Abstract
In this study, machining characteristics and mechanical properties of aluminum (Al) alloy 6061 were investigated with variations in discharge currents in electrical discharge machining. The machining characteristics included the electrode wear rate, material removal rate, and roughness. Mechanical properties such as the fatigue life and surface hardness were also discussed in this work. Experimental results showed that better fatigue property of the electrical discharge machined workpiece could be obtained when the discharge current was 15 A; meanwhile, the thickness of the white layer was around 19 µm. The relationship between the thickness of the white layer and the fatigue lifetime had a very strong positive correlation. Furthermore, the repeatability and stability of the machining process were explored by the quality control chart and Shewhart control chart. The results indicated that the electrical discharge machining process under optimum operating conditions was a well-controlled procedure and stab...
Highlights
With the development of high-precision technology, more and more high-strength, high-hardness, and hightemperature materials are needed
It was supposed that the surface roughness was caused by the accumulation of many discharging sparks and the pressure of vaporization during the electrical discharge machining (EDM) process, resulting in lots of surface damages and defects, such as debris, craters, cracks, voids, and molten ashes
We investigated the effect of the discharge current of the EDM process on the surface roughness, material removal rate (MRR), and electrode consumption of the aluminum alloy 6061 workpiece and analyzed the factors that affected the fatigue life and surface hardness of the workpiece
Summary
With the development of high-precision technology, more and more high-strength, high-hardness, and hightemperature materials are needed. We investigated how the discharge current of the EDM process affects the fatigue behavior of the workpiece. The results of this work would provide a reference for determining the discharge current of the EDM process in Al alloy 6061 and improving the machining properties.
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