A Mathematical Model to Assess the Material Removal Rate during Gas-Assisted Electrical Discharge Drilling Process

Abstract

This research work investigates the use of Gas-Assisted Electrical Discharge Drilling (GAEDD) of high carbon-chromium die steel. The poor material removal rate (MRR) is one of the profound drawbacks of the traditional Electrical Discharge Drilling (EDD) process. Hence, over the years researchers have been feeling the requisite to develop an advanced strategy that can enhance the MRR. This study has examined the utilization of compressed gas in conventional EDM under the constraint state to assess MRR. The impact of procedure parameters likedischarge current, pulse on time, duty cycle, electrode speed, and discharge gas pressure, on MRR, has been explored too. In addition, Variance Analysis (ANOVA) was performed to determine the significant parameters affecting the MRR. During the examination, a mathematical model was established MRR employing Buckingham π-theorem while the GAEDD was being applied. The experiment and anticipated values of the model show a noteworthy impact of the coefficient of thermal expansion in GAEDD of high carbon-chromium steel. In addition, the Response Surface Method (RSM) model has also been evolved. The comparative analysis of the models developed shows considerable agreement in anticipation. Moreover, the semi-empirical model appears to be even more adaptable especially in comparison to the RSM-based model. In fact, the conclusion of this work is that the dimensional analysis model is an effective and reliable strategy to precise EDD response prediction.