Improvement of machining time in micro-EDM with workpiece vibration and graphite powder mixed in dielectric fluid

Improper flushing of debris in micro-EDM processes has created more frequent short-circuiting between a tool electrode and a workpiece resulting in longer machining process. Longer machining time (34 min) is required only to fabricate a blind hole with 500 μm of depth. In order to solve this problem, powder suspended dielectric fluid and workpiece vibration have been introduced into micro-EDM system in order to reduce the machining time. The introduction of graphite powder suspended dielectric fluid at concentration of 10 g/L has reduced the machining time up to 5 times faster than machining time in pure dielectric fluid. Whilst, the application of vibration on the workpiece has sped up the machining time up to 3 time faster than the machining process without workpiece vibration. The results conclude that the introduction of graphite powder and the application of workpiece vibration have improved the machining stability, results in a significant reduction of machining time.