Proceedings of 2012 IEEE
International Conference on Mechatronics and Automation
August 5 - 8, Chengdu, China
A Review of the Current Understanding and Technology
of Powder Mixed Electrical Discharge Machining
(PMEDM)
Yanzhen Zhang, Yonghong Liu, Yang Shen, Renjie Ji, Baoping Cai, Hang Li and Fei Wang
College of Electromechanical Engineering
China University of Petroleum
Dongying 257061, Peoples Republic of China
upc12345@yahoo.cn
Abstract - This paper reviews the current understanding of
powder mixed electrical discharge machining (PMEDM),
highlighting particularly the mechanisms proposed for PMEDM
under the influence of additive of powders in the dielectric fluids.
Generally, the mirror surface phenomenon in PMEDM can be
explained by the enlarged gap widths which can expand the
discharge channel and thereby reduce the electrical power
density since lower power density can yield large and shallow
craters that evenly distributed on the machined surface.
Moreover, the increment of the inter electrodes distance will limit
the capacitive effect and enable a small surface roughness even in
a large area. Another possible mechanism, multi-discharge model
was also presented in this paper. More investigations on the
fundamental mechanism in power mixed EDM are highly
desirable since it has not been understood clearly. In this paper,
the traditional and some recent development technology for
PMEDM is also reviewed. Historically, PMEDM was invented to
improve the surface quality of the machined components.
Nowadays, some new applications of this technology, such as
micro machining, rough machining and surface modification
were proposed; some novel variations that based on power mixed
EDM, such as PMEDM combined with ultrasonic or abrasive,
powder mixed near-dry EDM and powder mixed electrical
chemical discharge machining (ECDM) were also developed.
Index Terms - Electrical discharge machining; Powder
mixed; Dielectric; surface modification.
I. INTRODUCTION
A conventional EDM surface is generally matt, since it is
generated by a network of individual craters as a result of
discharges. It was reported that the hard recast layer was often
found to contain microcracks, caused by high tensile residual
stresses exceeding the ultimate strength of the material [1, 2].
This surface imperfection further reduces the fatigue, wear and
corrosion resistance of EDMed components [3, 4, 5, 6].
Therefore, micro-energy EDM or hand smoothing has usually
been used for finishing plastic moulds, dies and casting
moulds. However, both methods are time consuming and
economically unattractive.
Apart from the other EDM-based methods of improving
the surface finish such as planetary EDM, multi-electrode
EDM and high resistance coated electrode, powder-mixed
EDM/micro- EDM has been found to affect the spark gap
between the electrodes in addition to discharging process, thus
significantly influencing the performance of the process [7].
978-1-4673-1278-3/12/$31.00 2012 IEEE
Powder mixed electric discharge machining (PMEDM)
was originally invented during late seventies and it can
enhance the capabilities of the conventional EDM process. A
mirror like finish can be obtained on the already machined
components at a relatively high machining rate [8, 9].
It has been reported by many researchers that surface
roughness and surface quality can be distinctly improved by
PMEDM machining. Despite the promising results, PMEDM
process is not commonly used in industry application. One of
the main reasons is that the machining mechanism and many
fundamental issues of this new process are still not understood
well. Due to the complexity of the process, a thorough
investigation is highly desirable, particularly on the influence
of the thermo physical properties of the powders [10]. In
addition, the characteristics of the powders, such as type,
shape, size concentration, etc., also need a thorough
investigation.
The influence of powders that suspended in dielectric
fluid on the EDM performance has been investigated by many
researchers experimentally and theoretically. Some
innovational applications of this technology have been
reported in recent years. While going through the newly
published papers on this process, we felt that it is necessary to
summarize all the conclusions and results made by different
investigators. Therefore, a review of the investigations that
carried out in the past decade in the field of PMEDM is
submitted in this paper.
II. CURRENT UNDERSTANDING OF PMEDM
A. Behaviors of the Powder in the Discharge Gap
The motions of the powders are caused by many
mechanisms, such as Brownian motion, sedimentation,
flocculation and electrophoresis. When fine powders are
subjected to an intense electrical filed, the primary force that
dominates their behaviors would be electrostatic force. In most
case, the influence of gravity that leads to sedimentation can
be neglected only when the density or the size of the particle is
relatively big.
The classical equation of the dipole-dipole interaction
between two similar spherical particles gives the electrostatic
force as
2240
 24 0 1r 6 E 2 Where 1 is the dielectric constant of the dielectric, 2 is the
F= . (1)
( d + 2r ) 4 dielectric constant of the powders, Em is the maximum field
Where 0 is the permittivity of the vacuum, 1 the dielectric strength caused by the presence of the conductive sphere, E0
constant of the dielectric liquid, d the distance between the is the initial field strength in the gap [22]. Since 2 is much
near surfaces of the two particles, E the electric field strength
and r the particle radius [11]. larger than 1 , the maximum field strength, Em , will be about
A particle may initially possess electric double-layer charges, two times larger than E0 . Therefore with the same voltage
as given in
between the electrodes, the width of the gap will be two times
4r 2 0 1 larger than the initial gap that without the additive of powders.
qd = . (2)
DL This equation was extensively used to explain the wider gap in
PMEDM by many researchers [22, 23].
Where the double layer thichness The typical current assumption of PMEDM is shown in
K dif 01 Fig. 2. Due to the presence of the conductive or semi-
DL = . (3) conductive powders in the discharge gap, the discharge gap
Cm was enlarged during the machining process due to the
Where is the zeta-potential of the particle, K dif the aberration of the electric field in the discharge gap. Lots of
negative and positive charges gathered at the bottom and top
coefficient of the diffusion and Cm the conductivity of the of the powders respectively under the effect of gap voltage
dielectric liquid [12]. Further charging can occur, by (Fig. 2.b). A nearer distance from the top or bottom will result
contacting an electrode [12] as given in in a higher electric charge density. Discharge breakdown will
firstly occur at points a and b between two nearby powder,
2
qi = 4r 2 0 1 E . (4) where the electric field density is the highest. Discharge
6 breakdown then causes redistribution of the electric charges
The electrophoresis phenomenon of the particle had been and a short circuit between the two powder particles. More
reported by Kansal et al [13] and Furutani et al [14]. electric charges then gather at points c and d, which leads to
According to Furutani [14], the behavior of the particle in the the discharge between these two powder and other powders.
As a result, series discharge between the electrode and the
discharge gap can be classified in four types: (1) reciprocating
motion, (2) adhesion on either electrode, (3) stagnation like a workpiece will take place [18].
cluster in the gap and (4) stagnation like a chain connecting C. Capacitive Effect
the electrodes (Fig. 1). According to Furutani [14], the Generally, the capacitive effect is considered to be one of
behavior type is determined by the characteristics of the the main reasons that lead to machining instability and hinder
particles. Under the influence of electric forces, the powder the further improvement of the surface quality, especially for
particles were arranged in the form of chains at different large machining area [24, 25].With rough machining
places under the sparking area. The electrodes were bridged parameters, the capacitance can be neglected since it is very
by the chain formation of powder particles which can reduce small. However, the capacitive effect will be enhanced when
the insulating
strength of the dielectric fluid and gap voltage [15,16,17].The
fourth type of particle behavior was extensively used by many
researchers [7,8,10,15,18]to explain the facilitated ignition
process of the discharge in power mixed EDM.
B. Aberration of the Electrical Field and Gap Width.
It has been extensively reported that discharge gap width
increases significantly with the increase of powder
concentration [7, 18, 19, 20, 21]. The presence of conductive
or semi-conductive powders in the working gap can drastically
lower the breakdown strength of dielectric, which eventually
results in a higher spark gap [21].
The classical equation for influence of the sphere
conductive powder gives the electrical field strength as
Fig. 1 Behavior of the powder particles in the discharge gap
Em = 1 + 2 2 1 E0 . (5)
2 + 2 1

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Fig. 2 Schematic diagram of the: (a) aberration of the electrical field,
(b) series discharge
finish machining parameters were adopted due to the very
small inter-electrodes distance (Fig. 3). The capacitive effect
would locally intensify the discharge and deteriorate the
surface quality. Just as analyzed above, the addition of
powders in the dielectric promotes the gap increasing and
results in a drastic reduction of capacitive effect.
In actual EDM process, the inter-electrodes capacitance
can be given as
S powders, the discharge waveforms were entirely different
C = 0 1 . (6)
Where is the permittivity of the vacuum, the dielectric
constant of the dielectric liquid, S the area of the electrodes,
the inter-electrodes distance.
The energy stored by the capacitance can be given as
1 5). Reports presented by Chow et al [28], Han et al [29] and
W = CU 2 .
2
Where U is the voltage applied on the electrodes.
The release of the stored energy will intensify the
discharge and consequently hinder the further improve of the
surface quality.
D. Diameter of the Discharge Passage
Because of the complicated physical phenomena
occurring in the discharge gap, precise analysis of the EDM
discharge passage (plasma) is difficult. The diameter of the
discharge passage in PMEDM was generally considered to be
larger than the conventional EDM [18, 26]. According to Zhao
et al [18], there are two factors that can widen the discharge
passage; one is the longer carriers (ions and electrons)
movement routes, the other is the lower pressure of the
surrounding medium on the discharge passage. Both of the
factors are associated with the width of the discharge gap. At
electric discharging, carriers are accelerated to move to the
anode and cathode, and accumulate energy and collide with
medium molecules and micro-particles, this causing them to
gather energy and release more carriers, resulting in avalanche
increase of carriers in the passage and then the widening of the
passage. Apparently, larger discharge gaps and longer carrier
movement routes imply more carriers and wider discharge
passage [18].
Meng et al [26] assumed that the diameter of the
discharge passage on the workpiece is much larger than on the
tool electrodes when positive polarity and small pulse duration
was adopted. At the finish machining condition (positive
Fig. 3 Schematic diagram of the inter-electrodes capacitance
polarity, small peak current and short pulse duration), the
carrier are mainly electrons since the ions need much more
time to be accelerated due to their larger mass. The avalanche
increase of electrons will yield a passage in the shape of cone.
By spectroscopic measurement, Kojima et al [27]
measured the diameter of the arc plasma. It has been
confirmed than the diameter of the arc plasma increased with
increasing gap width.
E. Multi-Discharge
Chow et al [20] found that after the addition of extra
from these without addition of the powders (Fig. 4). A
multiple discharging effect was created within a single input
pulse. This was caused by the effect of dispersion of the
discharging energy. Restated, several discharging paths were
generated within one single input pulse. Thus, a single input
pulse could generate several discharging spots (Fig. 4 and Fig.
(7) Kung et al [30] also supported this conclusion.
III. INFLUENCE OF POWDER CHARACTERISTICS
The characteristics include particle size, particle
concentration, particle density, thermal conductivity, electrical
resistivity, melting point, evaporation point, and specific and
latent heat [31]. It has been reported by many researchers that
the mirror-finish condition was significantly affected by the
correct combination of powder characteristics and workpiece
material [7, 15]. Whilst mirror finish components for SKH-51
material could be obtained by Al powder suspended dielectric
[32], Al suspended dielectric does not seem to result in mirror-
finish surfaces for SKH-54 material [7]. Although many works
has been done in this area, their roles in the EDM process are
so far unclear.
A. Conductivity
Usually the gap width is significantly influenced by
conductivity of the powder. Conductive powders always yield
a larger gap width than semi-conductive powders [31, 33].
Studies on the effects of different types of powder such as
copper, MoS2, and SiC on the surface roughness have been
conducted by Prihandana et al [15]. From the results, it is
found that MoS2 provides the best surface quality compared
with others. Meng and Zhao [26] found that both conductive
(Al) and semi-conductive powders (Si) can significantly
improve the surface quality except insulative powder (Al2O3).
Beside surface quality, MRR and EWR were also considered
to be affected by particle conductivity.
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Fig. 4 Typical waveform of voltage and current using: (a) kerosene alone, (b)
kerosene with SiC powder, and (c) kerosene with Al powder (Ip.0.5 A, ton.10
ms)
B. Size
Tzeng and Lee [31] found that the gap width was
significantly affected by particle size. Under the same particle
concentration experiments, the smallest suspended particle
size led to the best surface finish [21], the greatest MRR, and,
thus, the lowest TWR [31]. It is reported that particle size has
opposite effect on the recast layer, as the smallest particles
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Fig. 5 Effect of suspended Al powder on the sparking mechanism: (a) typical
sparking model for normal EDM using kerosene without Al powder, (b)-(g)
sequence of discharging dispersion occurring during one pulse using kerosene
with Al powder, and (h) voltage waveform of one pulse using kerosene with
Al powder
generated the thickest recast layer of the EDMed surface, and
the greater the particle size the thinner the recast layer[21].
C. Concentration
In general, an increase in powder concentration tends to
increase the spark gap distance [19,]. Using finishing
discharge energy levels and graphite powder suspended in the
dielectric, Jeswani [34] , Kun et al [30], Jahan et al [19] and
Pecas and Henriques [35] reported that the powder
concentration had an important influence on the discharge
process. There was an optimum of the powder concentration.
For lower concentrations the gap increasing is not enough to
promote the discharge stability and for higher concentrations
the higher gap distance generates discharge inefficiency. The
ratio of normal discharge is significantly affected by powder
concentration [35]. Pecas and Henriques [35] found that a
small level of silicon powder concentration can significantly
reduce the crater diameter, crater depth and the white-layer
thickness.
To date, the roles of the powder characteristics in the
process are unclear although many works have been done in
this area. The complexity of PMEDM process makes it very
difficult to give a quantitative analysis of the influence of the
powder characteristics. More fundamental investigations are
highly desirable to clarify the mechanism.
IV. APPLICATION OF THE PMEDM
A. Application of PMEDM in Large Area and Finish
Machining
Current EDM technologies have major limitations when
dealing with fine surface finish over large process area. Indeed
this is one reason that explains the need of final manual
polishing of mould cavities performed by EDM. In
conventional EDM, due to the capacitive effect and the
difficulties in gap cleaning, the mirror surfaces are only
achievable for small area [36]. The addition of conductive or
semi-conductive particles in the dielectric promotes the gap
increasing and results in a drastic reduction of both the
capacitive effect influence and the abnormal discharge
occurrence [24, 37]. The stability of the process increases and
consequently the polishing time and the influence of the
electrode area in the surface roughness are reduced [38, 32].
Moreover, even for large electrodes, the occurrence of stable
discharges all over the electrode area results in homogeneous
surfaces with lower roughness [39, 40].
Mohri and co-workers [41, 42, 43, 44] found that an EDM
finishing process using dielectric mixed with silicon powder
provides a mirror surface on an area of up to 500cm2.
B. Application of PMEDM in Micro Machining
In recent years, micro-electric discharge machining is
considered to be one of the most promising nonconventional
machining techniques in terms of precision and size of
product. It has advantages over other fabrication process, such
as LIGA, laser, ultrasonic ion beam etc., because of its lower
cost, although the majority of such non-conventional
processes are slower and limited in planar geometries [19].
However, the main drawback of using micro- EDM in
industries is that micro-EDM of hard metals usually yields a
relatively poorer surface finish and integrity including craters,
micro cracks and unfavourable residual stress due to the
thermal action [6]. Improvement to this process has resulted in
the use of powder mixed dielectric, which results in better
surface quality and faster machining time.
Yeo et al. [45] found that with the introduction of SiC
powder into dielectric, the craters formed after machining
have smaller diameters and depth, as well as having a more
consistent circular shape than those produced in dielectric
without additives.
Prihandana et al [46] found that the introduction of MoS2
micro-powder in dielectric fluid and using ultrasonic vibration
significantly increased the material removal rate and improved
surface quality by providing a flat surface free of black carbon
spots. (Sinking)
Jahan et al [19] found that powder mixed milling micro-
EDM was found to provide smoother and defect-free surface
compared to sinking micro-EDM. The lowest value of Ra (37
nm) and Rmax (0.17 m) was achieved in powder-mixed
milling micro-EDM at optimum concentration of 0.2 g/L and
electrical setting of 60 V and stray capacitance.
2244
In the area of micro-slot machining, Chow et al [20]
found that the gap between electrode and workpiece was
enlarged by addition of SiC or aluminum powder to kerosene,
and consequently the debris removal efficiency was enhanced.
C. Application of PMEDM in Rough Machining
Traditionally, the main purpose of mixing powder into the
dielectric was to enhance the surface quality of the machined
components. To date, little research work has been carried out
to investigate the PMEDM in rough machining. Zhao et al
[18] first conducted rough machining using powder mixed
dielectric. As reported, the machining efficiency in PMEDM
can be highly increased by selecting proper discharge
parameters at similar surface roughness with conventional
EDM machining. Although PMEDM can improve machining
efficiency in rough efficiency, a series of problems such as
electrode wear, and efficient separation of the debris from the
powder mixed dielectric, should be carried out before
PMEDM machining is applied in rough machining.
D. Application of PMEDM in Surface Modification
Traditionally, Electrical discharge machining (EDM) was
used as a removal process. In these years, surface modification
and accretion methods by EDM have been studied. In an
accretion process using a green compact [37, 47] or a semi-
sintered electrode [48], a surface of the electrode is crumbled
by discharge and powder is always supplied on the workpiece
after the powder reacts on cracked carbon that comes from
working oil by the heat caused by discharge.
Although the constituents of the green compact electrode
migrated to, and penetrated, the machined surface to form a
modified layer during EDM, the modified agents supplied by
the electrode reduced the machining accuracy. Electrode wear
was serious in providing enough agents to modify the
machined surface, so this modified process is associated with
poor machining accuracy. Therefore, appropriate particles
were added into the dielectric as agents to modify the surface,
to overcome the drawback of poor accuracy. The added
particles were the modifying agents so the electrode wear was
maintained at a reasonable value to facilitate precise
machining.
Furutani and Shimizu [49] proposed a deposition method
to produce parts with solid lubricant layer of molybdenum
disulphide by suspending its powder in the dielectric. Furutani
et al [14] proposed a new material accretion method by EDM
with titanium powder suspended in working oil and obtained
titanium carbide layer of hardness 1600HV on carbon steel.
Chen and Lin [50] found that an alloyed layer that can
improved the hardness and wear resistance of the machined
surface can be obtained by adding TiC particles into the
dielectric. Ming and He [22] investigated the effect of
additives in the dielectric fluid for EDM process, and the
experimental results showed that the additives could improve
the surface quality of workpiece and suppress the loss of alloy
elements on the machined surface. A wire saw was fabricated
by Furutani and Murase [51]. They patterned hard bumps
discretely on the surface of a thin stainless steel wire by EDM
with titanium powder suspended in working oil.
 V. SOME NEW VARIATION OF PMEDM working time could be reduced significantly to within the
range of 5 to 10 min.
A. PMEDM Combined with Ultrasonic Vibration
C. Powder-Mixed Near Dry EDM
Due to the electrostatic force or sedimentation, the
The use of gaseous dielectrics in EDM has been
powder added into the dielectric may agglomerate together to
investigated by Kunieda and his coworker [54, 55]; it is
degrade the expected effect. Ultrasonic vibration was
observed that the performance of EDM using gas (air and O2)
introduced to prevent the agglomeration of the powders [46,
50]. It is reported that the ultrasonic vibration of a dielectric
fluid is significant in increasing the material removal rate. The
ultrasonic vibration of a dielectric fluid reduces adhesion of
debris and prevents the micro-powder from being deposited at
the bottom of the tank providing a better distribution of
powder to the sparking gap (Fig 6). As a result, there is more
powder to flow between the workpiece and the tool electrode
to sustain the stability of the machining process and hence
increase the material removal rate [46, 50].
It has confirmed by Quan and Liu [22] that the addition of
lipophilic surfactant in the dielectric can also provide a better
distribution of the powder and contribute to better EDM
performance, such as higher MRR and lower surface
roughness. Just as stated above, the distribution of the powder
has a significant influence on the EDM performance.
Surfactant moleculars act as steric barrier to separate the
agglomerated powder and disperse them within dielectric. The
surface roughness of workpiece in EDM process is thus
improved.
B. PMEDM Combined with Abrasive
Besides the traditional dielectric fluid of EDM, resent Fig. 7 Schematic diagram of the proposed method using ER fluid and abrasive
gifts
researches have revealed the feasibility of some other
dielectrics, such as electrorheological (ER) fluid [52] and
electrolyte [53] mixed with fine abrasive grits, usually Al2O3
powder.
Y.Y. Tsai et al [34] proposed a novel method of EDM that
used ER fluid instead of water or oil and employed fine
abrasive grits to carry out the combined process of EDM and
polishing (Fig. 7). surface roughness of Ra 0.08-0.06 m can
be obtained after adding the alumina abrasives of 0.3m.
By electrophoretic deposition (EPD), Yan et al [53]
coated Al2O3 particles uniformly on a rotation electrode in
electrolyte after the micro-energy discharge process. The
precision polishing process was then applied on the discharged
workpiece with the abrasive particles coated electrodes (Fig.
8).

Fig. 6 Power mixed EDM with ultrasonic vibration of dielectric fluid
The experimental data showed that when 0.3 m of Al2O3
particles was used for the EPD polishing process, the initial
roughness of a discharge surface could be improved from 0.52
m Ra to a mirror-like surface of 0.068 m Ra. Also, the total
Fig. 8 The (a) experimental set up of the electrophoresis deposition and (b) the
appearance of the Al2O3 particles deposited electrode
can be better than that with a dielectric liquid under some
especial situations. The main factor that inhabits the extrusion
of the debris is believed to be the small discharge gap when
machining with gaseous dielectrics [56, 57]. In order to

2245
enlarge the gap, Qing et al [58] investigated the EDM
machining feasibility by mixing powder in mist and they
named this technology Powder-mixed Near Dry EDM (Fig. 9).
Experiments results showed that both MRR and surface
quality can be improved by mixing powders in mist.
D. Powder-mixed Electrical Chemical Discharge Machining
(ECDM)
In electrical chemical discharge machining (ECDM)
processes, which is thermal erosion machining process using
spark energy similar to the EDM, powder-mixed ECDM (PM-
ECDM) fluids have been used to improve machining quality
by Han et al[59]. In conventional ECDM processes the
generation of fine sparks with uniform energy has been most
desired technique to improve the machining efficiency and the
surface quality [59]. The use of electrolyte mixed with
conductive particle improved the surface integrity of ECDM
process. By use of 1.0 wt. % graphite powder concentration in
30% NaOH, the surface roughness was improved from 4.86 to
1.44 m and the number of microcracks was significantly
reduced [59].
VI. CONCLUSIONS
A detailed summary of the current understanding and
technology reported in the area of PMEDM was presented in
this paper. From this review, it can be concluded that PMEDM
holds a bright promise, particularly with regard to surface
quality and process productivity of workpiece in application of
EDM. However, to date the some of the fundamental principle
of PMEDM has not been understood clearly. Extensive study
is highly required to understand machining mechanism and
other aspects of PMEDM. Many novel technologies based on
PMEDM, such as PMEDM combined with ultrasonic or
abrasive, powder mixed near-dry EDM and powder mixed
electrical chemical discharge machining (ECDM), have
Fig. 9 Schematic diagram of the Powder-mixed Near Dry EDM
proposed recently. These newly developed technologies
showed the great application aspect and potential of PMEDM
technology.
ACKNOWLEDGMENT
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The work is partially supported by a grant from Chinese
National Natural Science Foundation (Grant No. 50675225), a
grant from Department of Science & Technology of Shandong
Province (Grant No. 2006GG2204001), and the Fundamental
Research Funds for the Central Universities (Grant No.
11CX04031A).
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