Influence of flushing on performance of EDM with bunched electrode

• Published in: International journal of advanced manufacturing technology Vol. 58; no. 1-4; pp. 187 - 194
• Main Authors: Li, Lei, Gu, Lin, Xi, Xuecheng, Zhao, Wansheng
• Format: Journal Article
• Language: English
• Published: London Springer-Verlag 2012; Springer Nature B.V
• Subjects: CAE) and Design; Computer-Aided Engineering (CAD; EDM electrodes; Electric discharge machining; Electrodes; Engineering; Flushing; Industrial and Production Engineering; Material removal rate (machining); Mechanical Engineering; Media Management; Original Article; Performance indices; Process planning; Tool wear; Wear rate; Dielectric flushing; Multi-hole; EDM; Bunched electrode
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-011-3357-8

The existing applications of electrical discharge machining (EDM) for bulk material removal are restricted by their comparatively low material removal rates. The bunched-electrode EDM proposed in this study, using the powerful multi-hole inner flushing, is an effective way of being released from this restriction. This paper investigates the mechanism by which flushing (flushing modes and flushing parameters) influences machining performance indices, i.e., material removal rate and tool wear rate, using experiments and simulations. Based on an investigation conducted, compared with traditional solid electrode with mono-hole inner flushing, a bunched electrode with multi-hole inner flushing endures higher peak current and results in larger material removal rate and higher relative tool wear ratio because of a more effective flushing process. By properly choosing inlet velocity and electrode effective-area ratio, a higher material removal rate is achieved and relative tool wear ratio is kept at a lower level.