Effect of debris distribution on wall concavity in deep-hole EDM

In deep-hole electrical discharge machining, the electrode jump height and hence the movement of the machining debris inside the side gap affect the wall concavity of the machined holes. In this study, the dielectric fluid flow and the debris distribution in the machining gap caused by electrode jump is analyzed to understand the wall concavity phenomenon of the holes using a computational fluid dynamics (CFD) simulation program. Fluid flow and debris-fluid interaction under low and high electrode jumps are examined and compared. The accuracy of the predictions obtained by the numerical calculation is assessed through comparisons with experimental data.