Prediction of Material Removal Rate in Die-Sinking Electrical Discharge Machining

This project proposes a new model for material removal rate (MRR) of conductive materials using die-sinking electrical discharge machining (EDM). Five different engineering materials were used in this study. Small holes were drilled by EDM and the hole dimensions were measured to determine the MRR on each material. The process parameters and material thermal properties were used to derive the empirical model. While the existing model predicts MRR with ~1000% error, the new model is much more accurate and can predict the MRR to ~ 70%