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Mathematical modelling with experimental correlation for multiple craters dimension, material removal rate and surface roughness in electrical discharge machining

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Abstract

Electric discharge machining (EDM) is a non-conventional machining process, which has gained popularity in the manufacturing industries. In this study, analytical models have been presented to calculate the surface roughness and material removal rate based on multiple-craters geometry. To begin, the geometry of a single crater is calculated that was converted into multiple craters. Following on, the material removal rate (MRR) and average surface roughness were calculated. The model was able to estimate crater depth, width, average roughness and MRR with a deviation of 3–5%, 5–7%, 4–7% and 5–8%, respectively. It was found that as the pulse energy is 20 times greater as compared to the lower capacitance thereof, a deeper crater is realized. The pulse energy becomes quadruple as open voltage upsurges from 60 to 120 V, but the capacitance remains unchanged. The crater depth, on the other hand, does not increase as the open voltage is increased. The crater’s width expands linearly as the capacitance and open voltage increase. This is attributed to the expansion of plasma radius at higher magnitude of pulse energy, causing the crater to widen.

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Acknowledgements

Muhammad Arif Mahmood acknowledges with thanks the European Union’s Horizon 2020 (H2020) research and innovation program under the Marie Skłodowska-Curie, agreement no. 764935.

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Authors and Affiliations

  1. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Kashif Ishfaq & Mudassar Rehman

  2. Laser Department, National Institute for Laser, Plasma and Radiation Physics (INFLPR), Magurele-Ilfov, 077125, Magurele, Romania

    Muhammad Arif Mahmood

  3. Faculty of Physics, University of Bucharest, Magurele-Ilfov, 077125, Bucharest, Romania

    Muhammad Arif Mahmood

  4. Department of Industrial and Manufacturing Engineering (Rachna College), University of Engineering and Technology, Lahore, 54700, Pakistan

    Ahmad Raza Khan

  5. Department of Industry Engineering, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Mudassar Rehman

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Contributions

Conception: K.I. and M.A.M. Literature study: K.I. and M.A.M. Experiments: K.I., M.A.M., A.R.K. and M.R. Writing—review, and editing: K.I., M.A.M., A.R.K. and M.R. Funding acquisition and project administration: M.A.M. All authors have read and agreed to the published version of the manuscript. The authors agree to publish the current version of manuscript.

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Correspondence to Muhammad Arif Mahmood.

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Ishfaq, K., Mahmood, M.A., Khan, A.R. et al. Mathematical modelling with experimental correlation for multiple craters dimension, material removal rate and surface roughness in electrical discharge machining. Int J Adv Manuf Technol 120, 227–236 (2022). https://doi.org/10.1007/s00170-021-08582-2

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