Geometric modeling of the linear motor driven electrical discharge machining (EDM) die-sinking process

Based on Z-map method, in this paper the development of a geometric model for the linear motor equipped EDM die-sinking process is described. Firstly discussed are the advantages and benefits of the introduction of the linear motor into EDM die-sinker. The current model has been employed to calculate the minimum gap distance for sparks to occur and to analyze the possibility of spark generation between the workpiece and electrode surfaces. Also calculated is the crater formed by a single spark. The final machined surface topography is predicted. The influence of peak current and discharge duration on the average surface roughness is simulated. The experiment has been conducted to study the effects of machining conditions as well as to verify the effectiveness of the developed geometric model.