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Electrical discharge machining (EDM) is a nonconventional method that involves melting and vaporizing work materials. It is particularly useful for machining materials that are extremely hard because there is no physical interaction between the tool electrode and workpiece. However, traditional EDM has several drawbacks, including slow material removal rates and subpar surface finishes. To address these concerns, the near-dry EDM (NDEDM) approach has been developed, which uses a two-phase dielectric medium to improve stability compared to conventional EDM. The current study focuses on the use of the NDEDM approach for NIMONIC-90 alloys. Both EDM and NDEDM operations were conducted with careful manipulation of key machining parameters, including the current (Ip), pulse-on time (Ton), and pulse-off time (Toff), while the discharge voltage remained constant. Spark erosion oil was used as the dielectric fluid for EDM, whereas NDEDM used a mixture of liquid and compressed air. The NDEDM setup was augmented with a minimum-quantity lubrication unit (MQL) to produce mist. The evaluation criteria for both methods included material removal rate (MRR), surface roughness (SR), radial overcut (ROC), microscopic image analysis, and comparison. The surface topography was examined using scanning electron microscopy (SEM) in both cases, and crater formation was observed in both scenarios. The design of experiments (DOE) approach was used to systematically alter three variables: current (I), pulse-on time (Ton), and pulse-off time (Toff), based on a central composite design guided by response surface methodology. The results showed that near-dry EDM led to significant improvements, with a material removal rate witnessing an improvement of up to 25%, surface roughness experiencing a 20% reduction, and radial overcut registering a 5.6% increase compared to traditional die-sink EDM. The findings indicated that near-dry EDM yields marked enhancements in the material removal rate and surface roughness compared with conventional die-sink EDM.

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A Comparative Performance Study of Die Sink EDM and Near-Dry EDM Processes in Machining of NIMONIC-90

  • 会议论文

  • 发表日期：

    2026年

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  • M. Muniraju,
  • Gangadharudu Talla,
  • Eslavath Hathi Ram Naik

摘要

Electrical discharge machining (EDM) is a nonconventional method that involves melting and vaporizing work materials. It is particularly useful for machining materials that are extremely hard because there is no physical interaction between the tool electrode and workpiece. However, traditional EDM has several drawbacks, including slow material removal rates and subpar surface finishes. To address these concerns, the near-dry EDM (NDEDM) approach has been developed, which uses a two-phase dielectric medium to improve stability compared to conventional EDM. The current study focuses on the use of the NDEDM approach for NIMONIC-90 alloys. Both EDM and NDEDM operations were conducted with careful manipulation of key machining parameters, including the current (Ip), pulse-on time (Ton), and pulse-off time (Toff), while the discharge voltage remained constant. Spark erosion oil was used as the dielectric fluid for EDM, whereas NDEDM used a mixture of liquid and compressed air. The NDEDM setup was augmented with a minimum-quantity lubrication unit (MQL) to produce mist. The evaluation criteria for both methods included material removal rate (MRR), surface roughness (SR), radial overcut (ROC), microscopic image analysis, and comparison. The surface topography was examined using scanning electron microscopy (SEM) in both cases, and crater formation was observed in both scenarios. The design of experiments (DOE) approach was used to systematically alter three variables: current (I), pulse-on time (Ton), and pulse-off time (Toff), based on a central composite design guided by response surface methodology. The results showed that near-dry EDM led to significant improvements, with a material removal rate witnessing an improvement of up to 25%, surface roughness experiencing a 20% reduction, and radial overcut registering a 5.6% increase compared to traditional die-sink EDM. The findings indicated that near-dry EDM yields marked enhancements in the material removal rate and surface roughness compared with conventional die-sink EDM.