Abstract
Electrical discharge machining (EDM) is used for machining of any electrically conductive materials irrespective of their hardness. A number of EDM process variants have been developed over the years for improving the machining performance. Powder mixed EDM (PMEDM) and rotary tool EDM (REDM) are such process variants which have improved the efficiency of the machining process. In the present study, a comparative study of the effect of various process parameters were carried out on PMEDM and REDM process. The output characteristics measured were the material removal rate (MRR) and the tool wear rate (TWR). Experimental results reveal that the MRR in PMEDM was higher as compared to conventional die-sinking EDM. However, average MRR of REDM process was about 2.5 times higher as compared to that of the PMEDM process. In PMEDM, the debris accumulation in the inter electrode gap limited the machining rate. In case of REDM, tool rotation improved the flushing efficiency.
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