effective at clearing out waste. The workpiece of AISI P20 (Step-cylinder). The
drilling EDM method might be improved by percentage of wear was lower, and the MRR was
setting a minimum flute depth and angle[6, 10]. higher than conventional electrode
By employing the EDM method of cutting high- instruments. Electrodes with a higher surface
speed steel, Asaad and Maan investigated the roughness than the normal shape [16].
impact of various parameters on the material According to Naveed et al., a Taguchi L9 array
removal and wear rates with five forms of was used for multiple positive-voltage
electrode tool (triangle, square, circular, electrodes, i.e., graphite, aluminum, copper,
cylindrical solid, and polygon). The results and brass. Also, a Taguchi L9 array was utilized
indicated that the rectangular geometry of the for many negative-voltage electrodes.
electrode holes was the most effective electrode Consequently, 72 separate trials were
shape. With the same form, the best electrode conducted. To obtain the lowest possible levels
wear ratio was added. The electrode with the of tool wear and overcut (OC) around the
square hole had the highest MRR [11]. Micro machined surfaces, it is necessary to study the
precision in mold manufacture was nature of these responses. A tool with common
investigated by Pellicer et al., who examined the tool polarity was selected as optimal to achieve
impact of different EDM machining parameters the assessment approach of least tool wear and
and tool steel electrode shapes. Various minimal level OC [17]. The height of re-sticky
electrode geometries, i.e., flat, depth, slope, and particles decreased with increasing lift
width, and AISI H13 workpieces were studied. distance, as previously observed by Shih-Hsien
Regular polygons like rectangles and squares and Wang and throughout the current
best illustrated high precision in groove investigation. However, the finished product
processing due to their high EWR and stable exhibited a slight degree of material re-
machining. Due to rapid wear along the stickiness. However, almost 90 μm of height
electrode's triangular edges, this tool is was generated. Further, after a piece of the
ineffective [12]. Pani and Masanta investigated electrode was cut from the base of the trash re-
a copper-based hexagonal electrode tool sticky to the cylinder rod along its longitudinal
through a series of tests. A plate made from Al axis, the machined surface would gradually
alloy (A6063) was used in the production diminish. When the width of a specialized
process. This study's findings were used to electrode was 0.6D, re-sticky debris was also
refine the regression method, and RSM was minimized. The issue completely vanished [18].
employed to highlight the connection between Kliuev investigated a method to capture high-
stimulus and effect. A giant crater was created, speed, microscopic images of an EDM drill bit
and the rate at which material was removed, as in action. The average workpiece speed in the
the high current and spark output, was electrode's outflow area was 0.9 m/s, while the
increased. No interaction between the duty electrode was nearing the condition. In the
factor and pulse-on-time affects the removal second scenario, the electrode was situated
rate [13]. Tool steel P20 was the workpiece for inside the eroded cavity, and the average gap
Shailesh Kumar's presentation of a hollow U- velocity was 0.75 m/s [19].
shaped copper electrode tool with an internal 2.EXPERIMENTAL WORK
flushing mechanism; this steel is crucial in the This experimental investigation determines the
fabrication of mold steel. Taguchi analysis was effects of varying the electrode angle, current,
used to determine the optimal values for three pulse-on, and pulse-off times for an Electric
machining parameters, i.e., pulse on time, tool Discharge Machine while machining an Alloy
diameter, and discharging current. This study steel X210 workpiece (see Fig. 1). A detailed
demonstrated that current significantly research technique is offered, including
affected MRR, increasing MRR with current. guidelines for conducting experiments,
Tool wear can also be affected by the presence analyzing data, and drawing conclusions. As a
of current. The current discharge has a far more result of its high efficiency, copper was selected
significant effect on overcut than the pulse on as the electrode material for this experiment
time [14]. Kamlesh and Patel utilized an (see Fig. 2). (CM 323C+50N) EDM machine
ANOVA analysis with a few factors. Four copper was used in this study. Chemical composition
electrode tool shapes were employed with steel was analyzed by an ARL spectrometer in North
(AISI) H13 utilized primarily in tooling dies: Gas Company (NGC)-Kirkuk/Iraq. The X210
rectangular, square, triangle, and round. Alloy tool steel employed in the present
Electrode shape was an essential aspect investigation is the subject of the possible
affecting performance evaluations. Electrode process parameters for the objective response
shape contributed between ten and twenty parameters. The chemical elements of Tool
percent to analyses of variance and signal-to- steel X210 alloy are provided in Table 1.
noise ratios [15]. For drilling large holes, Electrodes with 0° and 90° angles have been
Jamkamon and Janmanee relied on a copper produced.

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Table 1 Chemical Composition (%) of 4.EXPERIMENTAL DESIGN

Workpiece Alloy Steel X210. Many aspects of the EDM process are under
Material % Weight control; however, to keep the scope of this study
C 1.9 manageable, only a small subset of these
Cr 11.71 aspects was changed. Table 2 displays these
Mn 0.49 adjustable parameters and their respective set
Cu 0.36
Zn 0.15
points. The copper was chosen in the electrodes
Mo 0.24 for its high efficiency and high quality. The
Sn 2.22 main characteristic of copper electrodes is their
Fe 81.82 Electrolytic nature.
Table 2 Process Parameters.
Levels
Parameter Unit
Min Max
Electrode Angle Degree 0º 90º
Current Ampere 15 35
Pulse-on time Micro Second 60 300
Pulse-off time Micro Second 20 140

5.RESPONSE-BASED VARIABLE
Material Removal Rate quantifies the efficacy of
any machining technique, including electrical
discharge machining (EDM). The EDMs’ ability
to calculate a volume cut-to-machining-time
ratio allowed for accurate estimation of
material removal. Therefore, mathematically
[21].
𝑊 −𝑊
𝑀𝑅𝑅 = 𝑖 𝑓 (1)
Fig. 1 Machined Workpiece by EDM Process. 𝑡 .ρ
where 𝑊𝑖 = initial weight before machining
(gm), 𝑊𝑓 = final weight after machining (gm), t
= machining time (min), and ρ= density of
workpiece (gm/mm3).
As in the MRR procedure, the workpiece
replaced an electrode. The equation for
Electrode wear ratio (EWR) is stated according
to [21]:
W𝑖𝑒 −W𝑓𝑒
𝐸𝑊𝑅 = (2)
𝜌𝑒 𝑡
where W𝑖𝑒 = initial weight of electrode before
machining (gm)
W𝑓𝑒 = final weight of electrode after machining
(gm), t = machining time, and ρe = electrode
Fig. 2 Copper Electrode with a Transverse
density (gm/mm3).
Hole.
The essential parameter Ra was used to
3.ANGLED ELECTRODE quantify the roughness of a surface; it is
A copper electrode was selected as the material obtained from the ratio of the highest and
electrode, and the process parameters that lowest points on a surface, which is then
might yield the desired value of response averaged over a given length [22]. In this study,
variables were identified. Two electrodes, one Ra was measured using a Pocket Surf III/ PMD
at an angle of 0° and the other at an angle of 90101 from the (Mahr Federal) company in the
90°, were designed, and a transverse hole was USA, with an accuracy of 0.05. All the acquired
drilled into them. Throughout this work, Fig. 3 variables for each controlled parameter set are
displays a comparison between the listed in Table 3. Minitab's analysis of variance
conventional and the novel electrodes [20]. (ANOVA) is a standard tool for examining
potential differences in the response
parameters' standard deviations. The central
hypothesis of ANOVA argues that any changes
made to the controllable variables or
interactions would result in similar changes to
the parameters measuring the mean response
[23]. The results showed that the parameters'
and interactions' impact on the variables was
Fig. 3 Angled Electrodes. negligible. The hypothesis suggested a

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significant discrepancy between the means of

the response parameters. Due to the variety of
available methods, it is essential to consider
how various input parameters and their
interactions affect the independent variables
[24]. The estimated response and its
influencing data, variables, and parameters
were entered into the statistical analysis
Minitab program. The software then developed
a design of experiment (DOE) formula, which
was used to examine and evaluate the results.
Table 3 Measurable Parameters of the Mean
Response. Fig. 5 Interaction Effect Plots of Mean MRR.
Run EA Current Pon Poff MRR EWR SR
6.MATERIAL REMOVAL RATE
1 90 35 300 20 0.220 0.019 4.454
Increasing the pulse on time and peak current
2 90 35 60 140 0.542 0.089 4.265 increased MRR, as seen in Fig. 4. Conversely,
3 90 15 300 20 1.111 0.007 3.168 decreasing the pulse of time and using an
4 0 15 60 140 1.168 0.224 3.981 angled electrode (90°) decreased MRR. Unlike
the standard vertical hole, which left a mark on
5 0 35 300 140 1.896 0.033 5.667
the workpiece, the transverse hole electrode left
6 0 35 60 20 2.418 0.536 3.679
no trace due to increased discharge energy and
7 0 35 20 20 3.792 0.045 6.081 enhancements in pulse on and peak current,
8 0 15 20 20 1.046 0.022 3.856 resulting in a faster MRR for (0°). Reduced
9 90 15 20 20 0.833 0.039 4.058
MRR results from fewer discharges occurring in
a particular period due to more extended
10 90 35 140 140 0.560 0.134 3.088
periods of inactivity between pulses. Table 4
11 0 15 140 140 0.729 0.005 5.459 displays the results of an analysis of variance
12 90 15 140 140 0.433 0.102 4.941 performed on the MRR by changing the
EA (Electrode Angle). Pon (Pulse-on time). Poff (Pulse-off time). observable parameters. Meanwhile, the
Table 4 ANOVA for Material Removal Rate. changing effect of these characteristics and
their interactions on the mean MRR is shown in
Parameter DOF Adj. SS Adj. MS F-Value P-Value
Figs. 4 and 5. The MRR was significantly
Electrode 1 0.1985 0.1985 1.37 0.032
Angle impacted by electrode angle and current, as
(degree) shown in Table 4 (also see Fig. 4) (P-value less
Current (C) 1 12.2061 12.2061 84.21 0.000 than 0.05) [26]. Fig. 5 demonstrates that
Pulse-on 1 0.2728 0.2728 1.88 0.0212 interactions between the current and the
Time (P-on) electrodes at an angle of 90 degrees also
Pulse-off 1 0.3669 0.3669 2.53 0.156
Time (P-off) affected the MRR. Along the length of the cut at
Error 7 1.0146 0.1449 an electrode angle of 0 degrees, the MRR varied
Lack-of-Fit 6 1.0077 0.1679 24.27 0.154 from minimum to maximum (see Fig. 4),
Pure Error 1 0.0069 0.0069
leading to a mean MRR that was greater than
the mean MRR at an electrode angle of 90
Total 11 14.0590
degrees. As shown in Fig. 5 and Table 4, MRR
increased significantly as the electrode angle
and current simultaneously altered,
particularly for the 90° electrode angle. As seen
in Fig. 5, increasing the current reduced the
MRR considerably, whereas increasing the
pulse-off duration had the opposite effect. The
mean MRR was the smallest at a 90° electrode
angle.
Table 5 ANOVA for Electrode Wear Rate.
P-
Parameter DOF Adj. SS Adj. MS F-Value
Value
Electrode 1 0.005916 0.005916 1.57 0.020
Angle
(degree)
Current (C) 1 0.024091 0.024091 6.40 0.039
0, 90: EA (degree) Pulse-on 1 0.006403 0.006403 1.70 0.023
15, 35: Current (A) Time (P-on)
60,300: Pon (µs) Pulse-off 1 0.002534 0.002534 0.67 0.043
20,140: Poff (µs) Time (P-off)
Error 7 0.026358 0.003765
Fig. 4 Main Effect Plots of Mean MRR [25]. Lack-of-Fit 6 0.024226 0.004038 1.89 0.505
Pure Error 1 0.002132 0.002132
Total 11 0.065303

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Table 6 ANOVA Surface Roughness.

Parameter DOF Adj. SS Adj. MS F-Value P-Value

Electrode 1 0.0238 0.02376 0.08 0.078

Angle
(degree)
Current (C) 1 7.4387 7.43873 26.28 0.001
Pulse-on 1 3.1951 3.19507 7.19 0.012
Time (P-on)
Pulse-off 1 0.0990 0.09901 0.68 0.573
Time (P-off)
Error 7 1.9816 0.28308
Lack-of-Fit 6 0.7271 0.12118 0.75 0.982
Pure Error 1 1.2545 1.25453
Total 11 12.7382

0, 90: EA (degree)
15, 35: Current (A)
60,300: Pon (µs)
20,140: Poff (µs)

Fig.6 Main Effect Plots of Mean EWR.

0, 90: EA (degree)
15, 35: Current (A)
60,300: Pon (µs)
20,140: Poff (µs)

Fig. 8 Main Effect Plots of Mean SR.

Fig.7 Interaction Effect Plots of Mean EWR.
7.ELECTRODE WEAR RATE
The results of the ANOVA performed on the
electrode wear ratio acquired during the EDM
process in the Alloy tool steel X210 workpiece
are shown in Table 5. Compared to the other
variables, the F-value of 6.40 demonstrates that
the current influence was the most important.
As a result, it had a far more significant impact
than the other variables. Fig. 7 demonstrates
that when electrode angles increased, EWR
decreased because more surface area was
exposed to erosion. Because the sparks were Fig. 9 Interaction Effect Plots of Mean SR.
spread out across a wider region, the electrodes
The results of an ANOVA performed on the
wear out faster. The EWR rose due to the
surface roughness achieved by the EDM
increased erosion rate within the exposed area
process in the Alloy steel X210 workpiece are
brought on by the more significant current.
displayed in Table 6. Current and pulse on both
8.SURFACE ROUGHNESS had P-values smaller than 0.05, indicating that
With a rise in current, the surface roughness of their influence was likely more noticeable than
Alloy steel X210(F value 26.28) also increased, chance suggests. Fig. 8 shows that the
as shown in Table 6. An increased EDM current roughness of a surface was most affected by the
was detrimental to the surface finish. When the current. Compared to the F-value of 7.19 for the
electrode was at a zero-degree angle to the pulse-on, which indicated a less significant
surface of the workpiece, the mean surface influence, the F-value of 26.28 for the current
roughness was most significant. As a result, the indicated a more significant influence. A
surface roughness of the Alloy tool steel X210 correlation exists between the current used in
increased due to its non-uniform melting. the EDM process and the surface roughness
Electrode angle, current, and pulse-on alone produced (F-value 26.28), supporting the
considerably impacted surface roughness; ANOVA for SR (Table 6). The electrode at 0
however, when combined, they had an even degrees had the most significant effect on the
more significant impact. The surface finish workpiece's mean surface roughness.
deteriorated as the pulse off was turned.

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9.CONCLUSIONS [3] Khleif AA, Sabbar OS. Electrode Wear

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