Abstract
ABSTRACT Electric discharge drilling (EDD) is a competent method for drilling hard-to-cut materials despite its drawbacks, including minimum material removal rate (MRR), excess tool wear rate (TWR), high surface roughness (R a ), and power consumption (PC). To address these issues, EDD’s performance was explored by varying factors like tool electrode geometry (TEG), current (I), pulse-on-time (TON ), and tool electrode speed (TES) to investigate the effect on MRR, TWR, R a , and PC. Cu-6 produced the highest MRR of 36.26 mm³/min, surpassing Cu-7, Cu-8, and Cu-solid by 28.309%, 44.866%, and 51.843% respectively. Cu-solid revealed the lowest TWR of 4.397%, significantly lower than Cu-6, Cu-7, and Cu-8. R a followed the trend: Cu-solid < Cu-8 < Cu-7 < Cu-6. Cu-solid consumed more power than hollow electrodes. Microscopic analysis attributed rough surfaces to high currents. Energy dispersive X-ray (EDX) analysis exhibits material migration from a workpiece and tool electrode on the machined surface. .
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