Machining Accurate Deep Curved Forms on Tungsten Carbide–Cobalt (WC-Co) Eliminating Tool Wear in the Electrical Discharge Turning Operation

Machining hard metals presents various challenges, especially with materials like WC-Co, known for their exceptional hardness and wear resistance, making them ideal for cutting tools. Among machining methods, Electrical Discharge Machining (EDM) stands out for its ability to machine hard materials with no mechanical damage, which is critical for machining fragile components. For form shape machining symmetrical parts like WC-Co bars, electrical discharge turning (EDT) could be applied. Despite its potential, limited research exists on deep form turning of hard metals like WC-Co using EDT. This study addresses that gap by comparing the final geometrical outcomes of two EDT setups: vertical and horizontal tool electrode configurations. Additionally, the impact of workpiece rotational speed on surface quality was examined. Results showed that the vertical tool electrode setup produced more accurate geometries and smoother surfaces. Furthermore, increasing the workpiece’s rotational speed improved flushing efficiency, resulting in reduced surface roughness and a cleaner machined surface.