Electrical Discharge Machining (EDM): Practices in Malaysian Industries and Possible Change towards Green Manufacturing

Abstract

Electrical discharge machining (EDM) is material removal process by a series of rapid recurring electrical discharges between the cutting tool (electrode) and the work piece in the presence of dielectric fluid. The process benefits Malaysian mould and die industries especially in making electrical, automotive and household products. Visits were conducted to a few EDM industries in Klang Valley in identifying the industrial practices. Hydrocarbon based dielectric usually kerosene is widely used by the Malaysian industries. The paper highlights on findings obtained from industrial interviews: machine used and products made, types of electrode materials, machining technique, usage of dielectric and measuring quality of machined products. Calculation on the usage of kerosene and related cost at a company is presented. Estimation of kerosene as waste is provided. Suggestions on alternative machining method such as machining with distilled water or dry EDM are given.