Ultra-high-speed combined machining of electrical discharge machining and arc machining

In this study, a new kind of ultra-high-speed combined machining of electrical discharge machining and arc machining was developed. A rotating graphite electrode and a workpiece were connected to the negative and positive poles of the power supply, which consisted of a pulse generator and direct current power. Efficient electrode injection flushing and side flushing yielded a noncontinuous arc and achieved a maximum material removal rate of 12,688 mm³/min at a relative electrode wear ratio of 2.3% during quenched mold steel machining. The characteristics of the combined machining process were determined by studying the effects of flushing, rotation, peak current, and peak voltage on process performance, such as on the material removal rate and relative electrode wear ratio. The recast layer and surface defects were also investigated. The result shows that the novel combined machining process has great potential to reduce machining time.