Maglev Electric Discharge Machine (MEDM): Design and Development

Electro-discharge machining (EDM) is a non-traditional thermal process for material removal through the electrically controlled spark. A pulsed/RC power supply is connected with a gap maintaining mechanism known as servo mechanism. The maintenance of proper inter-electrode gap (IEG) is responsible for the smooth discharge. It gets affected by polluted environment due to debris, ions, and uneven surface of the electrodes. Despite of the above problems it is commercialized and available in the open market. Other issues with the existing system are: slow response, less precise, intricacy, and import of key components. A solution of the above problems has been identified, designed, and developed. A self-servo bipolar linear actuator has been developed to control the IEG with a pure DC power supply. A simple electrical circuit has been implemented so that it decreases the magnetic strength when the tool goes closer to the job and increases the magnetic strength when the tool goes away from the job. Therefore, it balances at a fixed discharging distance. Any generic DC power supply/DC adapters/battery/a battery charge/an electric arc welding machine can be used as a power source. Since the proposed mechanism is replacing the two major components, i.e., servo mechanism and power supply, its proposed cost may be much lower than the existing EDM system.