Work

Balancing Productivity and Sustainability in EDM: A Comprehensive Analysis of Energy Consumption and Electrode Degradation

Year: 2025

Type: article

Abstract: Die Sinking Electrical Discharge Machining (EDM) is a manufacturing process for fabricating complex geometries in challenging applications. However, its energy-intensive nature and complex parameter interactions pose challenges in balancing productivity, sustainability, and electrode-wear. This study presents a comprehensive analysis of the energy consumption and electrode degradation in EDM. Utilising an advanced experimental setup with real-time energy monitoring, this study investigated the trade-off between the machining parameters, energy efficiency, and electrode wear. The study employed a simple and standardised electrode geometry and varied EDM parameters, such as discharge current and pulse duration. Comparative analyses between high-current and low-current settings highlighted a critical trade-off: although conservative parameters minimised electrode wear, they drastically increased machining times and energy consumption. In contrast, the optimised high-current settings reduced the machining time by up to an order of magnitude while maintaining acceptable electrode wear levels. Quantitative metrics, such as Specific Energy Consumption (SEC), reinforce these findings. The study outcomes provide practical guidelines for enhancing EDM's operational efficiency and sustainability of EDM in advanced manufacturing sectors.

Source: Machines

DOI: 10.3390/machines13060469

Authors: Sunil Kumar Maurya, Gianni Campatelli, Massimo Veracini, Massimo Arcioni, Dario Clori

Institutions: University of Florence, Baker Hughes (United States)

Language: English

Topic: Advanced Machining and Optimization Techniques

Subfield: Electrical and Electronic Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Responsible consumption and production

Open Access status: gold

Estimated APC paid: $2,896