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Applicant:
Indian Institute of Technology (IIT) Roorkee 
Title:
An electrode for removal of debris during electric discharge machining 
Inventor(s):
Inderdeep Singh and Mr. Ravinder Kumar 
Applicant:
Indian Institute of Technology (IIT) Roorkee 
Application type:
Applied - 2017-02-17 
Application Number:
201711005674  
Applied at:
India 
Entered by:
Indian Institute of Technology (IIT) Roorkee 
Abstract:
During electric discharge machining, the eroded material from the tool and the work piece need to be flushed out from the discharge area, otherwise, it would create the problem of arcing and short circuiting. Short circuiting results from metal-to-metal contact between the work piece and tool. Short circuit pulse does not generate electrical spark; hence, no material removal takes place. Arcing is an unwanted phenomenon causing continual material removal due to improper deionization of the dielectric fluid resulting in damage to the work piece and tool material. Flushing is an important factor, which helps in removing the debris from the machining zone, and also helps in preventing the occurrence of arcing and short circuiting. But at higher depth values, the flushing becomes ineffective, causing no machining beyond a critical depth. The following problems are identified during electric discharge drilling provided with jet flushing- • Accumulation of debris at higher depths • Phenomena of arcing and short circuiting • Holes of low aspect ratio Modification of electrode geometry can also be a feasible alternative for avoiding arcing and short circuiting. The literature, related to the tool electrodes featured with the slots and helices, confirms the easy escape of debris from the inter electrode gap through the featured slots and helices. A novel tool has been designed in order to improve the performance of EDM by improving the debris removal from the inter electrode gap (sparking zone). The proposed tool is a standard cylindrical rod drilled with a series of inclined through holes. The inclined holes act as a pathway for the debris. The bubbles (along with the debris) enter from the lower side of the featured hole and leaves from the other side. The proposed tool electrode has been shown in figure 1.The angle as well as the diameter of the pathway has been optimized for maximum MRR and minimum TWR. The effect of tool rotational speed has also been evaluated. The electrode with pathway angle of 15°, pathway diameter of 0.4 mm and tool speed of 1000 rpm provides highest MRR and lowest TWR. Table 1 compares the maximum depth achieved among featured electrodes and the solid electrode. It is very interesting to know that the depth achieved by proposed tool electrode is 390% higher as compared to the solid tool electrode. Moreover, the use of the proposed electrode completely eliminates the need of flushing during the process, making it a self-flushing electrode.  

 
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