Vol. 7, Special Issue 2 (2025)

Electrical discharge machine (EDM) is one of the widely used manufacturing methods in aerospace industry and difficult-to-machine materials field. But the research on theoretical basis and machining mechanism of EDM is insufficient. This paper presents a new method for increasing the material removal rate (MRR) in EDM by introducing composite pulse power with pre-ignition excitation voltage and end pulse inrush current. The pre-ignition excitation voltage provides high effect of spark discharge and end pulse inrush current effectively reduces the thickness of the recast layer. In order to prove this effectiveness, experiment and simulation is invested. Spark discharge characteristics are studied based on the simulated model of composite pulse power in MATLAB/SIMULINK environment. Also experiments show that pre-ignition voltage excitation of the pulse produces effective spark pulses and end pulse inrush current decrease recast layer. Finally introduction of composite pulse power in EDM can provide higher material removal rate than traditional single pulse power.