Electric Discharge Machining

Abstract

The goal of this project is to create a power supply for an electrical discharge machine (EDM). This machine can drill holes and create shapes in metal objects by evaporating material using discharges from the electrode to the workpiece. The electrode should be supplied with a high-voltage pulse wave in order to initate sparks. The power supply produces this waveform by turning a DC source on and off using a transistor as a switch. A current-limiting resistor that is placed between the source of the MOSFET and the electrode prevents short circuits during discharges. The circuit was first created with a DC voltage of 15V. A gate driver circuit to drive this MOSFET was designed to reduce power losses and to make the frequency and duty cycle adjustable. Then the design was improved by adding a diode to remove oscillations caused by the parasitic inductance of the power resistor. Afterwards, the circuit was built on a custom PCB to reduce parasitics. A filtering capacitor was added to remove high-frequency noise, after which a stable 15V pulse signal was obtained. A microcontroller is employed to regulate the pulse duration, detect spark occurrences, and relay this information to a speed regulator. This establishes a closed-loop system aimed at optimizing the overall system operation. To achieve this, circuitry is employed to convert the power supply output into a digital format, enabling the utilization of the microcontroller’s specialized hardware for rapid sampling.