Improving the fatigue life of electro-discharge-machined SDK11 tool steel via the suppression of surface cracks

Tai, Tzu-Yao; Lu, Shin-Zong

doi:10.1016/j.ijfatigue.2008.07.013

Cited by 69 publications

(31 citation statements)

References 9 publications

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“…Surface cracks are surface defects which are generated from white layer surface and penetrate into heat affect zone of the EDM machined surface [20]. The density of surface cracks and AWLT has a direct relation with work-piece thickness and inverse relation with thermal conductivity because greater thermal conductivity increases the heat distribution equally [17].…”

Section: Introductionmentioning

confidence: 99%

EDM of Aluminum Alloy 6061 Using Graphite Electrode Using Paraffin Oil and Distilled Water as Dielectric Medium

Imran¹,

Rahmanshah²,

Mehmood³

et al. 2017

Adv. Sci. Technol. Res. J.

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EDM machining of Al 6061 was performed under varying conditions of pulse current and pulse duration. Graphite was used as an electrode material with distilled water and paraffin oil as two different dielectric mediums. The aim is to characterize the surface integrity produced as a result of EDM machining under both varying electrical and non-electrical parameters as it is important in determining the service life of EDM machined components. The vertical, horizontal and corner surfaces are studied independently for each single set of conditions. The average white layer thickness (AWLT) and surface roughness was found to be dependent on pulse current values and pulse duration. The dielectric medium also has an influence on the thickness and nature of white layer. It was found that the thickness and nature of the white layer formed from distilled water is different from that of paraffin oil. New methods of AWLT and surface roughness measurement through an optical microscope are described. The surface roughness method developed was calibrated against an identical surface roughness tester. Finally, material removal rate, tool wear rate, the presence of micro cracks, voids and globules were compared for different conditions and conclusions were drawn according to the actual physical conditions during machining.

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Section: Introductionmentioning

confidence: 99%

EDM of Aluminum Alloy 6061 Using Graphite Electrode Using Paraffin Oil and Distilled Water as Dielectric Medium

Imran¹,

Rahmanshah²,

Mehmood³

et al. 2017

Adv. Sci. Technol. Res. J.

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“…This is dependent on the chemical composition of the original workpiece, the heat treatment conditions applied prior to machining and the EDM machining parameters, most notably the pulse current and the pulse-on duration. The depth and size of the cracks formed on the recast layer increase as the heat energy per spark increases [3]. Of all the factors which affect crack formation, thermal conductivity has the most significant influence since a material with a higher thermal conductivity has the ability to quickly conduct heat away from the heating region, thus reducing the tendency for cracks to form [11].…”

Section: Microcracksmentioning

confidence: 99%

“…[3]. EDM also provides significant improvement in productivity and extends the range and sophistication of tools and dies that can be produced [4].…”

Section: Introductionmentioning

confidence: 99%

“…Under such conditions, the cracks on the machined surface act as stress raisers and lead to a considerable reduction on the fatigue life of the component. Although a post-machining treatment can be performed to remove the recast layer to ensure the mechanical integrity of the component, this adds to the time and expense of the manufacturing operation [3].…”

Section: Introductionmentioning

confidence: 99%

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Metallurgical alterations in the surface of steel cavities machined by EDM

et al. 2013

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The electrical discharge machining (EDM) is a process characterized by high thermal demands, which tend to cause metallurgical changes in the surface of the workpiece [1][2]. This work aims to conduct a discussion of metallurgical changes in the surface of cavities obtained by the process of EDM in the machining of steel. Several variables were employed, such as cavity depth, electrode geometry and technological parameters of the process. Thus, the goal was to identify the different metallurgical changes that can occur in the machined surfaces. The evaluation of these changes was made from metallographic analysis, measurements of microhardness and of the depth of the layer affected by process. The results of this work identified several metallurgical changes such as formation of white layer, hardness variation and change of microstructure. The occurrence of microcracks also was observed, especially in severe conditions. The greatest variations in results were caused by the change of technological parameters. However, the variation in cavity depth and the change of the electrode geometry also showed influence on the results.

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“…Although the roughness of the EDM treated specimens is high, it has been found to exhibit higher fatigue strength [2]. In a study of fatigue tests at loads ranging from 1470 to 2401 N with the aim of determining the fatigue lives of steel specimens treated with EDM SKD11 [3]; A fatigue test was also performed for comparison of the surface polished SKD11 sample. The results indicated that increasing the current and decreasing the waiting time of the pulses reduced the surface cracking probability.…”

Section: Introductionmentioning

confidence: 99%

Theoretical determination of the fatigue strength limit of electrical discharge machined (EDM) AISI 8740 steel

Özerkan

2018

IOP Conf. Ser.: Mater. Sci. Eng.

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Improving the fatigue life of electro-discharge-machined SDK11 tool steel via the suppression of surface cracks

Cited by 69 publications

References 9 publications

EDM of Aluminum Alloy 6061 Using Graphite Electrode Using Paraffin Oil and Distilled Water as Dielectric Medium

EDM of Aluminum Alloy 6061 Using Graphite Electrode Using Paraffin Oil and Distilled Water as Dielectric Medium

Metallurgical alterations in the surface of steel cavities machined by EDM

Theoretical determination of the fatigue strength limit of electrical discharge machined (EDM) AISI 8740 steel

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