Processing Performance Improvement in Electrical Discharge Machining of Deep Narrow Groove Using Rounded Corner Electrode

The processing performance of deep narrow grooves by electrical discharge machining (EDM) needs to be further improved, mainly reflected in the serious electrode wear and low processing efficiency. This study firstly conducted a single-factor experiment on electrical parameters to analyze the influence of electrical parameters on electrode length wear and electrode sharp corner wear, respectively. It was found that the increase in pulse width and duty cycle could reduce electrode length wear, but at the same time led to an increase in electrode sharp corner wear. The reason is that bubbles and debris tend to accumulate at the sharp corner of the electrode. It causes short circuits and arcing phenomena, intensifying the sharp corner wear of the electrode. To address this issue, it is proposed to use a rounded corner electrode to facilitate the exclusion of bubbles and debris from the machining gap, reduce the occurrence of short circuits and arcing phenomena, thereby lowering the electrode length and sharp corner wear, and enhancing processing efficiency. Through the simulation of the flow field in the machining gap, it is theoretically proven that the rounded corner electrode can promote the movement of bubbles and debris towards the outlet of the machining gap and slow down the accumulation of bubbles and debris. Through the EDM of deep narrow groove, it is proven that the electrode wear and processing efficiency of the rounded corner electrode are both superior to those of the sharp corner electrode, and the electrode wear and processing efficiency increase with the increase in the rounded corner radius of the electrode. The research results have contributed to improving the performance of deep narrow grooves by EDM.