Electrical Discharge Machining (EDM) applications in manufacturing EDM is best suited for non-traditional removal on hard or difficult-to-machine materials. Which of the following practical applications correctly reflects where EDM is commonly applied?

Introduction / Context:
Electrical Discharge Machining (EDM) is a non-traditional machining process that removes material by a series of rapidly recurring electrical discharges (sparks) between an electrode tool and a conductive workpiece. It is particularly valuable for creating intricate shapes in very hard materials where conventional cutting fails or becomes uneconomical.

Given Data / Assumptions:

• The workpiece and tool are electrically conductive.
• Material removal occurs by localized melting and vaporization in a dielectric fluid.
• Goal: identify typical industrial applications of EDM.

Concept / Approach:
Because EDM does not rely on mechanical cutting forces, it can machine hard carbides, tool steels, superalloys, and delicate features without inducing large stresses. Its strengths include producing complex cavities, fine holes, and detailed markings with excellent dimensional control.

Step-by-Step Solution:
Match EDM capability to application: hard carbides/tool steels → die and punch shaping.Assess small-hole drilling: EDM (including fast-hole EDM) produces numerous precise micro-holes in nozzles and sieves.Consider surface detail: spark erosion enables embossing/engraving on hard substrates.Hence, all listed uses are valid → choose “all of these”.

Verification / Alternative check:
EDM dies and molds are industry standards; aerospace fuel injector orifices and turbine cooling holes frequently use EDM drilling; engravings on hardened components are routinely spark-machined.

Why Other Options Are Wrong:
Option (E) mentions soft plastics and HSS cutters—this relates to conventional machining, not EDM, and plastics are typically non-conductive.

Common Pitfalls:
Forgetting the conductivity requirement; assuming EDM is fast for bulk removal (it is slower than conventional machining for large stock removal); neglecting recast layer and the need for post-processing in high-spec components.

Final Answer:
all of these