Synchronous-spark series-multi-channel electrical discharge machining

Generating multiple discrete discharges per voltage pulse application is an intriguing approach to enhancing the low material removal rate (MRR) inherent to electrical discharge machining (EDM). To this end, this paper presents a novel, scalable series-EDM system that generates synchronous unipolar discharges across multiple channels per voltage pulse, which enables the concurrent machining of several workpieces. When tested on a twin tool-work pair, this system increased MRR by 1.75 times and doubled the power efficiency, relative to a conventional single-channel system. This highlights its significant potential in addressing the low MRR and the energy-intensive nature of EDM.