Investigation on Reduction of Tool Wear in Electrical Discharge Finishing Processes with Graphite Tool Electrodes

In order to meet the increasing demand for products with complex geometries, the investigation of the use of novel materials for Electrical Discharge Machining (EDM) processes is necessary. In the case of Sinking Electrical Discharge Machine (S-EDM) it has been proven that the use of graphite tool electrodes enables a high material removal rate while maintaining a low relative tool wear in roughing operations. However for finishing operations, copper is still the most used material due to its lower relative tool wear. Nevertheless, the manufacturing of graphite tool electrodes with complex geometries is more cost-effective in comparison with copper tool electrodes. This makes graphite a suitable alternative material for EDM finishing operations, if the parameters used ensure a low relative tool wear whilist achieving the desired surface roughness in adequate machining times.