Optimization of material removal rate and tool wear rate of Cu electrode in die-sinking EDM of tool steel

Abstract

The principle of electrical discharge machining is based on electrical discharge which occurs between two electrodes (a cathode and an anode). The cathode is generally represented by workpiece and the anode by electrode tool. An electric discharge between the cathode and the anode occurs always upon fulfillment of basic conditions. A decisive influence has a kind of workpiece and tool electrode materials; spacing between the electrodes, called also gap; properties of dielectric fluid; and the main technological parameter setting. The combination of these parameters generates crater of specific shape on the workpiece and also on the tool electrode. The shape and size of the crater, formed during one electric discharge in die-sinking EDM, have a significant impact on material removal rate and on electrode wear. The aim of the paper is based on experimental measurement to identify the impact of selected process parameters on material removal rate and electrode wear in die-sinking EDM of tool steels EN X210Cr12 with Cu electrode EN CW004A, based on acquired dependencies to perform optimization of these parameters with a view of maximization of material removal rate and minimization of tool wear rate.