Carmelo Javier Luis-Pérez

Today, the high-precision manufacturing of small cavities in difficult-to-machine materials is still a challenge, even more so if they need to be threaded. The machining time, the wear suffered by the electrodes and the surface finish are determining factors in the efficiency of the threading process. However, there is scant literature on this subject so there is a need to study the process and the parameters involved. Thus, this study presents a novel machining strategy for the manufacture of nuts using die-sinking electrical discharge machining (EDM). Moreover, the novelty of this strategy is that it is carried out in a single stage and with a conventional EDM generator. To do so, a design of experiments (DOE) methodology has been followed. First, the optimal machining conditions are determined by studying the influence of EDM parameters on operation variables and mathematical models are developed using multiple linear regression. These models allow the behavior of the response variables under study to be predicted. Finally, this machining strategy developed from the previous experimental results is validated in the manufacturing process of a final part, specifically a square nut. It can be concluded that the mathematical model is good enough to predict the experimental results. Thus, the new method presented and described in this present study allowed a nut to be obtained with a real arithmetic mean deviation of the roughness profile (Ra) value of 1.27 μm whereas the predicted value from the model was 1.28 μm. To do so, the machining conditions selected were: 4 A (current intensity), 5 µs (pulse time) and 0.4 (duty cycle), which also gave a material removal rate (MRR) value of 0.5370 mm 3 /min. The machining strategy proposed here may be used for future research works related to the manufacturing of mechanical joints made of conductive ceramic materials.