OPTIMIZATION OF PROCESS PARAMETERS OF DRY ELECTRIC DISCHARGE MACHINING

Abstract

Different non-traditional machining techniques are increasingly employed to manufacture different high quality industrial components. Nontraditional machining processes are necessary for machining of such materials. Among the nontraditional methods of machining processes, electrical discharge machining (EDM) has drawn a great deal of attention because of its broad industrial applications including different dies and tools [1]. Electrical Discharge Machining (EDM) is one such process which is widely used to machine electrically conductive materials. EDM is a thermo-electric process in which material removal takes place through the process of controlled spark generation. In this process material is removed by controlled erosion through a series of electric sparks between the tool (electrode) and the work piece. The thermal energy of the sparks leads to intense heat conditions on the work piece causing melting and vaporizing of work piece material [2]. Due to the high temperature of the sparks, not only work material is melted and vaporized, but the electrode material is also melted and vaporized, which is known as electrode wear (EW). Like other machining processes, the quality of machined parts in EDM is significantly affected by input parameters [3, 4]. This is one of the most popular non-traditional machining processes being used today in the industry. EDM is commonly used in mold and die making industry and in manufacturing automotive, aerospace and surgical components. Since there is no mechanical contact between the tool and the work-piece, thin and fragile components can be machined without the risk of damage.