Comparison of Gas Assisted Hybrid EDM, Rotary EDM and Conventional EDM Processing of High Carbon High Chromium Die Steel


  • Nishant K. Singh
  • Anand Poras
  • Subrato Das





Dielectric, MRR, EDM, EWR, Helium.


The high carbon high chromium die steel is most widely used in various industrial applications. However, effective machining of high carbon-chromium die steel is extremely difficult due to its high hardness and stiffness. In the present work, comparative analysis of Gas Assisted Hybrid EDM (GAHEDM), Rotary EDM (REDM), and Conventional EDM processes have been done with respect to process responses like electrode wear ratio (EWR), material removal rate (MRR), and surface roughness (SR). Experimentation has been done to the study influence of process factors like discharge current, pulse on time, duty cycle, tool rotation and discharge gas pressure on MRR, EWR and SR. Further, from a comparative study, it has been observed that high MRR, low EWR and low SR are obtained in GAHEDM process in comparison of REDM and EDM processes. Analysis of surface morphology reveals that the formation of recast layer and cracks on the surface are fewer in number on work piece machined by GAHEDM process with respect to specimen machined with REDM and EDM processes. The results show that the use of compressed helium gas in GHEDM process has a positive impact on the machining performance. This process may be used for industrial machining operation.




[1] Singh N K, Pandey P M, Singh K K, Sharma M K, (2016) Steps towards green manufacturing through EDM process: A review. Cogent Engineering 3:1272662.

[2] Ramani M, Cassidenti M L (1985) Inert gas electrical discharge machining. NASA Technol NPO 15660.

[3] Kuineda M. et al. (1991) Improvement of EDM Efficiency by Supplying Oxygen Gas into Gap.CIRP Ann- Manufac Technol, 40: 215-218.

[4] Kunieda M, Yoshida M (1997) Electrical discharge machining in gas.Ann of CIRP 46 (1): 143–156.

[5] Yu Z, Jun T, Kunieda M (2004) Dry electrical discharge machining of cemented carbide.J Matter Process Technol, 149 (1-3): 353-357.

[6] Soni et al. (1994) Microanalysis of debris formed during EDM of titanium alloy and die steel. Wear,177(1): 71-79.

[7] Mohan B, Rajadurai A, Satyanarayana K G (2002) Effect of SiC and rotation of electrode on electric discharge machining of Al-SiC composite.J MaterProcessTechnol, 124: 297-3042.

[8] Kuppan P, Rajadurai A, Narayanan S (2008) Influence of EDM process parameters in deep hole drilling of Inconel 718. Inter J Adv Manufac Technol, 38: 74–84.

[9] Koyano T, Suzuki S, Hosokawa A, Furumoto T (2016) Study on the effect of external hydrostatic pressure on electrical discharge machining.18th CIRP Conference on Electro Physical and Chemical Machining (ISEM XVIII), Procedia CIRP, 42: 46-50.

[10] Aliakabari E, Baseri H (2012) Optimization of machining parameters in rotary EDM process by using the Taguchi method.Inter J Advanc Manufac Technol, 62(9-12): 1041-1053.

[11] Plaza S, Sanchez J, Perez E, Gill R, Izquierdo B, Ortega N, Pombo I (2014) Experimental study on micro EDM-drilling of Ti6Al4V using helical electrode.J Precision Engg, 38 (4): 821-827.

[12] Singh NK, Pandey PM, Singh KK (2016) EDM with Air Assisted Multi-Hole Rotating Tool. Mater Manufac Processes 31 (14): 1872-1878.

[13] Yoshida M, Ishii Y, Ueda T (2017) Study on electrical discharge machining for cemented carbide with non-flammable dielectric liquid: Influence of form of oxygen supplied to dielectric liquid on machining Proc IMechE Part B: J Engg Manufac, DOI: 10.1177/0954405417706995

[14] Chattopadhyaya K D, Verma S, Satsangi P C, Sharma P C (2009) Development of empirical model for different process parameters during rotary electrical discharge machining of copper–steel (EN-8) system.J Mater Process Technol, 209 (3): 1454–1465.

[15] Teimouri R, Baseri H (2012) Effects of magnetic field and rotary tool on EDM performance.J Manufac Process, 14 (3): 316-322.

[16] Koshy P, Jain V K, Lal K (1993) Experimental investigation into electrical discharge machining with rotating disk electrode.J Precision Engg, 15: 6-15.

[17] Srivastava V, Pandey PM (2012) Experimental investigation on electrical discharge machining process with ultrasonic-assisted cryogenically cooled electrode.Proc IMechE Part B: J Engg Manufac,227 (2): 301-314.

[18] Srivastava V, Pandey P M (2012) Performance Evaluation of Electrical Discharge Machining (EDM) Process Using Cryogenically Cooled Electrode.Mater Manufac Processes 27(6): 683-688.

[19] Wang CC, Yan BH. Feasibility study of rotary electrical discharge machining with ball burnishing for Al2O3/6061Al composite. Int J Mach Tools Manuf2000; 40: 1403–1421.

View Full Article:

How to Cite

K. Singh, N., Poras, A., & Das, S. (2018). Comparison of Gas Assisted Hybrid EDM, Rotary EDM and Conventional EDM Processing of High Carbon High Chromium Die Steel. International Journal of Engineering & Technology, 7(3.12), 1154–1160.
Received 2018-08-18
Accepted 2018-08-18
Published 2018-07-20