Improving the productivity of electrical discharge machining process by using multi-thin electrodes

In the electrical discharge machining (EDM) process, thin tool-electrodes are constantly gaining much importance due to the growing demand for manufactured parts with more functional characteristics and with small geometrical dimensions for applications in many work fields. This article highlights the utilization of the EDM process using multi-thin tool-electrodes with diameters of 0.3, 0.5 and 1.0 mm and different lateral spaces (3.0 to 0.8 mm). This machining technology requires using more than one tool-electrode in the same time for fabrication of microholes with high process performance and productivity. One of the principal aims of the experimental investigations of this article is to determine the minimum lateral spacing required between tool-electrodes for reducing process costs under acceptable conditions related to the surface of the machined workpiece. Tool-electrode wear and material removal rate are investigated as result of these experiments under adjustment of different process parameters. The beneficial effects of this machining process are also highlighted. The first experimental results of EDM with multi-thin tool-electrodes indicate some technical and economical advantages as a machining process.