Operation parameter optimization for fabrication of a narrow, deep hole in metal by electrical discharge machining using a dielectric-encased wire electrode

The electrical discharge machining (EDM) method is frequently employed to fabricate a narrow, deep hole in metal. A new EDM system using as the tool electrode a wire encased in a dielectric pipe, which serves as a jacket, was previously developed, but the operation parameters of the system were not systematically optimized. In this study, the optimum width of the current pulse applied, the optimum distance between the tips of the electrode and the jacket, and the optimum vibration amplitude of the electrode feed control were determined. This optimization provides a ∼35% higher machining speed and ∼40% less electrode wear than the parameters used in the previous study.