Mechanism analysis of hybrid machining process comprising EDM and end milling

STD 11 alloy steel is an extremely hard and difficult-to-cut material that is used extensively in cutter and die manufacturing for its superior wear resistance. This paper introduces a hybrid machining process (HMP) based on EDM and end milling (EDM-end milling) as an effective method for machining difficult materials. The HMP combines cutting action and an electrical thermal process. The machining mechanism was investigated, and a mathematical model of EDM-end milling is presented. Simulated and experimental cutting results were compared to validate the model. A tungsten carbide end mill was used as a tool electrode to machine STD 11 alloy steel (HRC 60) with different electric energy pulses. The results show that the method greatly improves tool wear and machining efficiency.