Electrical discharge machining of Ti6Al4V with a bundled electrode

Lin Gu, Lei Li, Wansheng Zhao, K. P. Rajurkar

Research output: Contribution to journalArticlepeer-review

144 Scopus citations


The aim of this study is to investigate an efficient Ti6Al4V electrical discharge machining (EDM) process with a bundled die-sinking electrode. The feasibility of machining Ti6Al4V with a bundled electrode was studied and its effect on EDM performance was compared experimentally using a solid die-sinking electrode. The simulation results explain the high performance of the EDM process with a bundled electrode by through the use of multi-hole inner flushing to efficiently remove molten material from the inter-electrode gap and through the improved ability to apply a higher peak current. A 3-factor, 3-level experimental design was used to study the relationships between 2 machining performance parameters (material removal rate: MRR, tool wear ratio: TWR) and 3 machining parameters (fluid flow rate, peak current and pulse duration). The main effects and influences of the 2-factor interactions of these parameters on the performances of the EDM process with the bundled electrode are discussed.

Original languageEnglish (US)
Pages (from-to)100-106
Number of pages7
JournalInternational Journal of Machine Tools and Manufacture
Issue number1
StatePublished - Feb 2012


  • Bundled electrode
  • Computational fluid dynamics
  • EDM
  • Multi-hole inner flushing
  • Ti6Al4V

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


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