Abstract
Although electrical discharge machining (EDM) is one of the first established non-conventional machining processes, it still finds many applications in the modern industry, due to its capability of machining any electrical conductive material in complex geometries with high dimensional accuracy. The current study presents an experimental investigation of ED machining aluminum alloy Al5052. A full-scale experimental work was carried out, with the pulse current and pulse-on time being the varying machining parameters. The polishing and etching of the perpendicular plane of the machined surfaces was followed by observations and measurements in optical microscope. The material removal rate (MRR), the surface roughness (SR), the average white layer thickness (AWLT), and the heat affected zone (HAZ) micro-hardness were calculated. Through znalysis of variance (ANOVA), conclusions were drawn about the influence of machining conditions on the EDM performances. Finally, semi empirical correlations of MRR and AWLT with the machining parameters were calculated and proposed.
Highlights
Electrical discharge machining (EDM) is one of the most extensively used non-conventional machining processes, with many applications in the modern industrial environment
The real interest focuses on the interaction of machining parameters, as it is presented in the interaction plot of material removal rate (MRR), see Figure 1b
For IP = 21 A the maximum MRR has been measured for Ton = 200 μs, while the MRR for 300 μs is higher than that for 100 μs; this is the exact opposite in relation with the 15 A pulse current
Summary
Electrical discharge machining (EDM) is one of the most extensively used non-conventional machining processes, with many applications in the modern industrial environment. EDM is a thermoelectric process, as the material erosion mechanism is the result of a series of discrete electrical discharges. These occur between the electrode and workpiece, which are immersed in a dielectric fluid [2]. The electrical energy turns into thermal, generating a plasma channel between the cathode and the anode. When the pulsating current supply is turned off, the plasma channel breaks down, allowing the dielectric fluid to flush the molten and ablated material in the form of microscopic debris
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