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I. Read the text and give the answers to the questions.

1. When did English scientist Priestley first detect the erosive effect of electrical discharges on metals?

2. What did the Soviet scientists develop concerning this problem?

3. What process can we compare the EDM process with?

4. The Soviet scientists announced the construction of the first spark erosion machine in 1970,

didn’t they?

5. What spheres was the EDM process used in and why?

6. The conventional cutting process can be easily applied to electrical conductive materials, can’t it?

7. What makes the EDM process more versatile?

8. Is it true that, the process can be easily automated?

9. What other advantages of the EDM process can you enumerate?

Electric discharge machining

In 1970, the English scientist, Priestley first detected the erosive effect of electrical discharges on metals. More recently, during the research (to eliminate erosive effects on electrical contacts) the Soviet scientists Lazarenko ( father and son) decided to exploit the destructive effect of an electrical discharge and develop a controlled method of metal machining. In 1943, they announced the construction of the first spark erosion machine. The spark generator used in 1943, known as the Lazarenko circuit, has been employed over many years in power supplies for EDM machines and an improved form is being used in many current applications. The EDM process can be compared with the conventional cutting process, except that in this case, a suitably shaped tool electrode with a precision controlled movement is employed in place of cutting tool, and the cutting energy is provided by means of short duration electrical impulses. EDM has found ready application in the machining of hard metals or alloys which cannot be machined easily by conventional methods. It thus plays great role in the machining of dies, tools etc. made of tungsten carbides, satellites or hard steel. Alloys used in the aeronautics industry, for example, hastelloy etc. could also be machined conventionally by this process. This process has the added advantage of being capable of machining complicated components. The popularity of the EDM process is due to the following advantages:

The process can be easily applied to electrical conductive materials. Physical and metallurgical properties of the work material, such as strength, toughness, microstructure etc., are no barrier to its application.

During the machining the workpiece is not subjected to mechanical deformation as there is no physical contact between the tool and the work. This makes the process more versatile. As a result, slender and fragile jobs can be machined conventionally.

Although the metal removal in this case is due to thermal effects, there is no heating in the bulk of the material.

Complicated die counters in hard materials can be produced to a high degree of accuracy and surface finish.

The overall production compares well with the conventional processes because it can dispense with operations like grinding etc.

The surface produced by EDM consists of multitude of small craters. This may help in oil retention and better lubrication, especially for components where lubrication is a problem. The random distribution of the craters does not result in an appreciable reduction in fatigue strength of the components machined by EDM.

The process can be automated easily requiring very little attention from the machine operator.