Electrical Discharge Machining, Aluminum alloys, Material Removal Rate, Surface Roughness, pulse-on current and time, White Layer, Analysis of Variance.


Electrical Discharge Machining (EDM) is a non-conventional machining process, which allows the machining of any electrical conductive material, regardless its mechanical properties, with high dimensional accuracy, and in complex shapes and geometries. EDM widely utilized by modern industry, taking advantage of its unique inherent capabilities. Aluminum alloys find extensive use in numerous applications, and their machining consist an interesting topic, with tangible industrial interest. The current study presents an experimental investigation of machining Al6063 alloy with EDM. A full scale experiment was conducted, with control parameters the pulse-on current and time. The productivity of the process calculated based on the Material Removal Rate (MRR), while the Surface Roughness of the machined surfaces was estimated in terms of Ra and Rt. For these performance indexes Analysis Of Variance was performed and semi-empirical relations that correlate machining parameters with obtained results were proposed. Finally, the cross sections of the specimens were observed in optical microscopy, in order the formation of the White Layer to be studied.

Author Biographies

Emmanouil L. Papazoglou, National Technical University of Athens, (NTUA)

National Technical University of Athens, (NTUA), Department of Manufacturing Technology, Master of Science, Greece

Nikolaos E. Karkalos, National Technical University of Athens, (NTUA)

PhD Student, National Technical University of Athens (NTUA), Department of Manufacturing Technology, Greece

Angelos P. Markopoulos, National Technical University of Athens, (NTUA)

Professor, National Technical University of Athens (NTUA), Department of Manufacturing Technology

Panagiotis Karmiris-Obratański, AGH University of Science and Technology in Kraków

Doctorant Doctoral Schools of AGH University of Science and Technology in Kraków, Poland, Master of Engineering


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Mechanical processing of materials, the theory of cutting materials, mathematical and computer simulation of machining p