Quantification of surface damage of tool steels after EDM

Abstract

The surface transformation and damage in AISI O1, A2, D2 and D6 tool steels after EDM were investigated. The results show that the recast layer is composed of two distinct layers: a topmost layer solidifying inwards from the specimen surface and an intermediate layer solidifying outwards from the base of the molten metal. The depth of surface cracks is found to correlate well with the thickness of the white layer, the latter being a layer of rapidly solidified material which, depending on the tool steel material, may consist either primarily of the topmost recast layer, or both the topmost and a large part of the intermediate recast layer. The density of surface cracks, however, correlates better with the thickness of the overall recast layer. Attempts were made to quantify the depth of white (or damaged) layer with respect to the process parameters and surface roughness after EDM. It is found that with a fixed dielectric and flushing condition, the damaged layer correlates well with the pulse energy irrespective of the tool steel material. On the other hand, even though the thickness of the white layer increases with the surface roughness, the result shows considerably more scatter. Based on the present findings, ways of estimating the depth of the damaged layer produced by EDM are proposed.