Surface modification using a developed hybrid process of electrical discharge machining and abrasive jet machining

The aim of this investigation intends to explore the effect of a developed hybrid process of abrasive jet machining (AJM) and electrical discharge machining (EDM) on surface modifications. The appropriate abrasives delivered by high-speed gas are incorporated with a process of EDM in gas to produce a hybrid process of EDM and AJM. The high-speed abrasives impinge on the machined surface to remove the recast layer that results from the EDM process for increasing the efficiency of material removal and to reduce the surface roughness. The abrasives can be considered as the agents for surface modifications. In this study, the benefits of the hybrid process are determined by comparing the machining performance of the hybrid process with that for the process of EDM in gas. The implement of the main process parameters such as peak current, pulse duration, air pressure, and grain size were chosen to explore their effects on surface integrity and surface modifications. The experimental results show that a hybrid process of EDM and AJM results in surface modifications with improved surface quality as well as machining efficiency. This hybrid process fulfils the requirements of modern manufacturing applications.