Title: A comprehensive experimental analysis of vibration-assisted electrical discharge machining of Bohler K110 steel

Authors: Mahmoud Assem; Magdy Samuel; Sara A. El-Bahloul

Addresses: Mechatronics Department, Faculty of Engineering, Horus University, Egypt ' Production and Mechanical Design Engineering Department, Faculty of Engineering, Mansoura University, Egypt ' Production and Mechanical Design Engineering Department, Faculty of Engineering, Mansoura University, Egypt; Faculty of Engineering, New Mansoura University, Egypt

Abstract: Vibrations assisted electrical discharge machining (V-EDM) has emerged as a potent machining methodology capable of surmounting the inherent strength or hardness limitations encountered in the processing of diverse materials. Despite the well-recognised versatility of EDM, its pervasive utilisation has been impeded by constraints pertaining to lower material removal rate (MRR) and protracted machining time (MT). This study addresses this prevailing industrial challenge by endeavouring to augment the efficiency of EDM through the strategic incorporation of vibrations into the machining of Bohler K110 Steel. The investigation conducted herein systematically explores the ramifications of applying vibrations to both the dielectric fluid (DF) and the WP. The empirical findings unequivocally establish that the integration of vibrations engenders a substantial enhancement in MRR. Moreover, an elevated vibration frequency (VF) emerges as a particularly efficacious parameter, manifesting a noteworthy escalation in MRR and, consequently, a commensurate reduction in MT. Concurrently, this innovative approach exerts a discernible influence on surface roughness (SR), thereby underscoring a comprehensive amelioration in the overall quality of machining outcomes. This experimental validation substantiates the viability and practicality of V-EDM, thereby offering a promising avenue for addressing the efficiency constraints historically associated with conventional EDM methodologies.

Keywords: V-EDM; Bohler K110 steel; vibration frequency; VF; material removal rate; MRR; machining time; MT; surface roughness; SR.

DOI: 10.1504/IJMMM.2024.141485

International Journal of Machining and Machinability of Materials, 2024 Vol.26 No.3, pp.281 - 292

Received: 18 Jan 2024
Accepted: 10 Apr 2024
Published online: 17 Sep 2024 *

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