The drilling of holes beyond a length-to-diameter ratio of 5–10 is called deep drilling. The drilling process in real production places ever-increasing demands on the length and accuracy of the holes made.

The efficiency of the super dielectric-based EDM process is experimentally validated with the successful drilling holes of aspect ratio more than 100 in Inconel 718 within 6 minutes. In addition, the effect of super dielectric fluid on the plasma current is presented and the experimental observations have been validated through the plasma physics theory.

Therefore, in this study, the authors present the development of a novel super dielectric which is used in the EDM drilling process and experimentally demonstrates how the machining efficiency in the drilling of a deep hole is improved significantly. Furthermore, the standard dielectric-based EDM process is unable to meet the requirements of today’s fast-moving manufacturing industry. However, the process becomes unstable and slow when deep features are to be machined. Based on the grey relational technique, optimal process parameter settings were found such as spindle speed of 2228 rpm, FR of 0.023 mm/rev, and coolant pressure of 30 kgf/cm².Ī non-contact machining process such as electrical discharge machining (EDM) is generally employed for machining electrically conductive materials irrespective of its hardness. Also, the tool wear was reduced by decreasing spindle speed. The results indicate a yield of the better surface finish from higher spindle speed, lower circularity, and cylindricity. The experiments were conducted by varying the drilling parameters based on Taguchi’s Design of Experiment, and the output responses were measured and optimized using grey relation analysis. During the drilling process, the fitness of the tool wear was observed by using an accelerometer. Coolant pressure and spindle speed play a vital role in determining the quality of the hole. In this study, hole quality was analyzed using surface roughness, cylindricity, and circularity characteristics. The diameter and depth of the deep hole considered in the present work were 10 and 120 mm, respectively. This paper aims at investigating the effects of the deep-hole drilling parameters such as cutting speed (Vc), feed rate (FR) (Fr), and coolant pressure (Cp) on the quality of the hole produced.

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