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Study of electrical discharge machining of narrow grooves with foil tool electrode

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Abstract

The narrow groove structure is employed in a number of industries, including the prefabrication of narrow grooves before the workpiece is cracked. It is critical to do research on how to achieve efficient and cost-effective narrow groove processing. A novel technique of foil electrode EDM machining for narrow grooves was developed, and the flow field models of the discharge gap under the different injection methods were first simulated. The experimental study of pulse voltage, pulse frequency, duty cycle, and feed speed was carried out. The single-factor experiment showed that when the pulse voltage was 100 V, the pulse frequency was 25 kHz, the duty cycle was 40%, and the feed speed was 8 µm/s. After optimizing the parameters, a narrow groove with good geometrical dimensions and quality was obtained with an average width of 214.30 µm, an average depth of 642.33 µm, and a depth ratio (groove depth/(groove depth + wear depth)) of 0.708. An insulation treatment experiment was carried out for the discharge phenomenon on the side of the foil electrode that occurred during the experiment. The experiment indicated that the insulation treatment avoided the discharge on the side of the electrode to a certain extent and improved the quality of the groove.

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Funding

This work was supported by the Guangdong Provincial Science and Technology Project (2017B090913004) and the National Natural Science Foundation of China (51705088).

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Authors and Affiliations

  1. School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou, 510006, China

    Junfei Li, Guokang Su, Xiaolei Chen, Guixian Liu & Yongjun Zhang

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  1. Junfei Li
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  2. Guokang Su
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  3. Xiaolei Chen
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  4. Guixian Liu
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  5. Yongjun Zhang
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Contributions

Junfei Li: conceived the study and wrote the manuscript. Guokang Su: supervision, Resources, and Methodology. Xiaolei Chen: software, and investigation. Guixian Liu: supervision and writing reviews and editing. Yongjun Zhang: supervisions on experimentation and experimental data discussion. All authors read and approved the final manuscript.

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Correspondence to Guokang Su.

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Li, J., Su, G., Chen, X. et al. Study of electrical discharge machining of narrow grooves with foil tool electrode. Int J Adv Manuf Technol 128, 5405–5423 (2023). https://doi.org/10.1007/s00170-023-12273-5

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