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This study presents experimental and numerical investigation on the\udeffectiveness of electrode geometry on flushing and debris removal\udin Electrical Discharge Drilling (EDD) process. A new electrode\udgeometry, namely side-cut electrode, was designed and manufactured\udbased on circular electrode geometry. Several drilling operations\udwere performed on stainless steel 304 using rotary tubular\udelectrodes with circular and side-cut geometries. Drilling\udperformance was characterized by Material Removal Rate (MRR),\udElectrode Wear Rate (EWR), and Tool Wear Ratio (TWR). Dimensional\udfeatures and surface quality of drilled holes were evaluated based\udon Overcut (OC), Hole Depth (HD), and Surface Roughness (SR).\udThree-dimensional three-phase CFD models were built using\udANSYS FLUENT software to simulate the flow field at interelectrode\udgap. Results revealed that the overall performance of side-cut\udelectrode was superior due to improved erosion rates and flushing\udcapabilities, resulting in production of deep holes with good\uddimensional accuracy and surface quality

Comparative experimental investigation and gap flow simulation in electrical discharge drilling using new electrode geometry