An investigation on dimensional accuracy of EDM deep hole using multi-hole interior flushing electrode

Abstract

Improper flushing of dielectric fluid adversely affects the dimensional accuracy produced in EDM deep hole process. This paper investigates the dimensional accuracy (e.g. roundness error and gap clearance) in EDM deep hole process of AISI P20 tool steel. The inner flushing electrode is newly proposed in this study, using the multi-hole interior flushing technique coupled with electrode rotation. The results showed that the multi-hole interior flushing with electrode rotation improves the deviation of roundness error due to improved flushing. In addition, using multi-hole interior flushing with electrode rotation provides the cylindrical shape in gap clearance. Finally, a more powerful flushing technique is achieved with newly purposed multi-hole interior flushing technique on roundness error and gap clearance, respectively.