Macroscopic and microscopic phenomena of electro-discharge machined steel surfaces: An experimental investigation

Mamalis, A.G.; Vosniakos, George–Christopher; Vaxevanidis, Nikolaos M.; Prohászka, J.

doi:10.1016/0378-3804(87)90047-7

Cited by 79 publications

(47 citation statements)

References 3 publications

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“…[7][8][9][10] The melted material contracts more than the unaffected parent part during the cooling process, and when the stress in the surface exceeds the material's ultimate tensile strength, cracks are formed. [2,7,11] Results from previous studies [7,8,[11][12][13] have indicated that cracking increases as the pulse energy increases. However, increase in surface crack density was not found to be linear with respect to pulse energy, i.e., increasing the pulse energy does not lead to increased crack formation.…”

Section: Introductionmentioning

confidence: 89%

White Layer Composition, Heat Treatment, and Crack Formation in Electric Discharge Machining Process

Ekmekçi

2009

Metall Mater Trans B

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BÜ LENT EKMEKCICharacteristics of electric discharge machined (EDM) surfaces of normalized, quenched, and quenched and tempered-treated steels in kerosene and deionized-water dielectric liquids are investigated. Optical microscopy, scanning electron microscopy (SEM) and X-ray diffractometry are employed to analyze the machined surface. Surface cracks are examined in terms of white layer composition, heat treatment of the workpiece material, and operational parameters used, such as average discharge current and pulse-on duration. The present results reveal that base material properties and white layer composition have a distinctive function on crack formation that results in different crack network layouts on the surface and penetration depths in the substrate. Surface cracks, which initiate at the surface, travel down perpendicularly toward the interferential zone, and terminate at this interference, are mainly formed due to an increase in nonhomogeneities of metallurgical phases within the white layer. Such cracks are usually encountered on the surfaces when machining is performed in a hydrocarbon-based dielectric liquid using high pulse-on duration and low average discharge current. On the other hand, penetrating cracks, which penetrate the entire white layer thickness to an extent into the parent material, are mainly formed due to contraction of the recast structure joined to the circumferential edge of a crater rim during solidification. This type of crack is common when machining is performed in deionized water and the work material is brittle. Crack penetration depth is found to be proportional to the used pulse energy, and its path has a tendency to form parallel cracks to the machined surface at decreased pulse-on duration.

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Section: Introductionmentioning

confidence: 89%

White Layer Composition, Heat Treatment, and Crack Formation in Electric Discharge Machining Process

Ekmekçi

2009

Metall Mater Trans B

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“…The existence of carbon may be due to the migration of electrode materials, which was observed in previous studies [16]. Moreover, the smooth surface has some blow holes with the size of 10-20 μm because of entrapped gases [24].…”

Section: Cross Section Analysis Of Aisi 304 In High-speed Dry Edmmentioning

confidence: 94%

High-speed dry electrical discharge machining

Shen

Zhang

et al. 2015

International Journal of Machine Tools and Manufacture

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“…Several studies have been carried out to determine appropriate ED machining parameter combinations from the aspect of surface integrity [7,8]. However, these studies were based on the use of experimental approaches and statistical analyses.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation and 3D finite element prediction of the white layer thickness, heat affected zone, and surface roughness in EDM process

et al. 2011

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An axisymmetric three-dimensional model for temperature distribution in the electrical discharge machining process has been developed using the finite element method to estimate the surface integrity characteristics of AISI H13 tool steel as workpiece. White layer thickness, depth of heat affected zone, and arithmetical mean roughness consisting of the studied surface integrity features on which the effect of process parameters, including pulse on-time and pulse current were investigated. Additionally, the experiments were carried out under the designed full factorial procedure to validate the numerical results. Both numerical and experimental results show that increasing the pulse on-time leads to a higher white layer thickness, depth of heat affected zone, and the surface roughness. On the other hand, an increase in the pulse current results in a slight decrease of the white layer thickness and depth of heat affected zone, but a coarser surface roughness. Generally, there is a good agreement between the experimental and the numerical results.

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Macroscopic and microscopic phenomena of electro-discharge machined steel surfaces: An experimental investigation

Cited by 79 publications

References 3 publications

White Layer Composition, Heat Treatment, and Crack Formation in Electric Discharge Machining Process

White Layer Composition, Heat Treatment, and Crack Formation in Electric Discharge Machining Process

High-speed dry electrical discharge machining

Experimental investigation and 3D finite element prediction of the white layer thickness, heat affected zone, and surface roughness in EDM process

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