Electric discharge drilling with gas-assisted multi-hole slotted tool

This paper proposes the use of a novel electrode containing modified design explicitly intended to promote gas-assisted tool rotation-induced debris removal. The proposed tool was observed to be efficient in dispensing the accumulation of eroded materials from the discharge gaps. In this work, the influence of process parameters like discharge current, tool speed, gas pressure, pulse duration, and duty cycle has been investigated on output responses: material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). A comparative study of the output responses was made with a solid rotary tool and the gas-aided multi-hole slotted tool. The outcome reveals that the application of the multi-hole slotted tool increased the MRR in AAEDD by 40-80%. Besides this, the EWR decreased in AAEDD by 17–25% compared to REDD. Moreover, the SR of the AAEDD process was comparatively higher (9-15%) than that of the REDD process. It has been found less surface crack, micro pores and recast layers on specimens machined by the AAEDD process in comparison to the REDD process. The present work proposed a novel method for improving the machining performance by improving the flushing efficiency of the machining gap on the way to improve the material removal mechanism.