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Showing papers on "Electrical discharge machining published in 2011"


Journal ArticleDOI
TL;DR: In this paper, electrical discharge machining is used to generate an isotropic texture on the tool rake face, with a view to facilitating lubricant penetration and retention, and a significant reduction in feed and cutting forces that ensues from said texturing is demonstrated.

199 citations


Journal ArticleDOI
TL;DR: The model developed in this study can be used as a systematic framework for parameter optimization in environmentally conscious manufacturing processes.
Abstract: This paper aims to develop a combination of Taguchi and fuzzy TOPSIS methods to solve multi-response parameter optimization problems in green manufacturing. Electrical Discharge Machining (EDM), a commonly used non-traditional manufacturing process was considered in this study. A decision making model for the selection of process parameters in order to achieve green EDM was developed. An experimental investigation was carried out based on Taguchi L9 orthogonal array to analyze the sensitivity of green manufacturing attributes to the variations in process parameters such as peak current, pulse duration, dielectric level and flushing pressure. Weighing factors for the output responses were determined using triangular fuzzy numbers and the most desirable factor level combinations were selected based on TOPSIS technique. The model developed in this study can be used as a systematic framework for parameter optimization in environmentally conscious manufacturing processes.

126 citations


Journal ArticleDOI
01 Mar 2011
TL;DR: The proposed integrated (FEM-ANN-GA) approach was found efficient and robust as the suggested optimum process parameters were found to give the expected optimum performance of the EDM process.
Abstract: This paper reports an intelligent approach for process modeling and optimization of electric discharge machining (EDM). Physics based process modeling using finite element method (FEM) has been integrated with the soft computing techniques like artificial neural networks (ANN) and genetic algorithm (GA) to improve prediction accuracy of the model with less dependency on the experimental data. A two-dimensional axi-symmetric numerical (FEM) model of single spark EDM process has been developed based on more realistic assumptions such as Gaussian distribution of heat flux, time and energy dependent spark radius, etc. to predict the shape of crater, material removal rate (MRR) and tool wear rate (TWR). The model is validated using the reported analytical and experimental results. A comprehensive ANN based process model is proposed to establish relation between input process conditions (current, discharge voltage, duty cycle and discharge duration) and the process responses (crater size, MRR and TWR) .The ANN model was trained, tested and tuned by using the data generated from the numerical (FEM) model. It was found to accurately predict EDM process responses for chosen process conditions. The developed ANN process model was used in conjunction with the evolutionary non-dominated sorting genetic algorithm II (NSGA-II) to select optimal process parameters for roughing and finishing operations of EDM. Experimental studies were carried out to verify the process performance for the optimum machining conditions suggested by our approach. The proposed integrated (FEM-ANN-GA) approach was found efficient and robust as the suggested optimum process parameters were found to give the expected optimum performance of the EDM process.

126 citations


Journal ArticleDOI
TL;DR: In this paper, a tool electrode with a spherical end whose diameter (150 μm) is larger than that of its cylindrical body (100 μm), was used for micro-hole drilling.
Abstract: Electrochemical discharge machining (ECDM) is an emerging non-traditional processing technique that involves high-temperature melting and accelerated chemical etching under the high electrical energy discharged. However, there are still several obstacles to overcome. First, both machining time and hole entrance diameter were found to increase with increasing machining depth. In particular, the increase becomes drastic when machining depth exceeds 250 μm. In addition, achieving both high efficiency and accuracy in drilling a through hole in hard and brittle materials by ECDM poses even greater difficulty. To solve the above problems, this study proposed using a tool electrode with a spherical end whose diameter (150 μm) is larger than that of its cylindrical body (100 μm). Experimental results show that the curve surface of the spherical tool electrode reduces the contact area between the electrode and the workpiece, thus facilitating the flow of electrolyte to the electrode end, and enables rapid formation of gas film, resulting in efficient micro-hole drilling. Moreover, the curve surface does not cause excessive concentration of current density; and hence, bubbles grow at a more uniform speed; thus, increasing the discharge frequency. Comparison between machining depth of 500 μm achieved by conventional cylindrical tool electrode and the proposed spherical tool electrode shows that machining time was reduced by 83% while hole diameter was also decreased by 65%.

116 citations


Journal ArticleDOI
TL;DR: In this article, the authors reviewed the research trends in EDM process by using water and powder mixed dielectric as dielectrics fluid and showed that presence of metal partials in the dielectrical fluid diverts its properties and increases the spark gap between the tool and work piece, as a result, the process becomes more stable and metal removal rate increases.
Abstract: Basically Electrical discharge machining (EDM) is a well-established non-conventional machining process, used for manufacturing geometrically complex or hard and electrically conductive material parts that are extremely difficult-to-cut by other conventional machining processes. Erosion pulse discharge occurs in a small gap between the work piece and the electrode. This removes the unwanted material from the parent metal through melting and vaporizing in presence of dielectric fluid. Performance measures are different for different materials, process parameters as well as for dielectric fluids. Presence of metal partials in dielectric fluid diverts its properties, which reduces the insulating strength of the dielectric fluid and increases the spark gap between the tool and work piece. As a result, the process becomes more stable and metal removal rate (MRR) and surface finish increases. The EDM process is mainly used for making dies, moulds, parts of aerospace, automotive industry and surgical components etc. This paper reviews the research trends in EDM process by using water and powder mixed dielectric as dielectric fluid.

100 citations


Journal ArticleDOI
TL;DR: In this article, the effect of wire electrical discharge machining (WEDM) parameters such as pulse-on time (T ON), pulse-off time(T OFF), gap voltage (V) and wire feed (F) on material removal rate (MRR) and surface roughness (R R a) in metal matrix composites (MMCs) consisting of aluminium alloy (Al6063) and silicon carbide (SiCp) is discussed.
Abstract: In this investigation, the effect of wire electrical discharge machining (WEDM) parameters such as pulse-on time (T ON), pulse-off time (T OFF), gap voltage (V) and wire feed (F) on material removal rate (MRR) and surface roughness (R a) in metal matrix composites (MMCs) consisting of aluminium alloy (Al6063) and silicon carbide (SiCp) is discussed. The Al6063 is reinforced with SiCp in the form of particles with 5%, 10% and 15% volume fractions. The experiments are carried out as per design of experiments approach using L9 orthogonal array. The results were analysed using analysis of variance and response graphs. The results are also compared with the results obtained for unreinforced Al6063. From this study, it is found that different combinations of WEDM process parameters are required to achieve higher MRR and lower R a for Al6063 and composites. Generally, it is found that the increase in volume percentage of SiC resulted in decreased MRR and increased R a. Regression equations are developed based on the experimental data for the prediction of output parameters for Al6063 and composites. The results from this study will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine MMCs of Al6063 reinforced with SiCp at various proportions.

99 citations


Journal ArticleDOI
TL;DR: In this article, the influence of operating process input parameters on machining characteristics of nickel-based super alloy (Inconel 718) in aluminium AEDM with copper electrode was studied.
Abstract: Additive mixed electric discharge machining (AEDM) is a recent innovation for enhancing the capabilities of electrical discharge machining process. The objective of present research work is to study the influence of operating process input parameters on machining characteristics of nickel-based super alloy (Inconel 718) in aluminium AEDM with copper electrode. The effectiveness of AEDM process on Inconel is evaluated in terms of material removal rate (MRR), surface roughness (SR), and wear ratio (WR) using one variable at a time (OVAT) approach. It is found experimentally that particle concentration and size significantly affect machining efficiency. Aluminium powder (325 mesh size) particles of concentration 6 g/l in AEDM produce maximum machining rate, minimum SR, and 4 g/l produces minimum WR within experimental conditions.

98 citations


Journal ArticleDOI
TL;DR: In this article, a polycrystalline diamond micro hexagonal end mill with a diameter of 0.5 mm was fabricated by wire electrical discharge machining and evaluated on a nano milling center.
Abstract: Many researches have studied the micro tools either by simulations or experiments showing that the micro tools play very important roles in micro/nano machining, and micro tool geometries have a direct impact on the final machining quality. Commercially available micro milling tools are usually simply made from downsizing of macro milling tools, which may not be able to be accurately fabricated. Custom micro milling tools have been created by some researchers, but no design criteria for micro milling tools have been introduced. The above factors constrain the development of effective micro milling tools and consequently constrain the researches on micro/nano milling. Based on former researcher’s work, this paper tries to introduce the design criteria for the custom micro tooling. Firstly, the extent typical micro milling tools are studied, and their drawback/limitations are summarized. Secondly, experimental evaluations of the key drawback/limitations are processed. Thirdly, the design criteria for custom micro milling tools are proposed, and corresponding design process is introduced. Then, a new micro hexagonal end mill has been designed based on these criteria. Finally, a polycrystalline diamond micro hexagonal end mill with a diameter of 0.5 mm was fabricated by wire electrical discharge machining, and the evaluation experiments for the hexagonal end mill have been processed on a nano milling center. Experimental results show the newly designed hexagonal end mill can achieve submicron level surface roughness and has simultaneously high-accuracy side and bottom machining capabilities.

83 citations


Journal ArticleDOI
TL;DR: In this article, the influence of electrical discharge machining (EDM) input parameters on characteristics of EDM process was investigated, including machining features, material removal rate, tool wear ratio, and arithmetical mean roughness.
Abstract: This paper presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of Electrical Discharge Machining (EDM) input parameters on characteristics of EDM process. The studied process characteristics included machining features, embracing material removal rate, tool wear ratio, and arithmetical mean roughness, as well surface integrity characteristics comprising of the thickness of white layer and the depth of heat affected zone of AISI H13 tool steel as workpiece. The experiments performed under the designed full factorial procedure, and the considered EDM input parameters included pulse on-time and pulse current. The results of this study could be utilized in the selection of optimum process parameters to achieve the desired EDM efficiency, surface roughness, and surface integrity when machining AISI H13 tool steel.

80 citations


Journal ArticleDOI
TL;DR: In this paper, the authors have developed cemented tungsten carbide (CTC) micro-cutting tools of 3μm diameter by electrical discharge machining (EDM).
Abstract: We have developed cemented tungsten carbide (CTC) micro-cutting tools of 3 μm diameter by electrical discharge machining (EDM). Microdrilling and micromilling were carried out using the developed tools, and their cutting performance was investigated. Cutting was performed in free-cutting brass plates. Ultrasonic oscillation was employed to lower the cutting resistance. As a result, holes and a slot of 3 μm depth were successfully fabricated using tools made of CTC with 0.6 μm grain size, indicating that successful cutting with 3 μm-diameter tools was accomplished for the first time. Furthermore, CTC with 90 nm grain size was used as a tool material to improve the tool breakage resistance and tool form accuracy. The drilling performance of tools made of this ultrafine-grain-sized CTC was also investigated and found to exhibit a considerably improved average tool life.

80 citations


Journal ArticleDOI
TL;DR: In this article, a novel method of suspending nanographite powder in dielectric fluid, using ultrasonic vibration of dielectrics fluid, and using the number of discharge pulses in order to improve the accuracy of the PMD-μ-EDM process was presented.
Abstract: Micro-electric discharge machining (μ-EDM) is an important manufacturing process that is able to produce components and tools with micro-features. Improvement to this process has resulted in the use of powder mixed dielectric (PMD), which results in better surface quality and faster machining time. However, the presence of conductive powder in the dielectric fluid negatively affects the accuracy of the machining depth. This paper presents a novel method of suspending nanographite powder in dielectric fluid, using ultrasonic vibration of dielectric fluid, and using the number of discharge pulses in order to improve the accuracy of the PMD-μ-EDM process. As a result, machining time has been significantly reduced up to 35%, accuracy increased, and the appearance of micro-cracks on the workpiece surface has been reduced.

Journal ArticleDOI
TL;DR: In this article, tool steel ASP2023 was machined and surface integrity including surface finish, microstructure, microhardness, residual stress and element distribution was comprehensively compared.

Journal ArticleDOI
TL;DR: In this paper, a novel process has been developed and tested to improve material removal rate in magnetic-field-assisted microelectrical discharge machining (μ-EDM) for nonmagnetic materials.
Abstract: Previous magnetic-field-assisted microelectrical discharge machining (μ-EDM) techniques have been limited to use with magnetic materials Therefore, a novel process has been developed and tested to improve material removal rate in magnetic-field-assisted μ-EDM for nonmagnetic materials The workpiece electrodes were oriented to promote directionality in the current flowing through the workpiece, while an external magnetic field was applied in such a way as to produce a Lorentz force in the melt pool Single-discharge events were carried out on nonmagnetic Grade 5 titanium workpieces to investigate the mechanical effects of the Lorentz force on material removal Erosion efficiency, melt pool volume analysis, plasma temperature, electron density, and debris field characterization were used as the response metrics to quantify and explain the change in material removal with the applied Lorentz force By orienting the Lorentz force to act in a direction pointing into the workpiece surface, volume of material removed was shown to in-crease by up to nearly 50% Furthermore, erosion efficiency is observed to increase by over 54% Plasma temperature is unaffected and electron density shows a slight decrease with the addition of the Lorentz force The distribution of debris around the crater is shifted to greater distances from the discharge center with the Lorentz force Taken together, these facts strongly suggest that the Lorentz force process developed produces a mechanical effect on the melt pool to aid in increasing material removal The application of the Lorentz force is not found to negatively impact tool wear

Journal ArticleDOI
TL;DR: In this paper, an attempt was made to modify the surface integrity of C-40 steel in electric discharge machining (EDM) by using WC-Cu powder metallurgy (P/M) green compact tools.
Abstract: Electric discharge machining (EDM) is an electrothermal process where recast layer on the machined surface and heat-affected (HAZ) zone just below the machined surface are common phenomena. Thus, the assessment of surface integrity in EDM is a very important task. In this study, an attempt was made to modify the surface integrity of C-40 steel in EDM. WC-Cu powder metallurgy (P/M) green compact tools were used so that the tool material could be transferred to the work surface and thereby the surface characteristics could be altered. WC was used as tool material because of its ability to produce a hard layer over the work surface. A detailed experimental study was performed. The effect of various process parameters on the surface characteristics were presented with the support of analyses such as material transfer rate (MTR), tool wear rate (TWR), surface roughness, optical microscopy, scanning electron microscopy (SEM), energy dispersive x-ray (EDX), x-ray diffraction (XRD), microhardness testing, etc. It...

Journal ArticleDOI
TL;DR: In this article, grey relational analysis (GRA) is employed along with Taguchi method to optimize material removal rate (MRR) and surface roughness (SR) during intricate machining of a carbide block.
Abstract: In this paper, wire electrical discharge machining of WC-Co composite is studied. Influence of taper angle, peak current, pulse-on time, pulse-off time, wire tension and dielectric flow rate are investigated for material removal rate (MRR) and surface roughness (SR) during intricate machining of a carbide block. In order to optimize MRR and SR simultaneously, grey relational analysis (GRA) is employed along with Taguchi method. Through GRA, grey relational grade is used as a performance index to determine the optimal setting of process parameters for multiple machining characteristics. Analysis of variance (ANOVA) shows that the taper angle and pulse-on time are the most significant parameters affecting the multiple machining characteristics. Confirmatory results, proves the potential of GRA to optimize process parameters successfully for multi-machining characteristics.

Journal ArticleDOI
TL;DR: In this article, the variation of the performance parameters with machining parameters was mathematically modeled by Regression analysis method and the objective functions were defined as Dimensional Error (DE), Surface Roughness (SR) and Volumetric Material Removal Rate (VMRR).
Abstract: Wire-cut Electro Discharge Machining (WEDM) is a special form of conventional EDM process in which the electrode is a continuously moving conductive wire. The present study aims at determining parametric influence and optimum process parameters of Wire-EDM using Taguchi's technique and a Genetic algorithm. The variation of the performance parameters with machining parameters was mathematically modeled by Regression analysis method. The objective functions are defined as Dimensional Error (DE), Surface Roughness (SR) and Volumetric Material Removal Rate (VMRR). Experiments were designed as per Taguchi's L16 Orthogonal Array (OA) wherein Pulse-on duration, Current, Pulse-off duration, Bed-speed and Flushing rate have been considered as the important input parameters. The matrix experiments were conducted for the material Hot Die Steel (HDS) having the thickness of 40 mm. The Heat Affected Zone (HAZ) characteristics of the eroded materials were assessed by Scanning Electron Microscope (SEM) and the microhard...

Journal ArticleDOI
TL;DR: In this article, the effect of current, Pulse On-Time (POT) and flushing pressure (P ) on metal removal rate (MRR), tool wear rate (TWR) during electrical discharge machining of as-sintered Al-MMC with 5% and 2.5% reinforcement.

Journal ArticleDOI
TL;DR: In this paper, the authors used micro electrical discharge machining milling (micro EDM milling) to produce micro flow channels with an aspect ratio of 1.2, which is higher than those made from etching or deposition techniques.

Journal ArticleDOI
TL;DR: In this article, a power type function for the hybrid electrochemical discharge machining (ECDM) was developed, which emphasizes the influence of the electrode tool diameter, voltage applied to the electrodes, capacity of the electric circuit involved in obtaining the electrical discharges, and the density of the electrolyte upon the absolute axial wear of the workpiece.
Abstract: In the case of workpieces made of difficult-to-cut materials, the small-diameter holes (1 mm diameter below) can be obtained by means of various nonconventional machining methods, one of these being the hybrid electrochemical discharge machining (ECDM). In the literature they researched, the authors could not find enough information that would allow them to establish adequate work conditions for the ECDM of small diameter holes by using an electrolyte. The use of a spring in order to obtain the work motion required to drill thin workpieces, and the need to remove the insulating film appearing on the workpiece, including in the last stage of the machining, were considered. The experimental research ended in the development of a power type function, which emphasizes the influence of the electrode tool diameter, of the voltage applied to the electrodes, of the capacity of the electric circuit involved in obtaining the electrical discharges, and of the density of the electrolyte upon the absolute axial wear o...

Journal ArticleDOI
TL;DR: In this paper, the effect of the suspended powder and other selected parameters on process performance (machining rate (MR) and surface roughness (SR)) and subsequent optimal settings of the variables have been obtained using Taguchi method.
Abstract: This article reports the results of an experimental study conducted with the objective to understand the mechanism of material removal (role of silicon powder) in powder mixed electric discharge machining (PMEDM) while machining the Al-10%SiCP metal matrix composites. PMEDM is relatively a new development in the direction of enhancement of process capabilities of EDM. A new experimental set-up has been developed in the laboratory for experimentation. This research points out how the suspended powder helps in improving the performance of EDM. Further, the effect of the suspended powder and other selected parameters on process performance (machining rate (MR) and surface roughness (SR)) and subsequent optimal settings of the variables have been obtained using Taguchi method. The obtained experimental results indicate significantly improved performance of PMEDM over EDM. The appropriate addition of silicon powder into the dielectric fluid of EDM increases the MR and decreases the SR. The experimental results...

Journal ArticleDOI
TL;DR: In this paper, the effects of varying seven different machining parameters in addition to varying the material thickness on the machining responses such as material removal rate, kerf, and surface roughness of tungsten carbide samples machined by wire electrical discharge machining (WEDM) were investigated.
Abstract: In this article, the effects of varying seven different machining parameters in addition to varying the material thickness on the machining responses such as material removal rate, kerf, and surface roughness of tungsten carbide samples machined by wire electrical discharge machining (WEDM) were investigated. The design of experiments was based on a Taguchi orthogonal design with 8 control factors with three levels each, requiring a set of 27 experiments that were repeated three times. ANOVA was carried out after obtaining the responses to determine the significant factors. The work piece thickness was expected to have a major effect on the material removal rate but showed to be significant in the case of surface roughness only. Finally, optimization of the machining responses was carried out and models for the material removal rate, kerf, and surface roughness were created. The models were validated through confirmation experiments that showed significant improvements in machining performance for all investigated machining outcomes.

Journal ArticleDOI
TL;DR: In this article, the micro-EDM behavior of an Al 3 O 2 and ZrO 2 based electrically conductive ceramic composites is investigated towards the definition of suitable micro EDM technologies.

Journal ArticleDOI
TL;DR: In this article, a low-frequency vibration on a stainless steel (SS 304) was used to increase the material removal rate and decrease the surface roughness and tool wear rate.
Abstract: High-frequency vibration aided EDM has become one of the ways to increase material removal rate in EDM process, due to the flushing effect caused by vibration. However, utilizing high-frequency vibration, especially in ultrasonic range consumes a lot of setup cost. This work presents an attempt to use a low-frequency vibration on workpiece of stainless steel (SS 304) during EDM process. The workpiece was vibrated with variations of low-frequency and low-amplitude. The results show that the application of low-frequency vibration in EDM process can be used to increase the material removal rate, and decrease the surface roughness and tool wear rate.

Journal ArticleDOI
TL;DR: In this article, a novel method to measure gap force intensity and wire lag under any given machining condition has been proposed by developing an analytical model and the impact of wire deflection on profile accuracy during cutting cylindrical job has been investigated.
Abstract: Wire bending due to gap force is a major cause of imprecision in WEDM applications. To achieve higher precision and accuracy the knowledge of gap force and wire lag is extremely essential. In the present research, an in depth study on wire lag phenomenon has been carried out. A novel method to measure gap force intensity and wire lag under any given machining condition has been proposed by developing an analytical model. Experiments were carried out to verify the proposed model. Beside this, the impact of wire deflection on profile accuracy during cutting cylindrical job has been investigated. Based upon the developed analytical model an effective method has been proposed to eliminate this inaccuracy using wire lag compensation technique. The research finding will lead to better understanding of the gap force phenomena and will promote significant development in the domain of high precision WEDM.

Journal ArticleDOI
TL;DR: In this article, a silicon nitride/carbon nanotubes microgear is electrically discharge machined with a remarkably high material removal rate, low surface roughness, and low tool wear.

Journal ArticleDOI
TL;DR: In this paper, the analysis of surface characteristics like surface roughness, micro cracks of Inconel-825 is carried out and an excellent machined nano finish can be obtained by setting the machining parameters at optimum level.

Journal ArticleDOI
TL;DR: In this article, the effect of vibrations on the electrical discharges in the micro-EDM (electrical discharge machining) process was investigated using sophisticated measuring equipment to record and analyse current and voltage waveforms as well as electrode feeding.
Abstract: In this study, the effect of vibrations on the electrical discharges in the micro-EDM (electrical discharge machining) process was investigated. The electrical discharge machining of micro bores was chosen to represent a typical application. Using sophisticated measuring equipment to record and analyse current and voltage waveforms as well as electrode feeding during the process, deeper insight into the discharge mechanisms was achieved. It was found, that the micro-EDM boring process can be subdivided into three major parts, the start-up process, the major boring process and the workpiece breakthrough of the tool electrode. Extensive investigations have shown a delayed start-up process on the workpiece surface for conventional micro-EDM; however, this effect can be reduced by inducing vibration on the workpiece. The cause of this reduction was analysed by single discharge analysis which also provides a means to investigate the effect of vibration frequency.

Journal ArticleDOI
TL;DR: In this article, the laser assisted machining (LAM) method was proposed to cut and remove softened parts by locally heating the ceramic with laser, where the laser power is the machining factor that controls the temperature.
Abstract: This paper describes the Laser Assisted Machining (LAM) that cuts and removes softened parts by locally heating the ceramic with laser. Silicon nitride ceramics can be machined with general machining tools as well, because YSiAlON, which was made up ceramics, is soften at about 1,000°C. In particular, the laser, which concentrates on highly dense energy, can locally heat materials and very effectively control the temperature of the heated part of specimen. Therefore, this paper intends to propose an efficient machining method of ceramic by deducing the machining governing factors of laser assisted machining and understanding its mechanism. While laser power is the machining factor that controls the temperature, the CBN cutting tool could cut the material more easily as the material gets deteriorated from the temperature increase by increasing the laser power, but excessive oxidation can negatively affect the quality of the material surface after machining. As the feed rate and cutting depth increase, the cutting force increases and tool lifespan decreases, but surface oxidation also decreases. In this experiment, the material can be cut to 3mm of cutting depth. And based on the results of the experiment, the laser assisted machining mechanism is clarified.

Journal ArticleDOI
TL;DR: An axisymmetric three-dimensional model for temperature distribution in the electrical discharge machining process has been developed using the finite element method to estimate the surface integrity characteristics of AISI H13 tool steel as workpiece as discussed by the authors.
Abstract: An axisymmetric three-dimensional model for temperature distribution in the electrical discharge machining process has been developed using the finite element method to estimate the surface integrity characteristics of AISI H13 tool steel as workpiece. White layer thickness, depth of heat affected zone, and arithmetical mean roughness consisting of the studied surface integrity features on which the effect of process parameters, including pulse on-time and pulse current were investigated. Additionally, the experiments were carried out under the designed full factorial procedure to validate the numerical results. Both numerical and experimental results show that increasing the pulse on-time leads to a higher white layer thickness, depth of heat affected zone, and the surface roughness. On the other hand, an increase in the pulse current results in a slight decrease of the white layer thickness and depth of heat affected zone, but a coarser surface roughness. Generally, there is a good agreement between the experimental and the numerical results.

Journal ArticleDOI
TL;DR: In this article, the micro-hole machining performance for polycrystalline diamond (PCD) by micro-electrical discharge machining (micro-EDM) was investigated, and an optimal set of machining conditions was chosen among the investigated ranges of nominal capacitance and electrode rotation speed.