Improving the Speed of Small Deep Hole Electrical Discharge Machining by Combining Rotation of the Electrode with a Rapid-Response

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In this paper, we report on the co-operative control of a 5-DOF controlled magnetically-levitated (maglev) local actuator (MLA) combined with a conventional electrical discharge machine, which we developed as a means to increasing the electrical discharge machining (EDM) speed for small deep holes. The MLA enables the electrode to be rotated as well as to be rapidly positioned. Compared to conventional EDM without electrode rotation, the machining speeds in machining φ0.5×4mm and φ1×4mm through holes were increased by 125% and 337%, respectively, using the EDM machine combined with the MLA without electrode rotation ; while with electrode rotation, the co-operatively controlled combination increased the machining speed by a maximum of 343% in machining φ0.5×4mm through holes at 800rpm and 433% in machining φ1×4mm through holes at 600rpm.