Increasing the Performance of EDM Process Using Tool Rotation Methodology for Machining AISI D3 Steel

Electric Discharge Machining is one of the most accurate unconventional manufacturing processes used for cutting or creating intricate shapes in very hard or difficult-to-cut, electrically conducting materials. The adoption of tool rotation methodology increases the material removal rate by increasing the spark efficiency and effective debris clearing.The experiments have been performed on AISI-D3 Steel. Results show that the tool rotation phenomenon significantly improves the average MRR and surface finish by 41% and 12% respectively. Moreover, the final surface is more uniform in structure with less number of microcracks and thinner recast layer as compared to the stationary tool EDM.