Proceedings of the National Conference on

Trends and Advances in Mechanical Engineering,

YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012

ELECTRICAL DISCHARGE GRINDING (EDG): A REVIEW

Ravindra Nath Yadav1 and Vinod Yadava2
1. Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad, India
Email: rnymnnit@yahoo.com
2. Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad, India
vinody@mnnit.ac.in

Abstract
The machining of thin and fragile material is very difficult for manufacturing industries and rapid demand of
requirement could not be achieved. Electrical discharge machining is more acceptable machine tool for
machining hard and brittle electrically conductive materials but its productivity is very slow. In past decade,
researchers are focus on electrical discharge grinding (EDG) for machining these material because there is no
mechanical forces exerted on workpiece during machining and it gives better performances than EDM due to the
rotating speed of wheel. The aim of this paper is to summarize a review on EDG process along with
developments in same area and also focus on the future research scope in the same area.
Keywords: Electrical discharge Machining (EDM), Electrical discharge grinding (EDG), ED milling
1. INTRODUCTION
Electrical discharge grinding (EDG) is a non-traditional thermal process for machining difficult to machine hard
and brittle electrically conductive materials. EDG has been developed by replacing the stationary electrode used
in electrical discharge machining (EDM) with rotating electrode. In EDG process, material is removed melting
and vaporization as same as EDM process. But there are ample differences with EDM instead of mechanism of
material. In EDG process, an electrically conductive wheel is used as a tool electrode instead of stationary tool
electrode used in EDM. There is no contact with workpiece and tool electrode (rotating wheel) except during
electric discharge. Due to the rotational motion of wheel electrode, the peripheral speed of wheel transmitted to
the stationary dielectric into gap between workpiece and wheel resulting flushing efficiency of process is
enhanced. Therefore, the molten material is effectively ejected from gap and no debris accumulation take place
into gap while in EDM debris accumulation is major problem which adverse effect on performances of process
[1]. Due to the enhanced in flushing, higher material removal and better surface finish is obtained as compare to
the conventional EDM process [2]. At the same machining condition, EDG gives better performances than EDM
and it is machined extremely hard materials faster (2-3 times) as compare to the conventional grinding [3]. The
high speed of wheel is not always beneficial and after a certain value of speed, the spark becomes instable and
produces adverse effect on performance [4]. There is no physical contact between workpiece and wheel, so that
the process becomes more advantageous for machining thin and fragile electrically conductive materials [3, 4].
The detail of EDG process has been illustrated in Fig 1 and wheel-workpiece interaction is shown in Fig. 2. In
this process, a rotating eclectically conductive metallic wheel is used which is known as grinding wheel. The
grinding wheel used in this process, having no any abrasive particles and rotates its horizontal axis. Due to the
similarities of process with conventional grinding and material is removed due to the electrical discharge, it is
known as electrical discharge grinding (EDG). In this process, the spark is generated between rotating wheel and
workpiece. The rotating wheel and workpiece both are separated by dielectric fluid and during machining both
(workpiece and wheel) are continuously deeped into dielectric fluid. The dielectric fluids are mainly Kerosene
oil, Paraffin oil, Transformer oil or de-ionized water. The main purpose of dielectric is to make a conductive
channel during ionization when suitable breakdown voltage is applied. The servo control mechanism utilized to
maintain the constant gap between workpiece and wheel in range of 0.013-0.075 mm. A pulse generator is used
for maintaining the DC pulse power supply in ranges of voltage, current and frequency are 30-400V, 30-100A
and 2-500 kHz respectively [3]. When pulse power supply is applied, the spark takes place into gap due to the
ionization and striking of ions and electrons at their respective electrodes. Due to spark, high temperature
generated between ranges of 8000C to 12000C [5] or as so high upto 200000c [6] by each spark resulting
material is meted from both the electrodes. Simultaneously DC pulse power supply switch is deactivated
resulting the breakdown of spark occurs and fresh dielectric fluid entering into gap. Due to the high flushing
efficiency, the molten materials flush away in form of micro debris from gap and formed the crater on work
surface [7].

2. RESEARCH AND DEVELOPMENTS IN EDG

Many research and developments have been done in field of EDG for machining difficult to machine materials.
In this process, a rotating electrically conductive wheel is used for spark erosion and simultaneously enhances
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Proceedings of the National Conference on

Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012

the flushing due to the rotational motion of wheel. There is many developments are found in particular process,
depending on type of wheel and its rotation that are used in EDG process. These developments are implemented
with two types of grinding wheels. Firstly, grinding wheel without abrasive particles while others is grinding
wheel with abrasive particles.

Fig. 1 Detail of EDG process

Metallic wheel

Pulse power
supply

Dielectric
Workpiece

Fig. 2 Wheel-workpiece interaction in EDG

In EDG without abrasive particle, the wheel is made of graphite which rotates on is horizontal axis [3] but
instead of graphite wheel, some other materials are used for making wheel for EDG process such as copper, brass
and mild steel. Due to the high wear resistance, the mild steel wheel gives low wheel wear as compare to the
copper and brass wheel. The main developments in EDG without abrasives are: electro-discharge grinding and
electro-discharge milling (ED milling). In EDG process with abrasive particle, the rotating wheel replaced with
metal bonded abrasive wheel or and such types of wheel is known as composite wheel. In composite wheel, the
main purposes of abrasive particles are: to enhanced the material removal, to achieve better surface finish and
requirement of low grinding forces. Electro-discharge abrasive grinding (EDAG) is the main development of
EDG process with abrasive wheel. It is further developed in three different grinding configurations such as
electro-discharge abrasive cut-off grinding, electro-discharge abrasive face grinding and electro-discharge
abrasive surface grinding.

2.1. RESEARCH IN EDG

In EDG process, a rotating metallic wheel is used in machining which may rotates either its horizontal axis or
vertical axis. Based on the rotation of wheel, the EDG process developed in three different configurations. These
are: electro-discharge cut-off grinding, electro-discharge face grinding and electro-discharge surface grinding
[8]. In cut-off grinding configuration, the metallic wheel rotates about its horizontal axis and fed into
perpendicular direction to the machine table. It is used to cut workpiece into pieces or making grooves into
workpiece. In face grinding configuration, the metallic wheel rotates about vertical spindle axis and fed into
perpendicular direction to the machine table. It is more suitable for end machining of cylindrical work surface. In
the surface grinding mode, the wheel also rotates its horizontal axis and fed into perpendicular direction to the
machine table. It is mostly applicable for machining of the flat surfaces.

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Proceedings of the National Conference on

Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012

Many researchers have made effort to identify the factors that affects the performance of EDG process. It has
been experimentally proved that material removal rate (MRR) and surface quality improved by properly
selecting of process parameters by Aoyama et al. [9]. Sato et al. [10] have claimed that electrode rotation served
as an effective gap flushing technique resulting better material removal. The edge quality of various grades of
polycrystalline diamond (PCD) cutting tool blanks after EDG on either the face or periphery of a rotating
graphite wheel has investigated by Thoe et al. [11] and found that as compare to the coarse grain, the fine grain
blank has higher MRR, grinding ratio and lower roughness of surface and edge. To obtain high material removal,
higher peak current and longer pulse duration with positive polarity of electrode are suggested by Shih and Shu
[12] as shown in Fig. 3 (a) while the negative tool polarity gives better surface finish as shown in Fig. 3 (b) at
same machining conditions.

Fig. 3 Effect of pulse on-time with positive and negative tool polarity [12]
(a) Effect of on-time MRR, (b) effect of on-time on surface roughness
Soni and Chakraverti [13] developed the orbital motion of the electrode for improving the machining rate and the
results were compared with stationary electrode. They have found that orbital motion of the electrode enhanced
the performance and MRR increases with rotation of electrode due to improved flushing action and sparking
efficiency, however the surface roughness is increased. Guu and Hocheng [14] have been experimentally proved
that rotating workpiece gives two times more MRR as compare to the conventional EDM but this process is most
suitable for axial-symmetrical die and mold work. Koshy et al. [15] have experimentally proved that MRR,
TWR, relative electrode wear, corner reproduction accuracy and surface finish aspects of a rotary electrode are
better as compare to stationary electrode. This is because the rotation speed of electrode would convey a velocity
to the dielectric in the gap hence more effectively flushing take place in the gap but at higher rotating speeds
result in discharge instability resulting lower MRR with improve in surface roughness.
Chow et al. [16] have been modified the EDG process by locating the rotating electrode below workpiece as
shown in Fig. 4. They have claimed that due to gravitational force debris removal rate was significantly
improved resulting higher MRR with better finish with rotating workpiece below workpiece. The effect of
vibration-rotary EDM as compare to the vibration EDM on MRR is high with higher surface finish has obtained
by Atkinson and Ghoreishi [17]. They have found that the combination of ultrasonic vibration enhanced the
performances of rotary EDM and rotation of electrode leads to increase the MRR but simultaneously TWR and
Ra values is also increased. For machining of non-sphere workpiece with EDG, the Fujun et al. [18] have
introduced the new shaping principle of machining these non-sphere materials. They suggested that the angle
speed of workpiece and tool electrode should not be too high otherwise working fluid cannot enter into discharge
gap under centrifugal effect of rotating wheel which plays adverse effect on the performances.

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Proceedings of the National Conference on

Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012

Fig. 4 Relative position of workpiece; (a) Conventional EDG, (b) Modified EDG [16]
Machining of metal matrix composites (MMCs) are very difficult due to the presence of hard and brittle ceramic
particles which leads to the rapid tool wear [19, 20]. But the MMCs are effectively machined with EDG due to
the performances of EDG is not affected by mechanical or physical properties of materials. Yan and Wang [21]
have study on machining characteristics of Al 2 O 3 /6061Al composite using with copper tube electrode and they
have found that current and volume fraction of Al 2 O 3 were have significant affects the performances but the
flushing pressure and electrode rotational speed have minor effect on performance parameters. Wang and Yan
[22] claimed that the electrical parameters more significant effect on performances as compare to the nonelectrical parameters. The effects of electrode material, electrode rotation, volume percentage of SiCp and
electrical parameters have been investigated by Mohan et al. [23]. They compared the performances of brass and
copper electrode and found that brass electrode gives higher MRR than copper electrode with positive polarity
electrode. They also claimed that the higher percentage volume of SiCp means lower value of MRR with good
surface finish due to SiC particles protect the matrix. It has been also found that the rotating tube electrode gives
higher MRR than the rotating solid electrode, when they were tested at same machining conditions.

2.2. RESEARCH IN ED MILLING

Electro-discharge milling is the new development of EDG process. In this process, tool electrode rotates and
workpiece fed toward or backward direction as shown in Fig. 5 The performance of ED milling in terms of
MRR and surface quality is much better and machining time reduced up to 50% as compare to the sinking EDM
[24].
Tool
Nozzle

Workpiece
NC Table

Pulse Power
Supply

Fig. 5 ED milling process [24]

Liu et al. [25] have proposed new method for ED milling for machining insulating Al 2 O 3 using a thin copper
sheet as assisting electrode, which fed between insulating ceramic and rotating wheel as shown in Fig. 6. They
have found that process shows high MRR with positive polarity as compare to the negative tool polarity while
negative tool polarity give higher surface finish. The dielectric fluid is a primary factor that affects the
performances of process in term of MRR and surface quality. It has also found that high velocity flow of
dielectric fluid resulting MRR increases with a slightly increases in Ra value [26]. But there is no harmful gases
generated during ED milling and the equipment is not corroded while water-based emulsion uses as a dielectric.
The effect of toothed steel wheel during ED milling of SiC has been also investigated by Liu et al. [27] as shown
in Fig. 7 and they have found that toothed wheel gives high MRR with positive tool polarity. They suggested that
high machining rate and good surface quality is obtained at suitable value of pulse on-time, pulse off-time and
peak voltage.

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Proceedings of the National Conference on

Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012

Fig. 6 Detail of ED milling of ceramic with assisted electrode [25]

Ji et al. [28] have also proposed a new method for ED milling in which workpiece connected to the servo system
during ED milling of silicon carbide ceramic resistivity 500 with steel electrode and it has been found that
smaller high-frequency pulse duration and pulse interval, higher peak voltage and peak current, and positive tool
polarity are suitable for machining the SiC ceramic. Ji et al. [29] have claimed that material is removed by
melting, evaporation and thermal spalling during end milling EDM of silicon carbide.

Fig. 7 ED milling with slotted wheel [27]

2.3. RESEARCH IN EDAG

To improve the efficiency of the EDG process, the metallic or graphite electrode has been replaced with metal
bond abrasive wheel and the developed is known as electrical discharge abrasive grinding (EDAG) [30-33]. In
this process, the material is removed by the combined effect of electro-erosion of EDM and micro-cutting of
grinding process as shown in Fig. 8. Due to the combined effect of EDG and grinding, the overall performances
of the process have been improved. This process becomes evident when machining super-hard materials,
engineering ceramics, sintered carbides and metal composites [31, 32]. The electrical discharge interactions on
the metal bond abrasive grinding wheel lead to its self dressing in process. The theoretical analysis and
experimental investigation of self-dressing mechanism of EDAG process has been investigated by Kozak [32].
They have also claimed that electro-erosion process could be applied in profiling of super-hard metal bonded
wheel.
In recent past, several attempts have been carried out for employing the feasibility of EDAG process with
different named proposed by researchers such as abrasive electro-discharge grinding (AEDG) and electrodischarge diamond grinding (EDDG). The enhancement of the MRR on introducing abrasion into the process has
been studied in comparison to conventional EDM and EDG with rotating graphite has been done by Rajurkar et
al. [31] during machining of Al-SiC composite and titanium alloy with copper bonded diamond wheel. They
have found that MRR obtained by EDAG process is about five times more than EDM and about two times more
than EDG process. Aoyama and Inasaki [33] have found that the normal and tangential grinding forces decrease
with an increased in the applied voltage at the expenses of wheel wear. The compound effect of electrical
discharge and mechanical grinding process of SiC with segmented wheel is developed by Ji et al. [34]. They
have found that the developed process effectively machine the large surface area with higher MRR and good
surface finish.
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Proceedings of the National Conference on

Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012

Fig. 8 Combined effect of EDG and grinding in EDAG process [37]

Koshy et al. [35] have suggested for effectively performance of EDAG process, the protrusion height of abrasive
particles is approximately 30% of the grain size is more suitable. It was found that the spark discharges thermally
soften the work material in grinding zone, hence soften material easily removed by grinding action and
consequently decrease the normal forces [35, 36]. Choudhury et al. [37] experimentally investigated that
tangential grinding force decreases with increase in voltage and duty factor for a particular value of current. Jain
and Mote [38] claimed that specific energy required in EDAG process is less than EDG. It has been investigated
by Yadav et al. [39] that the wheel speed and current are most significant factors that affecting performances of
EDAG. Yadav and Yadava [40-43] study the effects of parameters on self developed. Singh et al. [44-48]
developed EDAG process in face grinding mode for machining end surface of cylindrical workpiece and study
the effects of process parameters. Agrawal and Yadava [49, 50], Modi and Agrawal [51] developed EDAG
process in surface grinding mode for machining flat surface of workpiece and also study the effects of process
parameters on performance measures.

3. PROCESS PARAMETERS AND PERFORMANCE MEASURES

Similar to the EDM process, many parameters affected the performances of EDG. These are classified into two
categories: electrical parameters and non-electrical parameters. The electrical parameters are discharge voltage,
pulse current, pulse duration, pulse interval, pulse frequency, duty factor and polarity while non-electrical
parameters are types of dielectric and wheel rotational speed while the flushing method and flushing pressure of
dielectric are not significantly affects the performances of EDG. The performance measures are MRR, tool wear
rate (TWR), and average surface roughness (Ra). When the abrasive is added into metallic wheel then size of
abrasive, types of abrasive, bond materials and concentrations also affects the performance measured.

4. SUMMARY
In this paper authors are summarized to the published research papers on EDG process along with the process
parameters and their effects on performances measured. It cleared from the published papers that wheel speed
enhanced the flushing resulting performances of process is also enhanced. The ED milling is the unique
development in EDG process for machining insulating materials such as Al 2 O 3 . Adding the abrasive into
metallic wheel means unique changes in performances. This study helpful for researchers and developers, who
works in field of advanced manufacturing technology and making efforts for machining difficult to machine
materials at low cost.

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YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012

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