Design and Prototyping of an Electrostatic Discharge Machining (EDM) Device
Electrode, Dielectric Fluid and Structural Design
R. Helmer (TU Delft - Electrical Engineering, Mathematics and Computer Science)
T.C. Qualm (TU Delft - Electrical Engineering, Mathematics and Computer Science)
S. Mahmoud (TU Delft - Electrical Engineering, Mathematics and Computer Science)
Mohamad Ghaffarian Ghaffarian Niasar – Mentor (TU Delft - High Voltage Technology Group)
IE Lager – Graduation committee member (TU Delft - Electrical Engineering Education)
H. Vahedi – Graduation committee member (TU Delft - DC systems, Energy conversion & Storage)
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Abstract
This paper presents the design and development of an Electrical Discharge Machining (EDM) device aimed at achieving precise hole creation in diverse metal materials. The EDM device was conceptu- alized and constructed based on specific requirements identified by the group. The design process encompassed four main stages: dielectric fluid selection, electrode design, control system develop- ment and power supply. In the dielectric fluid stage, the importance and criteria for selecting an appropriate fluid were discussed, resulting in the choice of distilled water for its superior dielectric properties. The electrode design stage followed a similar methodology, leading to the selection of a copper rod as the optimal electrode material. The control system stage detailed the development of an open-loop, manual, and closed-loop control system, emphasizing the utilization of Klipper software for precise electrode control. The power supply section outlined three primary circuits: the power source, power amplification circuit, and square wave generator circuit. Detailed schematics, component justifications, and optimization values for key parameters were provided to enhance power supply efficiency. Experimental evaluation demonstrated the capability of the EDM device to effectively create holes in various metals using an open-loop control system. Additional experiments focused on parameter variations within the power supply setup further illustrated their impact on machining performance. The discussion highlights the challenges encountered throughout the project, particularly the constraints imposed by limited time, which prevented the realization of all initially set requirements. Despite these challenges, the EDM device successfully met most of the specified objectives, showcasing promising results for future refinements and applications in precision machining.