Performance Enhancement Through Slotted Tool in Rotary Tool Electrical Discharge Machining Process

Electrical discharge machining (EDM) is a popular but nonconventional machining technique for hard, complex, and challenging-to-machine materials. This process is significantly influenced by designing the tool and the machining parameters. In this study, a slotted tool has been designed and its machining performance investigated in terms of machining responses. The main objective is to improve material removal rate (MRR), tool wear rate (TWR), and surface finish. This slotted tool helps in more efficient debris removal from the interelectrode gap and reduces the chances of formation of secondary discharge. Also, the comparison study of slotted tool design with traditional solid tools in rotary tool EDM and stationary tool EDM has been done for experimental findings to show a significant improvement in MRR. Furthermore, studies of surface roughness reveal an enhanced finish, which is explained by the slotted tool’s ability to provide more reliable and effective discharge conditions. The rotary tool EDM with slotted tool produces 13.39% and 48.29% higher MRR and 6.95% and 31.33% lower Ra values compared with the RT-EDM with solid tool and stationary EDM with solid tool, respectively.