Title: Vibration-assisted electrical discharge machining of Bohler K110 steel: an industrial application and optimisation

Authors: Mahmoud Assem; Magdy Samuel; Sara A. El-Bahloul

Addresses: Mechatronics Department, Faculty of Engineering, Horus University, Egypt ' Production and Mechanical Design Engineering Department, Faculty of Engineering, Mansoura University, Egypt ' Production and Mechanical Design Engineering Department, Faculty of Engineering, Mansoura University, Egypt; Faculty of Engineering, New Mansoura University, Egypt

Abstract: Vibration-assisted electrical discharge machining is an influential machining technique that offers the ability to effectively machine various materials, regardless of their strength or hardness. However, the inherent limitations of electrical discharge machining (EDM), such as the lower material removal rate (MRR) and increased machining time (MT), restrict its widespread applications. To address these challenges and enhance the efficiency of the EDM process, this research proposes the integration of vibration with EDM for machining Bohler K110 steel, a material frequently encountered in industrial settings. The study investigates the influence of vibration by applying it solely to the dielectric fluid (DF) and solely to the workpiece (WP), as well as simultaneously to both WP and DF. The findings demonstrate that the introduction of vibration into the EDM process significantly improves the MRR. Moreover, increasing the vibration frequency results in a higher MRR, consequently reducing the overall MT. The proposed technique showcases its efficacy through the simultaneous application of vibration to both the WP and DF, employing a vibration frequency of 80 Hz.

Keywords: vibration-assisted EDM; Bohler K110 steel; material removal rate; MRR; vibration; machining time; frequency.

DOI: 10.1504/IJMMM.2023.136034

International Journal of Machining and Machinability of Materials, 2023 Vol.25 No.3/4, pp.432 - 442

Received: 23 Mar 2023
Accepted: 21 Jul 2023
Published online: 12 Jan 2024 *

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