Development of electrical discharge machining power generator

Abstract

Electrical Discharge Machining process has been widely used for manufacturing micro components due to its contactless process. The power generator design and configuration requirements for producing the desired spark have always been a challenge to the researchers. The aim of this project is to design and implement the power generator using Switch Mode Power Supply (SMPS) with 100W output power for the EDM system. The power generator is designed based on the SMPS push-pull topology. The hardware of the push-pull converter has been successful built its characteristic almost similar to the designed specification. The SMPS power generator for EDM machine is working properly according to the supply current needed by the load. The SMPS is based on the push-pull topology that utilize IGBT transistor. The project describes both simulation and experimental work carried out on the developed circuit. Simulation results show that this push-pull converter capable to produce DC voltage up to 100V. The experimental results show that the 100W EDM power generator with up to 1A gap currant is stable and reliable.