Investigation and Optimization of Process Performance of Electric Discharge Face Grinding and Its Variants

Abstract

Unconventional machining has emerged as a promising alternative for producing the desired shapes and profiles with the required precision in difficult-to-machine materials. Electrical discharge machining (EDM) is one of the widely employed unconventional machining processes that effectively machines hard materials, regardless of their hardness. newlineThe low efficiency in terms of material removal rate (MRR), inability to generate good surface finish quality of the machined workpiece, and excessive tool wear are the main limitations of the EDM. Moreover, the formation of a recast layer on the newly formed surface adversely affects the mechanical properties and metrology of the workpiece. The restrictions of EDM can be overcome by using hybrid machining processes (HMPs). newlineElectrical discharge grinding (EDG) is a HMP involving EDM and mechanical grinding, which has been recognized as a promising alternative for sweeping the recast layer produced by EDM before it solidifies after machining. The EDG process produces machined components with higher MRR and with better surface finish than the EDM process. newlineThe EDG process can be implemented in three different configurations depending upon the grinding wheel position and rotation. The configurations can be: electrical discharge face grinding (EDFG), electrical discharge surface grinding (EDSG), and electrical discharge cutoff grinding (EDCG).