Experimental investigation on feasibility of using spherical-tip tool electrodes in EDM for rough machining-machining of rectangular pockets

Abstract

In this study, feasibility of widely used spherical tip tool electrode for machining rectangular pockets instead of a model to form cavity on the work piece for rough machining in Electric Discharge Machining (EDM) was investigated. In CNC EDM machine, two alternative tool paths which gives the changes of the tool electrode geometry were examined using rough machining parameters provides minimum tool wear and maximum material removal rate. Electrode tools have been measured with optoTOP-HE 3B optical measurement system before and after manufacturing with EDM. Center coordinates of spherical electrodes, tool wear and deviation of machined cavities from expected surfaces have been determined from 3D data using Rapidform 2004 PPS software. Moreover, a basic algorithm of a CNC EDM CAM program is proposed for machining rectangular pockets. The accuracy of the algorithm which can find the electrode radius and the tool compensation deviations has been verified with comparing simulation and experimental results. © 2019 Gazi Universitesi Muhendislik-Mimarlik. All rights reserved.