Abstract
The electrical discharge machining (EDM) process is mostly used in conditions that complex and intricate shapes need to be machined on very hard metals. However, the process leaves behind some undesirable properties such as high surface roughness, rough topography, high residual tensile stresses, micro-cracks, heat-affected zone (HAZ), and recast layer. This paper investigates the effects of different output parameters on the properties listed above. The input parameters studied include current, pulse-on time, and the type of dielectric; and the material being machined is AISI 1045 steel. Results show that the deionized water improved the output variables in EDM. The use of deionized water as the dielectric, not only improved the machined surfaces’ topography but also lowered the micro-cracks and HAZ thickness. The experiments also show how the pulse-on and current time affect the outcome of EDM machining of AISI 1045 steel.
Highlights
Electrical discharge machining (EDM) is one of the advanced machining processes widely used in machining of complex shapes and parts made of hard alloys and materials
The surface topography as an output of electrical discharge machining (EDM) is a function of machining conditions and process variables like discharging voltage, current, pulse-on time, and dielectric type
As plasma channel increases the discharge power increases and results in a higher material removal rate from the surface that leads to producing a rougher surface topography
Summary
Electrical discharge machining (EDM) is one of the advanced machining processes widely used in machining of complex shapes and parts made of hard alloys and materials. In this process, an electrical discharge between the workpiece and electrode (tool) that are submerged in a dielectric media occurs and causes the removal of molten metal from the surface of workpiece. An electrical discharge between the workpiece and electrode (tool) that are submerged in a dielectric media occurs and causes the removal of molten metal from the surface of workpiece By repeating this phenomenon, machining operations is gradually carried out and eventually, a depression having the inverse shape of the tool is created on the workpiece [1]. The temperatures of spark is very high (around 8500–12,500°C) that are sufficient for melting and vaporize the metals [2,3]
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