Effects of Machining Variables on Electrode Wear in Electric Discharge Machining
Keywords:
Electric discharge machining (EDM), Electrode wear- wear ratio, Material removal rateAbstract
Electric Discharge machining (EDM) has achieved remarkable success in the manufacturing of conductive materials for the modern industry. EDM is a non-traditional machining method commonly used to produce die-cavities via the erosion effect of electric discharge. The material is removed rapidly and repeatedly by spark discharge across the gap between the tool and the work-piece. In EDM, tool wear problem is very critical since the tool shape degeneration directly affects the final shape of the die cavity. In most of the EDM operation, the contribution of Electrode (tool) cost to the total operation cost is more than 70%. Due to this reason, the wear of Electrode should be carefully taken into consideration in planning and designing EDM operation. In a complete EDM process, machining stages that include rough –cut, middle cut and finish cut are carried out sequentially. The variations of geometrical tool wear characteristics – namely, edge and front wear – and machining performance outputs – namely, work-piece removal rate, tool wear rate, relative wear and work-piece surface roughness – were studied in this paper with varying machining parameters. This research was focused on the electrode wear rate of Electro discharge machining with a focused review on effect of different machining parameters like Discharge current, Pulse duration, Pulse time, Polarity, Dielectric flushing method, flushing pressure, Use of powder suspension in dielectric, Particle size of Powder, Electrode material and Work-piece material, on electrode wear (tool wear) of EDM.
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