Title: Enhancing the performance of electrical-discharge machining via various planetary modes

Authors: T.A. El-Taweel, M.S. Hewidy

Addresses: Faculty of Engineering, Department of Production Engineering and Machine Design, Menoufiya University, Shebin El-Kom, Egypt. ' Faculty of Engineering, Department of Production Engineering and Machine Design, Menoufiya University, Shebin El-Kom, Egypt

Abstract: Planetary EDM is the best option when it comes to the reduction of machining time required to achieve the specifications of dimensional accuracy and surface finish of an EDM operation. In this paper, the validity of circular planetary EDM with two different modes namely, spiral and helix modes are assessed from the point of view of metal removal rate, machining time surface finish and dimensional accuracy. The effects of the tool eccentricity with different circular planetary modes on the metal removal rate, machining time, surface roughness, machined diameter and roundness were presented. Planetary motion proves its powerfulness in controlling the workpiece shape for various dimensional tolerances and surface quality by the use of the same tool. Increasing the tool eccentricity for the helix mode improved the roundness error by about 34% higher than that for the spiral one (spiral-10). The results of the analysis will be useful and of practical application for the user of the EDM die sinking process in order to adjust the dimensional accuracy, machining time and final surface quality.

Keywords: nontraditional machining; electrical discharge machining; EDM die sinking; electro-discharge machining; planetary movement; material removal rate; MRR; surface roughness; dimensional accuracy; roundness error; surface finish; machining time; surface quality.

DOI: 10.1504/IJMMM.2009.023397

International Journal of Machining and Machinability of Materials, 2009 Vol.5 No.2/3, pp.308 - 320

Published online: 20 Feb 2009 *

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