Electrical Discharge Machining, EDM is one of the technologies used for surface
texturing such as the embedded micro-dimples on the metallic acetabular cup. During
the machining process, changes in the gap distance may lead to load changes from
open to short circuit. Limiting the load current under short circuit conditions and load
voltage under open circuit conditions is the requirement in this system. Power supply
is one of the elements that controls the process parameters which is related to improve
the machining condition as well as Material Removal Rate (MRR). A considerable
number of power supply design method were proposed for various EDM application.
This research proposed a Switch Mode Power Supply method implementing new
design of Flyback power supply which can stabilize the voltage during open circuit
condition as well as during discharge condition. Experimental studies were conducted
to verify the capability of Flyback power supply by machining eight micro-dimples in
lower position and twelve micro-dimples in upper position, both in circular
arrangement on metallic acetabular cup. Research conducted shows that the Flyback
power supply improve the consistency of MRR when compared to Linear power supply.
This may help to predict the machining time, thus improving the production of microdimples
in required time.