A semi-empirical approach for residual stresses in electric discharge machining (EDM)

Ekmekçi, Bülent; Tekkaya, A. Erman; Erden, Abdülkadir

doi:10.1016/j.ijmachtools.2005.07.020

Cited by 64 publications

(29 citation statements)

References 14 publications

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“…In the investigation performed by Ghanem et al [22], it has been shown that a tensile residual stress is formed within the EDM transformation layer. Ekmekci et al [23] have developed a modified empirical equation to scale the residual stress in machined surface, and reported that the stress increases from the surface and reaches a maximum value, this maximum stress value is around ultimate tensile strength of the material, and then it falls gradually to zero or even to a small compressive residual stress at greater depths. When using the EDM hole-drilling strain gage method to measure the residual stress within a component, part of the released strain detected by the strain gage originates not from the original component, but from the residual stress induced in the transformation layer during the hole-drilling process.…”

Section: Hole-drilling Techniquementioning

confidence: 99%

Methods of measuring residual stresses in components

et al. 2012

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Residual stresses occur in many manufactured structures and components. Large number of investigations have been carried out to study this phenomenon and its effect on the mechanical characteristics of these components.Over the years, different methods have been developed to measure residual stress for different types of components in order to obtain reliable assessment. The various specific methods have evolved over several decades and their practical applications have greatly benefited from the development of complementary technologies, notably in material cutting, full-field deformation measurement techniques, numerical methods and computing power. These complementary technologies have stimulated advances not only in measurement accuracy and reliability, but also in range of application; much greater detail in residual stresses measurement is now available. This paper aims to classify the different residual stresses measurement methods and to provide an overview of some of the recent advances in this area to help researchers on selecting their techniques among destructive, semi destructive and non destructive techniques depends on their application and the availabilities of those techniques. For each method scope, physical limitation, advantages and disadvantages are summarized. In the end this paper indicates some promising directions for future developments.

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Section: Hole-drilling Techniquementioning

confidence: 99%

Methods of measuring residual stresses in components

et al. 2012

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“…[17][18][19] The microvoids can be attributed to gas bubbles that are expelled from the molten material during solidification. [20] The presence of a large volume of gases in the gap, especially water vapor and hydrogen, will lead to a high supersaturation of gas in the molten pool, which is the prerequisite for the formation of microvoids. [14] SEM images of workpiece surfaces treated by EDM in kerosene and ionized water using I = 25 A and t e = 300 ls are illustrated in Figure 3.…”

Section: Resultsmentioning

confidence: 99%

Effect of Carbon in the Dielectric Fluid and Workpieces on the Characteristics of Recast Layers Machined by Electrical Discharge Machining

Muttamara

Kanchanomai

2016

Metall Mater Trans A

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Electrical discharge machining (EDM) is a popular non-traditional machining technique that is usually performed in kerosene. Carbon from the kerosene is mixed into the recast layer during EDM, increasing its hardness. EDM can be performed in deionized water, which causes decarburization. We studied the effects of carbon in the dielectric fluid and workpiece on the characteristics of recast layers. Experiments were conducted using gray cast iron and mild steel workpieces in deionized water or kerosene under identical operating conditions. Scanning electron microscopy revealed that the recast layer formed on gray iron was rougher than that produced on mild steel. Moreover, the dispersion of graphite flakes in the gray iron seemed to cause subsurface cracks, even when EDM was performed in deionized water. Dendritic structures and iron carbides were found in the recast layer of gray iron treated in deionized water. Kerosene caused more microcracks to form and increased surface roughness compared with deionized water. The microcrack length per unit area of mild steel treated in deionized water was greater than that treated in kerosene, but the cracks formed in kerosene were wider. The effect of the diffusion of carbon during cooling on the characteristics of the recast layer was discussed.

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“…Because of the high pressure during heating in plasma channel, very little amount of material evaporates, so we can neglect the phase change of liquid to vapor [10,12,13,17,[25][26][27].…”

Section: Phase Changementioning

confidence: 99%

Experimental and finite element analysis of EDM process and investigation of material removal rate by response surface methodology

Kalajahi

Ahmadi

Oliaei

2013

Int J Adv Manuf Technol

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In this study, thermal modeling and finite element simulation of electrical discharge machining (EDM) has been done, taking into account several important aspects such as temperature-dependent material properties, shape and size of the heated zone (Gaussian heat distribution), energy distribution factor, plasma flushing efficiency, and phase change to predict thermal behavior and material removal mechanism in EDM process. Temperature distribution on the cathode has been calculated using ANSYS finite element code, and the effect of EDM parameters on heat distribution along the radius and depth of the workpiece has been obtained. Temperature profiles have been used to calculate theoretical material removal rate (MRR) from the cathode. Theoretically calculated MRRs are compared with the experimental results, making it possible to precisely determine the portion of energy that enters the cathode for AISI H13 tool steel. Also in this paper, the effect of EDM parameters on MRR has been investigated by using the technique of design of experiments and response surface methodology. Finally, a quadratic polynomial regression model has been proposed for MRR, and the accuracy of this model has been checked by means of analysis of residuals.

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A semi-empirical approach for residual stresses in electric discharge machining (EDM)

Cited by 64 publications

References 14 publications

Methods of measuring residual stresses in components

Methods of measuring residual stresses in components

Effect of Carbon in the Dielectric Fluid and Workpieces on the Characteristics of Recast Layers Machined by Electrical Discharge Machining

Experimental and finite element analysis of EDM process and investigation of material removal rate by response surface methodology

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