Die-sinking electrical discharge machining with oxygen-mixed water-in-oil emulsion working fluid

Abstract

Water-in-oil emulsion has been proposed as the working fluid of die-sinking electrical discharge machining in our previous research. Compared with the traditional mineral oil–based working fluid, the water-in-oil emulsion was more environmentally benign and efficiency. This study presents a new method of die-sinking electrical discharge machining that uses oxygen-mixed water-in-oil emulsion as the working fluid. Experimental results showed that the material removal rate can be highly improved, and the relative electrode wear ratio can be significantly reduced by mixing oxygen into the water-in-oil emulsion. The recast layer was much thinner with this oxygen-assisted machining method.