An Optimalization Study on the Surface Texture and Machining Parameters of 60CrMoV18-5 Steel by EDM

Abstract

As a non-conventional machining technology, EDM is used extensively in modern industry, particularly in machining difficult-to-cut materials. CALMAX is a chromium-molybdenum-vanadium tool steel with exceptional toughness, ductility, and wear resistance that has a wide range of applications. Despite the fact that EDM is routinely used in CALMAX machining, the related published research is brief and limited. The current research gives a complete experimental study of CALMAX machining using EDM. A Taguchi Design of Experiment (DOE) was used, using pulse-on current, pulse-on time, and open-circuit voltage as control parameters. Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR) were used to evaluate machining performance, while Ra and Rz were used to estimate Surface Quality (SQ). The produced White Layer (WL) parameters were determined using optical and SEM microscopy, as well as EDX measurements and micro-hardness studies. Finally, for each of the aforementioned indexes, Analysis of Variance (ANOVA) was performed, and multi-objective optimization was based on Grey Relational Analysis (GRA). The results show that higher open-circuit voltage produces lower WL thickness, although by increasing the pulse-on time, the TWR is increased. The average hardness of the WL is increased about 400% compared to the micro-hardness of the bulk material.

Theoretical and experimental analysis of plasma radius expansion model in EDM: a comprehensive study

“…This can also be supported by the fact that, in general, more intense machining parameters lead to an increased AWLT, a result of the partial only removal of the molten material from the crater's area. These phenomena and mechanisms have been extensively discussed in some previous studies [1,5]. Regarding the impact of the plasma channel radius model on the calculated PFE, and as can be seen from the data in Τable 3 and the respective plot of Fig.…”

“…The simulations were carried out for four different machining parameters' combinations, while the model validation and ne tuning was done based on a previously conducted extensive study regarding the machining of 60CrMoV18-5 (CALMAX) Steel with EDM [5]. The material thermophysical properties that were used in simulations are listed in Table 1, while in Table 2 the machining parameters are presented.…”

“…Various parameters can affect the e ciency of EDM, such as the pulse-on current, pulse-on time, machining voltage, duty factor, thermo-physical properties of the workpiece material etc. Due to the large number of parameters, researchers often conduct a considerable amount of experiments for each material and perform optimization studies [5].…”

“…EDM process has been extensively studied during the last decades, as it has been proven important for the construction of various parts for the automotive, aerospace and biomedical industries [6]. Although this process can be successfully carried out in industrial practice, its application for advanced or novel materials is not straightforward and requires optimization based on both the e ciency of the process, indicated by Material Removal Rate(MRR) and Tool Wear Ratio (TWR),and on the surface integrity, indicated by surface roughness or modi cation of the microstructure [5]. However, due to obvious di culties, both in directly monitoring the process and determining the procedure of the creation of heat affected zone (HAZ) and white layer (WL), reliable simulation models are required in order to provide a deeper understanding of the complex phenomena occurring in this process.…”

Influence of EDM Process Parameters on the Surface Finish of Alnico Alloys

“…They showedthat at higher current density, the process takes place more rapidly, but the surface roughness increases from 2.5 to 4.5 μm. Much of the research in this area focuses on the machining of iron alloys [ 31 , 33 , 34 , 35 , 36 ] and aluminum alloys [ 30 , 31 , 37 , 38 , 39 , 40 ]. The effects of the EDM parameters on nickel microstructure are described by Bai et al [ 41 ].…”