Experimental investigation on electrical discharge machining process with ultrasonic-assisted cryogenically cooled electrode

Abstract

In this work, the effect of process parameters, namely, discharge current, pulse on time, duty cycle and gap voltage, on electrode wear ratio, material removal rate and surface roughness has been studied in electrical discharge machining process using ultrasonic-assisted cryogenically cooled electrode. Analysis of variance and regression analysis have been used to model electrode wear ratio, material removal rate and surface roughness. The analysis reveals that discharge current, pulse on time and duty cycle have significant effect on electrode wear ratio and material removal rate. Discharge current and pulse on time were found to be significant in effecting surface roughness. Confirmation experiments established that predicted values from models were in agreement with experimental findings, and optimal processing conditions have been determined for the responses. A comparative study of electrical discharge machining process using ultrasonic-assisted cryogenically cooled electrode and conventional electrical discharge machining process has been done to establish the efficacy of the new process.