Experimental and simulation study on micro hole machining in EDM with high-speed tool electrode rotation

Abstract

In order to improve the machining characteristics, rotational electrode has been widely used in machining micro holes in electrical discharge machining (EDM). In the current work, a high spindle speed EDM was employed for machining holes, and the effect of the rotating speed on the material removal rate, electrode wear, and the taper of the hole was studied. Fluent software was used to simulate the flow field of the working gap medium at different rotating speeds of the tool electrode, and the velocity field of the working gap medium and the distribution of the discharge debris particles in the working gap at different rotating speeds of the tool electrode were investigated. The results show that increasing the rotating speed of the tool electrode brings higher removal rate and lower electrode wear and taper of the hole. This is because increasing the rotating speed of the tool electrode can promote the flow velocity of the working gap flow field, and the efflux velocity of working liquid containing discharge debris particles is speeded up.