Machining efficiency of powder mixed near dry electrical discharge machining based on different material combinations of tool electrode and workpiece electrode

Powder mixed near dry electrical discharge machining (PMND-EDM) is a novel electrical discharge machining (EDM) process. It is proposed to further improve the machining efficiency of dry EDM. The principle of material removal in PMND-EDM is illustrated and its deionization principle is proposed. The influence of residual heat on MRR is analyzed. The concept of superfluous residual heat is proposed. The material removal rate (MRR), the main index of machining efficiency for PMND-EDM process, is researched. Single factor experiments are performed to get effect of peak current, pulse on time, pulse off time, flow rate, tool rotational speed, air pressure and powder concentration on MRR under different material combinations of tool electrode and workpiece electrode. Thermal phenomena in PMND-EDM are illustrated. Effect of each process parameter on MRR of PMND-EDM is gotten and analyzed based on the deionization principle of PMND-EDM. Differences in MRR under different material combinations are found out. Brass tool electrode and W18Cr4V workpiece gain higher MRR under most of discharge conditions, while the superiority of copper tool electrode and 45 carbon steel workpiece in MRR arise when there is improper heat dissipation. The difference is analyzed based on the deionization principle of PMND-EDM.