Electronica Machine Tools Ltd.

EDM Division

Application hints
Selecting Electrode Materials
Important EDM Machining
Parameters and their Explanations.
Typical Applications and Commonly
Faced Problems
Case Studies

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Page 1

Electronica Machine Tools Ltd.

EDM Division

Selecting Electrode Materials

The mechanical properties of the electrode have negligible effect on machining
performance. However, the thermo physical properties of the electrode like thermal and
electrical conductivity, thermal expansion, and heat to vaporize from room temperate,
melting and boiling temperatures have considerable influence on the EDM process
performance in terms of material removal rate, electrode wear and surface integrity of
the workpiece.
There is a wide range of materials used to manufacture electrodes, for instance,
brass, tungsten carbides, copper, copper-tungsten , copper- graphite , graphite etc.
In respect to the application, performance of copper and graphite is summarized
below.
COPPER:
This electrode material is widely used when smooth workpiece surface finishes are
required. This material can be machined by all conventional methods such as drilling,
turning, milling, grinding etc. But machining can be sometimes difficult because
copper has a trend to drag on the edge of the cutting tool and the grinding wheel.
However, copper machines on Wire EDM better than graphite. Very complex shapes
can be obtained by Wire EDM onto copper electrodes. Another advantage of copper
in comparison to graphite is its ability to be coined and then to be a very good
material for engraving electrodes. For certain applications, such as electrodes to be
used in medicine engineering field, copper is the best choice because of its facility to
be highly polished.
GRAPHITE:
This material is available in many different grades from large grain sizes (20 m),
used in rough EDM operations, to very fine grains (1 m) for finish EDM operations,
particularly in steel. The costs of graphite vary from inexpensive, for coarse-grain
sizes, to very expensive for fine-grain sizes. Graphite provides a high material
removal rate and low electrode wear - depending on the EDM parameter settings - as
compared to copper. Graphite has a much lower density than copper, which makes it
the best material for large electrodes. Although graphite is very abrasive it is
relatively easy to be machined by all the conventional machining processes like
milling, drilling, turning and grinding. The major drawback of graphite is the fine dust
it produces during its machining. It is able to settle on the guides of the machine tool
and when mixed with the machine's cutting fluid it will act like a lapping compound,
which eventually reduces the accuracy of the machine. This EDM dust can also settle
on electrical parts of the machine causing local short circuits and can impose
breakdowns. Glass scales can give false measurements due to the settling of dust.
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Electronica Machine Tools Ltd.

EDM Division

Precautions must be taken when machining graphite. Most EDM jobs that can be
done with copper can also be executed with graphite. The end result might be the
same, but the cost to accomplish the job can be vastly different. In practical terms
selection of the electrode material will depend mainly on the electrode size, type of
EDM machine, methods of making the electrodes and most importantly the cost.

Important EDM Machining Parameters and their

Explanations.
Standard workpiece and electrode materials are used traditionally by machine
manufacturers to establish the EDM parameter settings. However, this is not the
usual situation of the tooling industry, where many different grades of workpiece and
tool electrode materials are used. Consequently, the customers are required to
develop their own process parameters, which normally demand many experimental
tests.
In order to enable the user carry out such experiments and develop the proper
settings it is required that the user knows the significance of each and every EDM
parameter used.

IP Sparking current
It is the power used for cutting material, more power more cutting rate but

there is a limitation. For faster cutting speed higher values of Ip are recommended,
but with higher values you get rough surface finish and also larger spark gap. To
achieve good quality finish lower values of Ip are recommended.
Recommended Ip range for different material combination are as
follows

Ton Pulse on time

It is pulse sparking time in EDM operation. The current Ip flows during this time.

More the value of Ton less is the wear of electrode, but there is a limitation when

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Electronica Machine Tools Ltd.

EDM Division

sparking different materials. For carbide machining higher values of Ton can result
into micro cracking. Also to reduce wear in Rib or thin and sharp profile job you can
use SAFE mode. This mode is not recommended in finishing. For machining using
graphite electrodes and also for carbide machining SAFE mode is not recommended.

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Electronica Machine Tools Ltd.

EDM Division

Recommended Ton range for different material combination are as follows

Material
Roughing

combination
Copper to Steel
Graphite to steel
Copper to carbide

Ton Range
Semi

Finish

200 to

finish
75 to 150

5 to 20

400
150 to 300
50 to 75

50 to 100
10 to 30

5 to 20
2 to 5

Tau Factor related to Pulse off time

After every pulse on time there is a pulse off time. Current Ip does not flow during
this time. A off time period helps the gap to recover in between 2 on times. More the
value of tau less is the pulse off time.
Lower values of Tau can result in better efficiency at the cost of higher electrode
wear.
Recommended Tau range for different material combination are as follows
Material
combination
Copper to Steel
Graphite to steel
Copper to carbide

Roughing

Tau Range
Semi

Finish

finish
7 to 8
6 to 7
4 to 5

9 to 10
8 to 10
6 to 7

6 to 7
5 to 6
3 to 4

Vg Sparking voltage

Sparking voltage or gap voltage is the voltage between electrode and the work
piece during sparking. It also represents the physical gap between the electrode and
the workpiece. More the value of Vg more is the gap between electrode and work
piece. Bigger gap helps clearing the debris during finishing operation.
Recommended Vg range for different material combination are as follows
Material
combination
Copper to Steel
Graphite to steel
Copper to carbide

Roughing

Vg Range
Semi finish

Finish

60 to 65
60 to 65
40 to 50

70 to 75
70 to 75
50 to 60

80 to 90
80 to 90
50 to 60

SEN Sensitivity

It is the speed of Z axis during sparking. More the value more is the speed.
Maximum speed at value 10 in open gap condition is around 80 mm/min. During
cutting process the SEN parameter decides the stability of operation.

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Electronica Machine Tools Ltd.

EDM Division

Recommended SEN range for different material combination are as follows

Material
combination
Copper to Steel
Graphite to steel
Copper to carbide

Roughing
7 to 8
7 to 8
7 to 8

SEN Range
Semi
finish
6 to 7
6 to 7
6 to 7

Finish
5 to 6
5 to 6
5 to 6

ASEN Anti arc Sensitivity

This parameter decides sensitivity of antiarcing circuitry. This sensitivity

decreases with the value of ASEN and the antiarc action gets bypassed at
ASEN=1.
Recommended ASEN range for different material combination are as follows
Material
combination
Copper to Steel
Graphite to steel
Copper to carbide

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Roughing
2 to 3
2 to 3
2 to 3

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ASEN Range
Semi
finish
3 to 4
3 to 4
2 to 3

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Finish
3 to 4
3 to 4
2 to 3

Electronica Machine Tools Ltd.

EDM Division

Typical Applications and Commonly faced Problems

Rib machining.
If length to width ratio exceeds 25 then that cross section falls under rib category.
e.g. 25 X 1mm, 50 X 2mm, 75 X 3mm, 100 X 4mm etc.
Copper electrode
Recommended to use oxygen free copper for best
results. Inferior grade of copper can result in more
electrode wear. Generally copper electrodes are used
for sections which are more than 2mm thick. For thin
sections copper electrodes can warp due to heat. Also electrodes wear can be
more as the current density is more. In such cases use of SAFE mode is
recommended to give ultra low electrode wear.
Word of caution Switch off SAFE mode in finishing.
Graphite electrode
Recommended to use fine grain structure graphite (1 to
4 Microns).Coarse grain graphite may disintegrate into
the cavity causing contamination of gap resulting into
instability. For sections which are less than 2 mm thick
graphite electrodes are preferred over copper as
graphite has good thermal stability as compared to
copper. Hence warpage of electrodes due to heat during
sparking is avoided.
Word of caution Switch off SAFE mode during use of graphite
electrodes.

General guidelines for rib machining

1. Use Jump function with lower working time (TW=0.4 to 0.6) and depth
proportionate RD values to avoid arcing problems.
2. To avoid arcing lower values of Tau than the standard recommended are to be
used.
3. Continuous supply of clean dielectric should be ensured for arc free rib
machining.
4. Side jet flushing should be along the length of the rib and not across.
5. Excessively high flushing pressure can cause deviation of very thin
electrodes. Minimum required flushing is advised.

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Electronica Machine Tools Ltd.

EDM Division

Fine Finishing.
Large Area
Contact area more than 5000 Sq.mm is
considered as large area in EDM process.
Copper electrode
Recommended to use oxygen free copper
as it wears out less.
Graphite electrode
Recommended to use 1 micron grain structure graphite for fine finish.

General guidelines for large area finishing.

1. In EDM achieving fine finish on large area has a limitation as compared to
smaller area. This is because the capacitance value of the gap increases with
the electrode area, which in turn increases the power of spark resulting in
rough surface finish
2. Current density should be maintained as per the guidelines given above.
3. The settings used for roughing operation depend on the number of electrodes
planned to be used.
If the cavity is to be finished using single
electrode then the roughing settings should
be necessarily of low wear type. For multiple
electrodes efficient settings for roughing can
be used.
4. Matching of finishing electrode in roughed
cavity becomes very critical in order to
achieve uniform fine finish. Quick fixing
precise tooling systems for electrode holding
are recommended in such cases.
5. For large area it is very important that enough amount of flushing should be
provided all over the contact area.
6. Frequent cleaning of cavity in final stages of finishing takes away the
accumulated carbon film from the cavity. This can make the process unstable
after resumption and prone to arcing or uneven finishing.
7. For large areas, a pulling force is exerted on the electrodes due to vacuum
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Electronica Machine Tools Ltd.

EDM Division

created in the gap. As the spark gap decreases with EDM parameter settings,
this pulling force increases. Hence if high speed jump is used there are
chances of electrode getting shifted. To avoid this phenomenon it is strongly
recommended to use soft jump function along with high speed jump.

Small Area
Contact area less than 100 Sq.mm is considered as
small area in EDM process.
Copper electrode
Recommended to use oxygen free copper for best
results.
Graphite electrode
Recommended to use 1 micron grain structure
graphite for fine finish.
General guidelines for small area finishing.
1. Most important prerequisite to achieve fine
finish is to have electrode surface finish better
than the required finish in the workpiece.
2. Thin carbon layer formed during finishing in the
cavity helps to dissipate energy and thus
achieve uniform fine finish in comparatively
less time. Hence feeble flushing or no flushing
is recommended during erosion.
3. For engraved electrodes having intricate details
like coining dies it is recommended use high
speed jump with very small working time (TW)
and practically no side jet flushing.
4. Use of reverse polarity (electrode negative) in
last finishing setting gives mirror finish to the
job, the quality of mirror finish depends upon
workpiece material, grade and its hardness.
Special materials like Stavax, NAK 80 etc. are some of the popularly used tools
steels from different manufactures due their high polishability.

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EDM Division

Carbide machining.
Tungsten carbide has two different grades
one is relatively softer and the other one is
hard. Best material to machine carbide on
EDM is copper tungsten. Copper graphite
can also be used which has comparatively
higher wear resistant properties.
General guidelines for carbide machining.
1. Use lower on and off times. That means carbide
machining needs high frequency.
2. Electrode wear is nearly 30 to 50%.
3. Carbide machining is very slow as compared to
steel machining.
4. Use of through job flushing (most of the carbide
dies have hole in the centre) can eliminate the need of jumping operation.
This makes the machining process much faster.
5. Positive polarity may work for softer grades but for harder grades of carbide
negative polarity is mandatory.

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Electronica Machine Tools Ltd.

EDM Division

Forging
In general as a concept, forging dies are
considered to be low accuracy requirement dies.
Erosion of forging dies asks for more material
removal rate than any other result like surface
finish or electrode wear. The electrode sizes in
forging applications are bigger as compared to other applications like plastic
moulding. Generally graphite electrodes are preferred because of their lower
density.
General guidelines for forging dies.
1. Since the surface finish requirement is not so important, even coarse grain
structured graphite can also be used for this application. In such case the
flushing becomes very important as the coarse grain structured graphite
disintegrates and this graphite dust interferes with the sparking process
causing instability.
2. It is advised to have holes in the electrode for flushing. Through electrode
flushing can accelerate the EDM process and save time. Also arcing tendency
is reduced substantially due to more efficient flushing.
3. Use of reverse polarity (electrode negative) increases the material removal
tremendously.
4. Copper electrodes can also be used in case the electrode size is not very big.

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EDM Division

Case Studies
Description:
Sparking Pre machined mobile case die.
Work-piece:
Material

: Stavax

Hardened

: Yes

Pre machining

: Yes

Electrode:
Material

: Oxygen free copper

Roughing settings :
Ton
Tau
Ip
IB
Vg
SEN
Asen
AF/ JUMP
Tw
RD
POL

100
10
6
Auto
60
6
3
06
0.6
3.0
Normal

75
8
3.0
Auto
60
6
3
06
0.6
3.0
Normal

50
8
3
Auto
60
6
3
06
0.6
3.0
Normal

20
8
2
Auto
60
6
3
06
0.6
3.0
Normal

10
8
2
Auto
60
6
3
06
0.4
3.0
Normal

Finishing Settings:
Ton
Tau
Ip
IB
Vg
SEN
Asen
AF/ JUMP
Tw
RD
Polarity

Page 12

20
8
0.5
Auto
90
6
3
06
0.6
3
Normal

20
8
0.5
Auto
100
6
3
06
0.6
3
Normal

20
7
0.5
Auto
125
6
3
04
0.6
3
Normal

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10
7
0.5
Auto
150
6
3
04
0.4
4
Normal

5
7
0.5
Auto
150
6
3
04
0.4
4
Rev

277937961.doc

4
6
0
Auto
150
6
3
04
0.4
4
Rev

2
6
0
Auto
150
6
3
04
0.4
4
Rev

Electronica Machine Tools Ltd.

EDM Division

Description:
Erosion bunch of 7 copper electrodes in
steel and Nickel alloy.
Work piece:
Material

: Steel

Electrode:
Material

Ton
Tau
Ip
Sv
Ig
Vg
SEN
Asen
JUMP
Tw
RD
Flushing Type
SAFE

: Electrolytic copper

75
10
20
60
7
60
6
3
06
1.0
2.0
Side flushing
On

Work piece:
Material

: Nickel alloy

Electrode:
Material
Ton
Tau
Ip
Sv
Ig
Vg
SF
Asen
JUMP
Tw
RD
Flushing Type
SAFE

: Electrolytic copper
20
10
10
65
5
60
7
2
06
1.0
2.0
Side flushing
Off

Description :

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EDM Division

Erosion of a cavity using single copper electrode of 53 mm X 70 mm to get good

surface finish.
Work-piece:
Material

: Stavax

Hardened

: Yes

Pre machining

: No

Electrode:
Material

: Oxygen free copper

Settings used:
Ton
t
Ip
Ib
Vg
Sen
Asen
Jump
Tw
Rd
Depth
Polarity

Page 14

50
8
0
5
75
6
3
06
0.6
5.0
-0.075
Normal

20
8
0
5
80
6
3
06
0.6
5.0
-0.100
Normal

10
8
0
3
100
6
3
06
0.6
5.0
-0.125
Normal

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5
8
0
1
125
6
3
06
0.6
5.0
-0.150
Normal

5
8
0
0
150
6
3
06
0.4
5.0
-0.180
Normal

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4
8
0
0
175
6
3
06
0.4
5.0
-0.190
Normal

2
8
0
0
175
6
3
06
0.4
5.0
-0.200
Normal

Electronica Machine Tools Ltd.

EDM Division

Description:
Erosion of fastener dies in carbide and steel.
Work piece:
Material

: Carbide.

Electrode:
Material

: Copper tungsten

FINISHING
15
Ton (sec)
Tau
8
Ip
3
Vg
60
SF
7
Asen
3
Jump
00
Tw
00
Rd
00
Flushing
Through
Type
flushing
FINISHING
SAFE
OFF
50
Ton (sec)
Tau
10
Ip
2
Vg
75
Sen
6
Asen
4
Jump
00
Tw
00
Rd
00
Flushing
Through
Type
flushing
SAFE
ON

ROUGHING
50
Ton (sec)
Tau
8
Ip
6
Vg
60
SF
7
Asen
2
Jump
00
Tw
00
Rd
00
Flushing
Through
type
flushing
ROUGHING
SAFE
OFF
150
Ton (sec)
Tau
10
Ip
4
Vg
60
Sen
7
Asen
3
Jump
00
Tw
00
Rd
00
Flushing
Through
Type
flushing
SAFE
ON

copper

Roughing
Finishing
200
50
Ton (sec)
Ton (sec)
Tau
10
Tau
10
Ip
20
Ip
6
Vg
60
Vg
70
Sen
6
Sen
6
Asen
4
Asen
4
Jump
06
Jump
06
Tw
1.0
Tw
1.0
Rd
3
Rd
3
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Flushing
Side jet
Flushing
Side jet
Type
flushing
Type
flushing
SAFE
OFF
SAFE
OFF

Work piece:
Material

: Hardened

Steel (SKD 11)

Electrode:
Material

: Copper

tungsten

Description:
Sinking of aluminium die
casting cavity of automobile
component
Work piece:
Material

: Tool Steel

Electrode:
Material

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: Electrolytic

Electronica Machine Tools Ltd.

EDM Division

Description:
Erosion of wrist watch cavity
Work piece:
Material

: Tool steel

Electrode:
Material

: Oxygen free copper

Settings used for roughing:

Ton (sec)
tau
Ip (Amps)
Vg
Sen
Asen
Jump
Tw
Rd
Flushing
Type

200
10
10
50
8
2
00
NA
NA
Through
work piece

150
10
8
50
8
2
00
NA
NA
Through
work piece

100
10
6
50
8
2
00
NA
NA
Through
work piece

50
10
3
60
8
2
00
NA
NA
Through
work piece

20
8
2
65
8
2
00
NA
NA
Through
work piece

Polarity

Normal

Normal

Normal

Normal

Normal

10
8
1
75
7
2
00
NA
NA
Through
work piece
Normal

5
8
0.5
85
6
2
00
NA
NA
Through
work piece
Normal

Settings used for finishing:

Ton (sec)
tau
Ip (Amps)
Vg
Sen
Asen
Jump
Tw
Rd
Flushing
Type
Polarity

Page 16

50
10
3
60
7
2
00
NA
NA
Through
work piece
Normal

20
10
2
65
7
2
00
NA
NA
Through
work piece
Normal

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Electronica Machine Tools Ltd.

EDM Division

Description:
Template mould cavity
Work piece:
Material

: Tool steel

Electrode:
Material

: Oxygen free copper

Settings used :
Parameter Roughing
s
Ton
150
Tau
10
Ip
8
Vg
50
Sen
6
Asen
4
Jump
06
Tw
0.8
Rd
2.0
Flushing Type
Side
flushing
Polarity
Normal

277937961.doc

Semi
finish
50
10
3
75
6
4
06
0.8
2.0
Side
flushing
Normal

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Finish
20
8
2
80
6
4
06
06
3.0
Side
flushing
Normal

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Electronica Machine Tools Ltd.

EDM Division

Description:
Center support 4 cavities
Work piece:
Material

: Hardened Steel

Electrode:
Material

: Oxygen free copper

Settings used:
Parameters
Ton
Tau
Ip
Vg
Sen
Asen
Jump
Tw
Rd
Flushing Type
Polarity

Page 18

Roughing
20
10
2
75
6
4
06
0.8
2.0
Side
flushing
Normal

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Semi finish
20
8
1
85
6
4
06
0.8
2.0
Side
flushing
Normal

Finish
10
6
1
90
6
4
06
0.8
2.0
Side
flushing
Normal

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Electronica Machine Tools Ltd.

EDM Division

Description:
Finishing in carbide
Work piece:
Material

: Carbide

Electrode:
Material

: Oxygen free copper

Parameters
Ton (sec)
tau
Ip (Amps)
Vg
Sen
Asen
Jump
Tw
Rd
Flushing
Type
Polarity

277937961.doc

Rough
50
6
5
50
7
3
06
0.4
2.0
Side jet

Semi finish
20
6
2
50
7
3
06
0.4
2.0
Side jet

5
4
0.5
60
7
3
06
0.6
2.5
Side jet

Finish
2
4
0
80
7
3
06
0.6
2.5
Side jet

2
4
0
90
7
3
06
0.8
2.5
Side jet

Rev

Rev

Rev

Rev

Rev

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