By Yi Qin (Auth.)

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Mechanical properties like Young’s modulus, hardness or strength do not have an influence on the process behavior. Consequently, EDM is especially used for the machining of hard and difficult-to-cut materials such as cemented carbides for punching tools, PCD for cutting inserts or high alloy steels for injection molding tools. The amount of material being removed is influenced by its thermal and electrical properties. Contrary to a high electrical conductivity (Fig. 3-26(a)) that promotes material removal, high thermal conductivity and high melting temperature reduce the material removal (Fig.

It is necessary to consider clear reference sides and to prevent machining operations from different directions due to multiple clamping and connected inaccuracies. At least one outside surface is needed for electrical touching. If possible, subsequent heat treatment should also be prevented due to risk of shape deviations. If heat treatment is still necessary it should be applied before EDM processing. In m-WEDM the workpiece height is limited by the thermal and mechanical stability of the wire electrode which depends on the diameter of the wire.

It isolates the tool electrode [11] from the workpiece electrode to achieve a high current density in the plasma channel. It cools down the heated surfaces of the electrodes and exerts a counter pressure to the expanding plasma channel [12]. Flushing with dielectric fluid removes the particles after the discharge process and prevents developing particle linkages causing process interruptions by short circuit, or damage of the electrodes’ surfaces [13]. There are two main types of dielectric fluids: deionized water and dielectric fluids based on hydrocarbon compounds, also known as dielectric oil.

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