Effects of non-electrical parameters on the characteristics of discharge craters and machining performance in short electrical arc milling

During electrical discharge machining (EDM), the process parameters greatly influence the discharge characteristics and machining performance, including electrical and non-electrical parameters. As a new EDM method, short electrical arc milling (SEAM) is plagued by frequent short circuits, poor debris removal, and low energy-transfer efficiency. Therefore, this paper investigated the influence of non-electrical parameters (electrode material, working medium, and electrode rotation) on the crater characteristics, machining efficiency, and electrode wear. The micromorphological characteristics of the workpiece were explored. The results suggested that non-electrical parameters compressed and fractured the plasma channels, thus changing the effect of EDM. The air-tap water medium and electrode rotation promoted debris removal and arc breaking, which prevented the arc from ablating the workpiece. When GH4099 alloy was machined with a copper electrode, the workpiece surface quality and machining efficiency were high, and the thickness of the heat-affected zone was small. This work reveals the characteristics of short electric arc discharge and provided a theoretical basis for the efficient and high-quality machining of difficult-to-cut materials by SEAM.