Abstract
Electric discharge machining (EDM) is a competitive process to machine difficult-to-cut alloys. However, the rapid heating and cooling process in EDM may result in poor surface integrity such as white layer on the component surface. Complex phase transformations occur in both white layer and heat affected zone (HAZ) which are detrimental to product performance. This paper presents a numerical approach to predict and analyze the formation mechanisms of WL and HAZ and corresponding phase transformation in EDM of ASP 2023 tool steel. Massive random discharges on the machined surface are successfully simulated. The predicted transformed martensite in WL and HAZ matches the experimental data in reasonable accuracy. Also, the effects of EDM conditions on the thickness of WL and HAZ are investigated. By increasing the discharge duration and voltage, more thermal damage can be found in EDMed surface including thick WL and HAZ and thick martensite zone in particular.
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