Relationship between electrode size and surface cracking in the EDM machining process

Lee, Hwa-Teng; Rehbach, Werner P.; Tai, Tzu-Yao; Hsu, Fu-Chuan

doi:10.1023/b:jmsc.0000047541.95138.17

Cited by 26 publications

(13 citation statements)

References 8 publications

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“…Previous results presented by Lee et al, [5][6][7] Lim et al, [8,10] and Rebelo et al [13] also support this conclusion. They have showed dense crack networks within the white layer with possibly some penetrating cracks between when machining was performed in a hydrocarbon-based dielectric liquid, especially at high pulse-on duration and low discharge current.…”

Section: Cracks Within the White Layersupporting

confidence: 63%

“…[2][3][4] Therefore, surface cracks became a fundamental consideration when evaluating the performance of the EDM technique, and the prime objective of EDM must be to establish the conditions that suppress their formation. [5] The formation of surface cracks was attributed to the differentials of high contraction stresses exceeding the material's ultimate tensile strength within the recast layer. [6] Thermal stress is produced when the discharges bombard the surface during the machining process.…”

Section: Introductionmentioning

confidence: 99%

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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: Cracks Within the White Layersupporting

confidence: 63%

Section: Introductionmentioning

confidence: 99%

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

Ekmekçi

2009

Metall Mater Trans B

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“…Haron et al [36] investigated that the tool wear rate decreases and material removal rate increases with the larger diameter of the tool as compared to the smaller diameter of the tool electrode in EDM process. Lee et al [52] found that larger diameter of electrode leads in formation of micro-cracks on EDMed surface as compared to the smaller diameter of tool electrode. Such phenomenon has been shown in the Fig.…”

Section: Esearch In Tool Designmentioning

confidence: 99%

Recent Research Trends in Tool Electrode of Electrical Discharge Machining: A Review

2016

Arimpie - 2016

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-Electrical Discharge Machining (EDM) is a thermo-electrical based non-contact material removal process for machining of the electrically conductive difficult-to-machine materials. The machinability of the EDM process is not affected by mechanical and physical properties of the workpiece materials. Even though, its performances are highly affected by the tool materials and their designs. Most of the research papers refer to enhance the productivity of the EDM process without considering the effect of the parameters related to the tool electrodes. Generally, the tool wear is the well known phenomenon of the EDM process that affects the plasma formation as well as surface quality and productivity. The aim of the present study is to summarize a report on the published works related to the tool electrodes materials, designs and their effect on the performances of the EDM process. Instead of this, the present paper also focuses to future research scope in the same field and discussed in the brief.

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“…Previous research has shown that the quality of the machined surface is determined primarily by the pulse current and the pulse-on duration time [5][6][7][8][9][10][11][12][13][14][15] but few literatures studied the effect of electrode material [16][17][18][19][20][21][22][23]. Accordingly, the current study is based upon these two parameters, and specifies pulse currents of 15, 30 and 50 A with pulse-on times of 20, 100, 180 ls.…”

Section: Edm Principlementioning

confidence: 99%

Effect of electrode material on electrical discharge machining of tool steel surface

Younis

Abbas

Gouda

et al. 2015

Ain Shams Engineering Journal

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In this study the effect of electrode material was studied to avoid resulting residual stresses, the surface roughness and cracks resulted during Electrical Discharge Machining (EDM). Two types of EDM electrode materials were chosen, Dura graphite 11 and Poco graphite EDMC-3. Two grades of tool steels are chosen as test materials, DIN 1.2080 and DIN 1.2379. Different machining methods were chosen ''rough, medium, and soft'', it was found that the Dura graphite 11 exhibits more surface cracks upon DIN 1.2379 less micro-cracks appeared on the surface than on DIN 1.2080 while the higher surface roughness appeared in DIN 1.2080 using Dura Graphite 11 electrode, also Residual stresses were studied upon the surface and it was found that POCO Graphite EDMC-3 electrode results higher residual stresses compared with Dura Graphite 11 electrode. Also Soft EDM machining exhibits higher residual stresses as a result of higher pulse on duration time. Ó 2015 Faculty of Engineering, Ain Shams University. Production and hosting by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

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Relationship between electrode size and surface cracking in the EDM machining process

Cited by 26 publications

References 8 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

Recent Research Trends in Tool Electrode of Electrical Discharge Machining: A Review

Effect of electrode material on electrical discharge machining of tool steel surface

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