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August 15, 2026Journal of Manufacturing and Materials ProcessingOpen Access

Dependence of Discharge Energy and Material Removal Dynamics on Tool Electrode–Workpiece Material Combinations in Electrical Discharge Machining

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Authors

CLChen LiuXYXiaodong YangXYXiaodong Yang

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Overview

Simulation and experimental study reveals that electrode-workpiece combinations govern heat flux and crater morphology in electrical discharge machining, indicating pathways for process optimization.

Key Points

  • To determine how tool electrode and workpiece material combinations influence arc plasma characteristics, discharge energy distribution, and material removal dynamics during electrical discharge machining.
  • Simulated arc plasma characteristics and thermo-hydrodynamic material removal behavior under positive polarity across multiple material combinations.
  • Tested a copper electrode with 304 stainless steel, Ti-6Al-4V, and Inconel 718 workpieces, and compared copper versus tungsten electrodes on 304 stainless steel.
  • Validated theoretical models using experimental high-speed imaging and crater morphology measurements.
  • Material combinations significantly altered anode heat flux and energy distribution, with 304 stainless steel displaying the highest heat flux and Inconel 718 absorbing the highest energy distribution ratio.
  • Crater depth correlated strongly with heat flux magnitude, whereas crater diameter was governed jointly by heat flux radius and melt flow dynamics.
  • Varying the cathode tool material between copper and tungsten produced only minor effects on discharge energy and removal dynamics.

Cite This Study

Liu et al. (2026) studied this question.

synapsesocial.com/papers/6a8019ce75c2e31742c85f91https://doi.org/10.3390/jmmp10080294
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