{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,2]],"date-time":"2026-09-02T08:07:42Z","timestamp":1788336462024,"version":"build-2803163510"},"reference-count":26,"publisher":"MDPI AG","issue":"11","license":[{"start":{"date-parts":[[2023,6,2]],"date-time":"2023-06-02T00:00:00Z","timestamp":1685664000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"Russian Science Foundation","award":["23-29-00104"],"award-info":[{"award-number":["23-29-00104"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>The study was performed to determine the optimum flushing condition for electrical discharge machining (EDM) of functional material titanium VT6 obtained by plasma cladding with a thermal cycle. Copper is used as an electrode tool (ET) to machine functional materials. The optimum flushing flows are analyzed theoretically by using ANSYS CFX 20.1 software which is also validated by an experimental study. It was observed that while machining the functional materials to adepth of 10 mm or more, the turbulence fluid flow dominates when nozzle angles are 45\u00b0 and 75\u00b0, consequently drastically affecting the quality of flushing and the performance of the EDM. For the highest machining performance, the nozzles should be at an angle of 15\u00b0 relative to the tool axis. The optimum flushing at deep hole EDM process minimizes the occurrence of debris deposition on tool electrodes, thus facilitating stable machining of functional materials. The adequacy of the obtained models was confirmed experimentally. It has been established that EDM of a hole with a depth of 15 mm, an intense accumulation of sludge, is observed in the processing zone. There arebuild-ups exceeding 3 mm in cross-section after EDM. This build-up leads to a short circuit and a reduction in surface quality and productivity. It has been proven that not correct flushing leads to intensive wear of the tool and a change in its geometric shape and, accordingly, to a decrease in the quality of EDM.<\/jats:p>","DOI":"10.3390\/ma16114158","type":"journal-article","created":{"date-parts":[[2023,6,2]],"date-time":"2023-06-02T08:50:31Z","timestamp":1685695831000},"page":"4158","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":10,"title":["Modeling of EDM Process Flushing Mechanism"],"prefix":"10.3390","volume":"16","author":[{"given":"Timur Rizovich","family":"Ablyaz","sequence":"first","affiliation":[{"name":"Department of Mechanical Engineering, Perm National Research Polytechnic University, Perm 614000, Russia"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Evgeny Sergeevich","family":"Shlykov","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Perm National Research Polytechnic University, Perm 614000, Russia"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Karim Ravilevich","family":"Muratov","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Perm National Research Polytechnic University, Perm 614000, Russia"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2023,6,2]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"3780","DOI":"10.1016\/j.matpr.2019.07.316","article-title":"Recent Research Status on Polymer Composite Used in Concrete\u2014An Overview","volume":"18","author":"Sarde","year":"2019","journal-title":"Mater. Today Proc."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"2242","DOI":"10.1177\/0731684414559864","article-title":"Mechanical performance of woven kenaf-Kevlar hybrid composites","volume":"33","author":"Yahaya","year":"2014","journal-title":"J. Reinf. Plast. Compos."},{"key":"ref_3","doi-asserted-by":"crossref","first-page":"106421","DOI":"10.1016\/j.polymertesting.2020.106421","article-title":"A review of the analysis and characterisation of polymeric glass fibresizings","volume":"85","author":"Thomason","year":"2020","journal-title":"Polym. Test."},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"878","DOI":"10.3103\/S1068798X20100275","article-title":"Electrical Discharge Machining of Polymer Composites","volume":"40","author":"Shlykov","year":"2020","journal-title":"Russ. Eng. Res."},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"898","DOI":"10.3103\/S1068798X19100058","article-title":"Electric-Discharge Machining of Polymer Composites","volume":"39","author":"Ablyaz","year":"2019","journal-title":"Russ. Eng. Res."},{"key":"ref_6","doi-asserted-by":"crossref","unstructured":"Ablyaz, T., Shlykov, E., Muratov, K., and Sidhu, S. (2021). Analysis of Wire-Cut Electro Discharge Machining of Functional materials. Micromachines, 12.","DOI":"10.3390\/mi12050571"},{"key":"ref_7","doi-asserted-by":"crossref","first-page":"185","DOI":"10.1007\/s00170-010-2625-3","article-title":"Effect of single and multi-channel electrodes application on EDM fast hole drilling performance","volume":"51","author":"Yilmaz","year":"2010","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_8","doi-asserted-by":"crossref","first-page":"504","DOI":"10.1080\/10426914.2015.1059451","article-title":"The Effectiveness of Multichannel Electrodes on Drilling Blind Holes on Inconel 718 by EDM Process","volume":"31","author":"Bozdana","year":"2016","journal-title":"Mater. Manuf. Process."},{"key":"ref_9","unstructured":"Pontelandolfo, P., Haas, P., and Perez, R. (2013, January 9\u201312). Particle Hydrodynamics of the Electrical Discharge Machining Process. Proceedings of the 17th CIRP Conferenceon Electro Physical and Chemical Machining, Leuven, Belgium."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"209","DOI":"10.1016\/j.cirp.2009.03.003","article-title":"Computational fluid dynamics analysis of working fluid flow and debris movement in wire EDMedkerf","volume":"58","author":"Okada","year":"2009","journal-title":"CIRP Ann."},{"key":"ref_11","first-page":"59","article-title":"Cutting of polished single-crystal silicon by wire electrical discharge machining using anti-electrolysis pulse generator","volume":"Volume 2","author":"Takino","year":"2014","journal-title":"Proceedings of the 14th Euspen International Conference"},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"11","DOI":"10.1016\/j.ijmachtools.2012.02.004","article-title":"Simulation model of Debris and bubble movements during electrical discharge machining","volume":"58","author":"Wang","year":"2012","journal-title":"Int. J. Mach. Tools Manuf."},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"197","DOI":"10.1016\/S0007-8506(07)61034-8","article-title":"About the role of debris in the gap during electrical discharge machining","volume":"39","author":"Schumacher","year":"1990","journal-title":"CIRP Ann."},{"key":"ref_14","first-page":"81","article-title":"Optimisation of the electrical discharge machining process using a GA-based neural network","volume":"24","author":"Su","year":"2004","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_15","doi-asserted-by":"crossref","unstructured":"Maradia, U., Wegener, K., Stirnimann, J., Knaak, R., and Boccadoro, M. (2013, January 15\u201321). Investigation of the Scaling Effects in Meso-Micro EDM. Proceedings of the ASME 2013 International Mechanical Engineering Congress and Exposition, San Diego, CA, USA.","DOI":"10.1115\/IMECE2013-63160"},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"21","DOI":"10.1007\/s00170-014-6131-x","article-title":"A new electrode sidewall insulation method in electrochemical drilling","volume":"75","author":"Wang","year":"2014","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"409","DOI":"10.4028\/www.scientific.net\/AMR.53-54.409","article-title":"Numerical Simulation of Liquid-Solid Two-Phase Flow Field in Discharge Gap of High-Speed Small Hole EDM Drilling","volume":"53","author":"Wang","year":"2008","journal-title":"Adv. Mater. Res."},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"254","DOI":"10.1016\/j.procir.2017.12.058","article-title":"Fluid Dynamics in Electrode Flushing Channeland Electrode-Workpiece Gap During EDM Drilling","volume":"68","author":"Kliuev","year":"2018","journal-title":"Procedia CIRP"},{"key":"ref_19","doi-asserted-by":"crossref","unstructured":"Ablyaz, T., Shlykov, E., and Muratov, K. (2021). Improving the Efficiency of Electrical Discharge Machining of Special-Purpose Products with Composite Electrode Tools. Materials, 14.","DOI":"10.3390\/ma14206105"},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"590","DOI":"10.1016\/j.procir.2018.08.210","article-title":"Flushing Velocity Observations and Analysis during EDM Drilling","volume":"77","author":"Kliuev","year":"2018","journal-title":"Procedia CIRP"},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"187","DOI":"10.1007\/s00170-011-3357-8","article-title":"Influence of flushing on performance of EDM with bunched electrode","volume":"58","author":"Li","year":"2012","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"227","DOI":"10.1007\/s00170-021-08582-2","article-title":"Mathematical modelling with experimental correlation for multiple craters dimension, material removal rate and surface roughness in electrical discharge machining","volume":"120","author":"Ishfaq","year":"2022","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_23","doi-asserted-by":"crossref","unstructured":"Chuvaree, S., and Kanlayasiri, K. (2021). Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes. Metals, 11.","DOI":"10.3390\/met11010148"},{"key":"ref_24","doi-asserted-by":"crossref","first-page":"7411","DOI":"10.3390\/app10217411","article-title":"EDM of D2 Steel: Performance Comparison of EDM die Sinking Electrode Designs","volume":"10","author":"Madiha","year":"2020","journal-title":"Appl. Sci."},{"key":"ref_25","doi-asserted-by":"crossref","unstructured":"Liu, Y., Chang, H., and Zhang, W. (2018). A Simulation Study of Debris Removal Process in Ultrasonic Vibration Assisted Electrical DischargeMachining (EDM) of Deep Holes. Micromachines, 9.","DOI":"10.3390\/mi9080378"},{"key":"ref_26","doi-asserted-by":"crossref","unstructured":"Jamkamon, K., and Janmanee, P. (2021). Improving Machining Performance for Deep Hole Drilling in the Electrical Discharge Machining Process Using a Step Cylindrical Electrode. Appl. Sci., 11.","DOI":"10.3390\/app11052084"}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/16\/11\/4158\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,10]],"date-time":"2025-10-10T19:48:01Z","timestamp":1760125681000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/16\/11\/4158"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2023,6,2]]},"references-count":26,"journal-issue":{"issue":"11","published-online":{"date-parts":[[2023,6]]}},"alternative-id":["ma16114158"],"URL":"https:\/\/doi.org\/10.3390\/ma16114158","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2023,6,2]]}}}