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<p>Due to its poor heat conductivity and tendency to harden, Inconel 825 is exceedingly challenging to machine using traditional drilling process. Any hard and brittle electrically conductive material may be machined using the well-known method of electrical discharge machining. The flushing conditions in Inconel 825 EDM drilling have been improved in this work using an extra setup that rotates the tool electrode. By varying the input current, tool rotation speed, pulse on time, and voltage through experiment based on RSM optimum custom design. The experimental findings show that MRR and TWR are higher at high tool RPM. The MRR increases by around 39.53 % and the SR decreases by about 40.02 % when tool rotation is increased from 0 to 900 RPM at the expense of a somewhat increased tool wear. Additionally, SEM was used to inspect the hole surface, the quality of the surface was increased with the rotating tool.</p>

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Comparative analysis of rotary and stationary tool EDM for improved machinability of Inconel 825

  • 期刊论文

  • 发表日期：

    2026年4月9日

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  • Amit Kumar,
  • Sudhanshu Kumar,
  • Mohan Kumar Pradhan

摘要

Due to its poor heat conductivity and tendency to harden, Inconel 825 is exceedingly challenging to machine using traditional drilling process. Any hard and brittle electrically conductive material may be machined using the well-known method of electrical discharge machining. The flushing conditions in Inconel 825 EDM drilling have been improved in this work using an extra setup that rotates the tool electrode. By varying the input current, tool rotation speed, pulse on time, and voltage through experiment based on RSM optimum custom design. The experimental findings show that MRR and TWR are higher at high tool RPM. The MRR increases by around 39.53 % and the SR decreases by about 40.02 % when tool rotation is increased from 0 to 900 RPM at the expense of a somewhat increased tool wear. Additionally, SEM was used to inspect the hole surface, the quality of the surface was increased with the rotating tool.