Mathematical modelling and experimental investigation of inter-electrode gap in vibration-assisted micro-EDM dressing Md Shamim Shah, Ravindra Sadashiv Deshpande, Ajeet Kumar Advances in Materials and Processing Technologies, 2025 Micro-electrical discharge machining (Micro-EDM) dressing with vibrating arrayed pre-drilled holes tool-plate can effectively improve the process stability and processing performance. But there is still a lack of systematic research on the specific effects of tool-plate vibration and ranges of amplitude and frequency. A mathematical approach is discussed along with experimental validation to explain the mechanism of contaminated dielectric fluid evacuation during tool-plate vibration-assisted and also how inter-electrode gap (IEG) is dynamically affected by vibration parameters. Tool-plate mostly allowed to vibrate axially (vertically) either to fabricate single or arrayed micro-rod(s), but most debris flush out radially. The proposed simplistic mathematical model quantitatively estimates the effect of axial vibration amplitude and frequency that are put by the tool-plate on the dielectric fluid, which is eventually flushing out from the IEG in radial direction. The amplitude and frequency of contaminated dielectric fluid carrying debris increase by 15 and 4.5 times, respectively, when moving radially, compared to when moving axially. The experimental study concludes that vibration amplitude from 0.65 µm to 4.41 µm improves normal pulse frequency by up to 52% and reduces spindle load by 50%. Additionally, performance measures such as mass of material removed exceed by 65% and area surface roughness enhanced by 60%.
