A Studying the effect of Depth of Cut on Electric Spark Machining parameters

Abstract

Several machining parameters impact the process's quality. These parameters may include variables such as the type of polarity, the kind of workpiece, the types of dielectric materials, methods for dielectric flow, and the selection of operational parameters, among other factors. This paper includes optimization studies designed to provide insights into the influence of these factors and the strategies utilized to achieve optimal performance. The study revealed that the depth of cut consistently increased with higher pulse time and current values. Additionally, the optimization of process parameters for the EDM process using a copper electrode was explored. Metal removal using electro discharge Machining (EDM) is primarily achieved through melting. The reported experimental results indicate an absence of melting, even during short pulses with a discharge duration of 5 seconds, despite their sensitivity to temperature variations. This is because short pulses do not provide sufficient time for the metal to heat up effectively (equivalent to approximately 45 minutes), leading to minimal or no melting. In the EDM parameters used, the depth of cut increased with higher voltage levels (140 V to 240 V), current (Ip) values (12 A, 24 A, 50 A), pulse-on time (Ton) durations (100 ms, 200 ms, 400 ms), and pulse-off time (Toff) intervals (3 ms, 6.5 ms, 12 ms). The increase in voltage (140 V to 240 V) and current (Ip: 12 A to 50 A) significantly contributed to the enhanced depth of cut. The ET system utilized for these parameters also showed a consistent increase in the depth of cut with rising voltage and current. Testing confirmed that these parameters positively influenced the depth of cut while simultaneously improving their combined effect. Four parameters—voltage (140 V, 240 V), current (Ip: 12 A), and pulse rates—were evaluated, revealing that as voltage and current increased, the depth of cut and overall performance improved, with gradual adjustments in pulse rates enhancing the process further.