Discharge Energy as a Key Contributing Factor Determining Microgeometry of Aluminum Samples Created by Electrical Discharge Machining

Abstract

The aim of this study is first to determine the effect of the discharge energy on the surface microgeometry of aluminum samples created by electrical discharge machining (EDM). Secondly, an additional purpose is to demonstrate the differences between the geometric multiscale methods: length-, area-scale, and curvature. Eleven samples were manufactured using discharge energies ranging from 0.486 mJ to 1389.18 mJ and, subsequently, measured with focus variation microscopy. Standard ISO and multiscale parameters were calculated and used for surface discrimination and regression analysis. The results of linear, logarithmic, and exponential regression analyses revealed a strong correlation (R2 > 0.9) between the geometrical features of the surface topography and the discharge energy. The approach presented in this paper shows that it is possible to shape surface microgeometry by changing the energy of electrical discharges, and these dependencies are visible in various scales of observation. The similarities of the results produced by curvature and length-scale methods were observed, despite the significant differences in the essence of those methods.

Exploring the Potential Application of an Innovative Post-Weld Finishing Method in Butt-Welded Joints of Stainless Steels and Aluminum Alloys

“…After visually analyzing them, to investigate the impact of the innovative method for removing excess material from welds in specimens made of various stainless steels and aluminum alloys on the key parameters of the surface geometric structures [33,34], surface roughness measurements were conducted using a non-contact optical method extensively described in the modern scientific literature [35,36]. To visually analyze the obtained surface and identify areas of characteristic roughness, images were captured at a magnification of 32 times using a SmartZoom 5 digital industrial microscope by Zeiss (Carl Zeiss AG, Oberkochen, Germany) [5].…”

Parametric Optimization of Powder-Mixed EDM of AA2014/Si3N4/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations

“…Electrically conductive materials can be intricately shaped using EDM, a nontraditional machining technique [26][27][28]. EDM, at its core, takes benefit of the phenomenon of electrical discharges amongst a tool electrode (cathode) and a workpiece electrode (anode), both of which are submerged in a dielectric fluid [29][30][31].…”

“…This involved aspects such as productivity, accuracy, surface quality, electrode wear, and material changes. Numerous scientific papers have contributed to understanding WEDM's characteristics, phenomena, performance, and trends over the last two decades [26,27].…”

Selection of Methods of Surface Texture Characterisation for Reduction of the Frequency-Based Errors in the Measurement and Data Analysis Processes

“…Therefore, a proper selection of methods for the definition of an S-F surface is required. The application of regular procedures, e.g., those commonly available in the software equipment, require, mindful users [29]. The separation of irrelevant components (F-and S-components in the process of S-F surface definition) from the results of surface texture measurements is required so they can be evaluated with frequency-based methods and procedures.…”