Comparison of Experimental and Theoretical Results of Tool Wear Rate in Electrical Discharge Machining

Abstract

Though electrical discharge machining (EDM) process is capable for complex and precise machining of materials irrespective of their hardness, it has certain limitations like low material removal rate (MRR), high tool wear rate (TWR), etc. which restrict its application areas. In EDM, material removal from workpiece and tool takes place by means of sparking between them which is a quite complex process. So, it is difficult to predict material removal rate and tool wear rate for various process parameters. In this paper, the experimental data available in existing literature are used to derive empirical formulas for heat distribution factor, crater radius and depth. The tool wear rate is calculated based on these formulas and validated with experimental results. For the selection of optimum process parameters, the proposed theoretical model can be used in EDM process.