Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

Qudeiri, Jaber Abu; Saleh, A.; Ziout, Aiman; Mourad, Abdel‐Hamid I.; Abidi, Mustufa Haider; Elkaseer, Ahmed

doi:10.3390/ma12060907

Cited by 81 publications

(37 citation statements)

References 195 publications

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“…Comparing the data in Table 4 in Detail 1 and 2, it is apparent that there was a slight decrease in the total amount of alloying elements locally, which was compensated locally by a higher amount of iron. A change in the concentration of alloying elements and iron was also observed in other materials, for example, there was a localized decrease in iron in the adherent part in AISI 304 steel [41].…”

Section: Tem Lamella Analysissupporting

confidence: 57%

Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

et al. 2020

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Die-sinking electric discharge machining (EDM) is an indispensable technological operation, especially in the production of molds and all internal and external shapes and cavities. For this reason, the effect of machine parameter settings (open-voltage, pulse current, pulse on time, and pulse off time) on the machining of two types of steels, 1.2363 and 1.2343ESR, was carefully investigated using graphite or copper electrodes in 10 mm × 10 mm or 100 mm × 100 mm shapes. For this purpose, a two-level half factor experiment was performed with one replication at the corner points and two replications at the central points, with a total of 80 rounds. The subject of the evaluation was the topography and morphology of machined surfaces including a detailed analysis of surface and subsurface defects in the form of cracks including the creation of regression equations describing the probability of crack occurrence. Furthermore, a study of the local hardness change in the subsurface area was performed, and lamellas were also made and studied by transmission electron microscopy. It has been found that by using die-sinking EDM, it is possible to effectively predict the probability of cracking on machined surfaces and also on machine 1.2363 and 1.2343ESR steels with a very good surface quality of Ra 1.9 and 2.1 µm using graphite electrodes. These findings will ensure the production of parts with the required surface quality without cracks, which is a crucial aspect for maintaining the required functionality and service life of the parts.

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Section: Tem Lamella Analysissupporting

confidence: 57%

Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

et al. 2020

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“…Most of these materials are usually difficult to cut by conventional manufacturing processes [3][4][5][6][7]. The unique characteristics of these hard-to-cut materials increase their applications, which further drive manufacturers to explore new machining processes with reasonable cost and high precision [8,9]. Therefore, it is important to have in-depth knowledge of this subject and, hence, the aim of this research paper is to provide comprehensive information and details of this process.…”

Section: Introductionmentioning

confidence: 99%

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

et al. 2020

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Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with regard to selection of the process, material, and operating parameters, the effect on responses, various process variants, and new techniques adopted to enhance process performance. This paper reviews research studies on the EDM of different grades of tool steel materials. This article (i) pans out the reported literature in a modular manner with a focus on experimental and theoretical studies aimed at improving process performance, including material removal rate, surface quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used to determine process conditions, and (iii) discusses the developments in EDM and outlines the trends for future research. The conclusion section of the article carves out precise highlights and gaps from each section, thus making the article easy to navigate and extremely useful to the related research community.

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“…At the beginning of the experiment design, input EDT parameters (factors) were defined: peak current I p , voltage discharge voltage U p , pulse-on time (pulse length) P ont and pulse-off time (the length of a technological pause) P offt and other electro-discharge texturing factors (roller speed, feed rate, shape and surface area of electrodes used, material of electrodes used), which may have an effect on the monitored target values of finishing rollers Ra T,FR and Pc T,FR [9,[20][21][22].…”

Section: Design Of Experiments Materials and Methodsmentioning

confidence: 99%

“…Studies related to the EDM have shown that the process performance can be considerably improved by properly selecting the process material and operating parameters. Since the EDM process has a very complex nature due to the complicated discharge mechanisms and their interactions, parameter optimization appears to be a hot research area [9]. In [10] authors optimized process parameters after die-sinking EDM of tool steel.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Electro-Discharge Texturing Parameters for Steel Sheets’ Finishing Rollers

2020

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Exterior car-body parts are made of steel or aluminum sheets. Their formability and appearance after painting depends not only on the mechanical properties but also on their surface texture. The surface roughness characteristics, the roughness average Ra and the peak count Pc per centimeter depend on the texture of rolling mill's finishing rollers, their wear and the degree of removal by the rolling mill. The research was carried out on heat-treated finishing rollers on the surface of which a controlled texture was created by changing the electro-discharge texturing (EDT) parameters. Parameters and the number of electro-discharge texturing experiments were optimized using full four-factor experiment techniques at the upper and lower levels of the parameters in the form of 2 4 . The significance of the impact of individual EDT parameters and their interactions was identified based on the variance results. The ANOVA variance analysis results confirmed that the roughness Ra and the peak count Pc depend primarily on peak current (I p ), discharge peak voltage (U p ), pulse on time (P ont ) and pulse off time (P offt ). Optimization of the effect of the above parameters on the target roughness Ra T,FR values and the peak count Pc T,FR of finishing rollers was performed by the response surface methodology (RSM). Obtained regression models describe relationships between the input parameters of the electro-discharge texturing of finishing rollers and the output characteristics of the Ra T,FR and the Pc T,FR texture to a very high degree. The reliability of the electro-discharge texturing process of working rollers was assessed using the process capability index C pk .

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Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

Cited by 81 publications

References 195 publications

Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

Optimization of Electro-Discharge Texturing Parameters for Steel Sheets’ Finishing Rollers

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