Performance Analysis of Pulse Generators on Residual Stress of Machined Silicon Steel Using the EDM Process

Abstract

The cracks in the workpiece specimens can reduce the fatigue life of any machine components. Since the residual stress has a considerable amount of influence on determining crack formation over the machined surface, it is very essential to analyze the residual stress developed in any machining process. However, it is a very tedious process to compute the residual stress over the machined surface. In the present study, an endeavor has been made to measure and analyze the residual stress of machined silicon steel as a workpiece using the EDM process with different energy distribution. The nano-indentation method was used to compute the residual stress produced over the machined surface. From the experimental results, it was found that the uniform energy distribution has produced higher compressive residual stress owing to the tiny and uniform spark energy distribution. It has also been observed that the tool electrode has a considerable amount of influence on determining development of residual stress in the EDM process.