Process Optimization In Automated Hybrid Edm Using Rotational Workpiece Fixtures

Abstract

Electrical Discharge Turning (EDT) represents an innovative and efficient approach that merges the principles of Electrical Discharge Machining (EDM) with conventional turning operations. This hybrid method is particularly suitable for machining intricate cylindrical components made from difficult-to-machine materials such as H13 die tool steel. The core aim of this study is to evaluate the machinability of H13 steel using a specially designed rotating workpiece fixture mounted on a die-sinker EDM.

To replicate turning-like conditions during the EDM process, a custom rotational attachment was developed. The experimental framework was structured using Taguchi’s Design of Experiments (DOE) method, with key process variables including pulse on time, pulse off time, peak current, and rotational speed. These parameters were systematically varied to analyze their influence on surface roughness (SR). The findings indicated that peak current was the most influential factor affecting on surface finish, followed by pulse on time.

An optimal surface roughness value of 7.647 µm was achieved under specific parameter settings. Overall, this research confirms that EDT, when implemented with a rotating fixture, offers a promising advanced manufacturing technique for producing high-precision cylindrical components from tough tool steels.