Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge side flushing multi-aperture to improve performance surface integrity. pulse on-time, off-time, current, rotation. Response methodology desirability function used optimize parameters. results showed that rotation positively correlated rate. was inversely on-time but current. Gap optimal condition 100 µs 20 15 A 70 rpm rotation; 130 µs, 2 A, rpm. novelty this lies in use performance, enable more uniform GC profile, minimize incidence recast layer.