Quantification of surface damage of tool steels after EDM

Lee, L.C.; Lim, L. C.; Narayanan, Vishnu; Venkatesh, V.C.

doi:10.1016/0890-6955(88)90050-8

Cited by 131 publications

(50 citation statements)

References 4 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…An excellent machined finish can be obtained by setting the machine parameters at a low pulsed current and a small pulse-on duration combined with a high workpiece rotation speed, but this approach is more time consuming. The trends observed for conventional EDM agree with the results reported by previous investigators [28].…”

Section: Surface Roughnesssupporting

confidence: 94%

“…The top surface of the workpiece resolidifies and subsequently cools extremely quickly. This process causes a ridged surface and induces damage such as micro-cracks in the surface layer [28]. Lee and Tai [29] used the Digitizing Area-Line Meter to measure the total length of the cracks in the scanning electron microscopy (SEM) photograph and defined a surface crack density to evaluate the severity of cracking.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Electrical Discharge Machining

Guu

Hocheng

2012

Advanced Analysis of Nontraditional Machining

View full text Add to dashboard Cite

Electrical discharge machining (EDM) is considered suitable for machining materials that are extremely hard or strong, and are wear or temperature resistant. In Chap. 2, we outline EDM characteristics of carbon fiber-reinforced carbon composites and AISI D2 tool steel. This article is organized as follows: first, the effects of EDM processing variables on delamination, the recast layer, surface roughness, and material removal rate (MRR) of carbon fiber-reinforced carbon composites are presented. Rotation of the workpiece allows fresh dielectric material to enter for effective spark discharge, and to provide better machining performance. Therefore, the second section of this chapter is devoted to a study of the effects of rotary EDM parameters on MRR and surface roughness of AISI D2 tool steel. The EDM process produces a damaged layer with different mechanical behaviors from those of the base metal. An understanding of the strength of an EDM sample is required. The third section describes an investigation of EDM AISI D2 tool steel surface characteristics and machining damage. EDM damage was studied using a new damage variable. An understanding of the surface texture of EDM specimens on the nanoscale is required. In the fourth section, surface morphology, surface roughness, and micro-cracks of AISI D2 tool steel machined by the EDM process were analyzed by atomic force microscopy (AFM). Experimental results show that the thickness of the recast layer, micro-crack depth, surface roughness, and residual tensile stress increase with the increase in power input. The EDM process effectively produces excellent surface characteristics in specimens, under low discharge energy conditions.

show abstract

Section: Surface Roughnesssupporting

confidence: 94%

Section: Introductionmentioning

confidence: 99%

Electrical Discharge Machining

Guu

Hocheng

2012

Advanced Analysis of Nontraditional Machining

View full text Add to dashboard Cite

show abstract

“…L.C. Lee [5]. According to them the electrical discharge machined surface of all the tool steels generally consists of three distinct layers the out most white layer, an immediate layer and the unaffected parent layer.…”

Section: IImentioning

confidence: 99%

Investigation of Process Parameters Optimization in Die - Sinking Edm to Improve Process Performance Using Taguchi Technique

Babu¹,

Soni²

2016

IOSR

View full text Add to dashboard Cite

show abstract

“…This ineffective removal of debris leads to arcing and abnormal discharges that makes flushing system an essential component of EDM process. With regard to flushing out the debris in EDM, techniques such as pressure flushing and jet flushing are commonly employed [48,10]. Debris removal by passing dielectric through a hollow electrode to the inter-electrode gap has also been used in drilling holes [49].…”

Section: Background and Motivationmentioning

confidence: 99%

“…47 2.42 Burrs produced by micro-machining at a feed rate of 0.33µm/flute [24]. 48 2.43 Two way interaction plots for tool life [26] [29] . .…”

mentioning

confidence: 99%

Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Pattabhiraman

Marla

Kapoor

2015

Volume 1: Processing

View full text Add to dashboard Cite

Electrical Discharge Machining is a non-traditional machining process that is widely used in the tool and die-making industry, automotive, and aerospace industries due to its ability to produce complex three-dimensional geometries with good accuracy and surface finish. Despite the aforementioned advantages, the consumption of a large quantity of dielectric (especially hydrocarbon oils) poses a significant health and environmental hazard including respiratory and skin irritation issues. Further, the disposal of waste dielectric that contains a significant amount of metal particulates poses safety concerns. In order to comply with environmental safety standards, extensive filtration and treatment systems capable of handling huge amounts of dielectric waste need to be set up for their safe disposal.This leads to an increased energy consumption and hence higher operating cost for the machining process. Thus, there is a need to reduce the consumption of oil-based dielectrics without compromising their superior machining performance.Several techniques including dry and near-dry EDM have been developed to reduce the consumption of dielectrics. However, they have poor debris flushing capability. This research seeks to develop a technique that minimizes the consumption of dielectrics and also improves the flushing of debris from the inter-electrode gap.A novel method of using atomized dielectric spray in EDM (Spray-EDM) to reduce the consumption of dielectric is developed in this study. The atomized dielectric droplets form a moving dielectric film up on impinging the work surface that penetrates the inter-electrode gap and acts as a single-phase dielectric medium between the electrodes. It also effectively removes the debris particles from the discharge zone. Single-discharge EDM experiments are performed using ii three different dielectric supply methods, viz., conventional Wet-EDM (electrodes submerged in dielectric medium), Dry-EDM and Spray-EDM in order to compare the processes based on material removal, tool electrode wear and flushing of debris from the inter-electrode gap across a range of discharge energies. It is observed that Spray-EDM produces higher material removal compared to the other two methods for all combinations of discharge parameters used in the study.The tool electrode wear using atomized dielectric is significantly better than Dry-EDM and comparable to that observed in Wet-EDM. The percentage of debris particles deposited within a distance of 100 µm from the center of EDM crater is also significantly reduced using the Spray-EDM technique. iv

show abstract

Quantification of surface damage of tool steels after EDM

Cited by 131 publications

References 4 publications

Electrical Discharge Machining

Electrical Discharge Machining

Investigation of Process Parameters Optimization in Die - Sinking Edm to Improve Process Performance Using Taguchi Technique

Atomized Dielectric Spray-Based Electric Discharge Machining (Spray-EDM) for Sustainable Manufacturing

Contact Info

Product

Resources

About