Effect of process parameters on the performance of EDM process with ultrasonic assisted cryogenically cooled electrode

In this work the parametric study on EDM process using ultrasonic assisted cryogenically cooled copper electrode (UACEDM) during machining of M2 grade high speed steel has been performed. Electrode wear ratio (EWR), material removal rate (MRR) and surface roughness (SR) was the three parameters observed. Discharge current, pulse on time, duty cycle and gap voltage were the controllable process variables. The effect of process variables on EWR, MRR and SR has been analyzed. The MRR, EWR and SR obtained in EDM process with normal electrode, cryogenically cooled electrode and ultrasonic assisted cryogenically cooled electrode have been compared. EWR and SR were found to be lower in UACEDM process as compared to conventional EDM for the same set of process parameters, while MRR was at par with conventional EDM process. The surface integrity of work piece machined by UACEDM process has been found to be better as compared to conventional EDM process. The shape of the electrode has also been measured and it was found that the shape retention was better in UACEDM process as compared to conventional EDM process. Thus in the present work UACEDM process has been established to be better than conventional EDM process due to better tool life, tool shape retention ability and better surface integrity.

► EDM with ultrasonic assisted cryogenically cooled electrode (UACEDM) has been successfully performed.
► The electrode wear ratio and surface roughness is significantly lower in UACEDM process in comparison with conventional EDM process.
► Material removal rate in UACEDM is at par with that of conventional EDM.
► The surface integrity is better in UACEDM process as compared with conventional EDM process.
► The out of roundness of electrode in UACEDM process is lesser than the out of roundness of electrode used in conventional EDM.