Recast Layer Thickness Research Articles

A novel late-stage oscillating discharge current for plasma regulation and its effect in material removal in electrical discharge machining

Abstract Improving the material removal rate (MRR) has recently become one of the most important issues in electrical discharge machining. During the discharge process, a large portion of molten material cannot be sufficiently expelled from the molten pool but re-solidifies, ultimately resulting in low energy utilization and machining efficiency. Unlike existing methods that primarily focus on optimizing general discharge parameters, this study aims to enhance molten material expulsion and MRR through discharge plasma regulation by employing a redesigned late-stage oscillating discharge current. During a single-pulse discharge process, this kind of discharge current firstly remains constant to ensure stable heat transfer from the plasma to the workpiece, then transitions to periodic oscillations to enhance plasma movement and facilitate molten material expulsion. High-speed plasma observations and heat-flow coupling simulations are conducted to analyze the effects of the discharge currents on material removal, and the optimal oscillation start time is obtained. Experimental results in machining stainless steel demonstrate that the use of the late-stage oscillating discharge current, in comparison to the conventional rectangular discharge current, results in a 74% increase in material removal volume per unit of energy and a 56% in average recast layer thickness.

Processing of silicon carbide particulate reinforced aluminum alloy composites using rotary electrochemical discharge machining

ABSTRACT As a kind of metal matrix composites, silicon carbide particulate reinforced aluminum alloy composites (SiCp/Al) have been widely applied in numerous fields. However, it is still difficult to process this composite material with electrical discharge machining (EDM) at present. To address this problem, this study introduces a novel rotary electrochemical discharge – chemical composite machining (RECDM-CM) method. This method uses rotating electrodes and workpieces to improve the flushing effect of working medium and utilizes the electrolysis to reduce the recast layer thickness. The chemical reaction between sodium carbonate (Na2CO3) and aluminum oxide (Al2O3) at high temperatures is used to remove the non-conductive Al2O3 in this composite machining. Rotary electrochemical discharge – chemical composite machining is used to process silicon carbide particulate reinforced AA2009 aluminum alloy composites with the silicon carbide volume fraction of 55%. The experimental results reveal that the material removal rate (MRR) of rotary electrochemical discharge – chemical composite machining is 5.2 times that of rotary electrical discharge machining, and its relative tool wear rate (RTWR) is 37.42% of rotary electrical discharge machining. The recast layer thickness is reduced to less than 13 μm via rotary electrochemical discharge – chemical composite machining.

To investigate the effect of discharge energy and addition of nano-powder on processing of micro slots using EDM assisted µ-milling operation

ABSTRACT Micro-electric Discharge-Milling (µ-ED-M) is a non-contact process that uses an electrical spark to remove the material from a submerged workpiece with an electrode in a dielectric. The present paper focuses on optimizing process energizing (Capacitor, Voltage) and process stabilizing (Tool Travel Speed, Nano-Powder) parameters for controlling the size and surface characteristics of micro-crater. The present work focuses on the effect of nano-powder concerning dimensional aspects and surface characteristics at high and low capacitance levels. A µ-slot has been generated on the copper material by a tungsten carbide electrode. The experimentation is performed with two capacitor levels and three voltage and tool travel speed levels using full factorial design technique using with and without mixing of nano-powder in dielectric. The desirability functional multi-objective optimization approach is used to analyze the MRR, TWR, Width, and Depth. Field emission scanning electron microscopy (FESEM), non-contact optical profilometer, and x-ray diffraction (XRD) techniques are used to analyze the surface morphology of machined surfaces. The ANOVA is used to optimize the results; at low discharge energy, tool travel speed contributes 41% and promotes a higher thickness of recast layer 12.7 µm, whereas high discharge energy and nano-powder concentration contribute approx.—36% with 8.56 µm of recast layer.

Optimizing the Die-Sink EDM Machinability of AISI 316L Using Ti-6Al-4V-SiCp Electrodes: A Computational Approach

Die-sink electric discharge machining (EDM) is essential for shaping complex geometries in hard-to-machine materials. This study aimed to optimize key input parameters, such as the discharge current, gap voltage, pulse-on time, and pulse-off time, to enhance the EDM performance by maximizing the material removal rate while minimizing the surface roughness, residual stress, microhardness, and recast layer thickness. AISI 316L stainless steel was chosen due to its industrial relevance and machining challenges, while a Ti-6Al-4V-SiCp composite electrode was selected for its thermal resistance and low wear. Using Taguchi’s L27 orthogonal array, this study minimized the trial numbers, with analysis of the variance-quantifying parameter contributions. The results showed a maximum material removal rate of 0.405 g/min and minimal values for the surface roughness (1.95 µm), residual stress (1063.74 MPa), microhardness (244.8 Hv), and recast layer thickness (0.47 µm). A second-order model, developed through a response surface methodology, and a feed-forward artificial neural network enhanced the prediction accuracy. Multi-response optimization using desirability function analysis yielded an optimal set of conditions: discharge current of 5.78 amperes, gap voltage of 90 volts, pulse-on time of 100 microseconds, and pulse-off time of 15 microseconds. This setup achieved a material removal rate of 0.13 g/min, with reduced surface roughness (2.46 µm), residual stress (1518.46 MPa), microhardness (259.01 Hv), and recast layer thickness (0.87 µm). Scanning electron microscopy further analyzed the surface morphology and recast layer characteristics, providing insights into the material behavior under EDM. These findings enhance the understanding and optimization of the EDM processes for challenging materials, offering valuable guidance for future research and industrial use.

Optimization of Machining Parameters in Wire Electric Discharge Machining Inconel 600 Using Regression analysis

In this investigation, Inconel 600 is used as the workpiece material, which is typically applied in aerospace products, chemical processing equipment, furnace parts etc., due to its good resistance to stress and wear resistance. In this work, the effect of machining parameters of Wire Electric Discharge Machining (WEDM) process is investigated. Molybdenum wire electrode of 0.1mm diameter and de-ionized water dielectric medium are used for machining. Voltage, Pulse on-time, Pulse Off-time, Peak Current and Bed speed are considered as the machining parameters. Recast layer thickness is considered as the response parameter. The type of design of experiments considered for this work is Taguchi’s L18 orthogonal array. Analysis of variance is indicating the percentage contribution of each machining parameters on response parameters. The optimum combination of machining parameters yielded minimum Recast layer thickness 4.11μm.

Meso-level surface modification of Hastelloy C276 by WS2 powder mixed electrical discharge alloying process through micro-EDM setup

The present research provides a rigid, wear-resistant lubricating localized layer on Hastelloy C276 (HC 276) surface at meso level by tungsten disulphide (WS2) powder suspended electrical discharge alloying (EDA) process through micro-electrical discharge machining (μ-EDM) setup. The performance characteristics of the coated surface were evaluated in terms of material deposition rate (MDR), surface morphology, surface roughness (Ra, Rz and Rq), recast layer thickness (RLT), compositional analysis, micro-hardness & indentation depth, wear test and water contact angle analysis. Maximum MDR has been achieved at 15 g/L WS2 concentration and 80 V of gap voltage whereas The RLT varies from 6.87 μm to 18.91 μm and is enhanced with the increase in WS2 concentration. The critical surface characterization confirms higher WS2 concentration reduces the crater dimensions and the presence of micro-cracks and micro-voids on the coated surface. The surface roughness has been increased with the gap voltage and capacitance, whereas higher WS2 concentration provides lower surface roughness. X-Ray diffraction analysis (XRD) confirms the presence of hard and wear resistance phases like WC, WO3, ZnO, and MoO2 on the coated surface. Energy-Dispersive X-Ray Spectroscopy (EDS) analysis along with elemental mapping justifies tool, dielectric materials, and powder particles migration on the coated surface. The micro-hardness of the coated surface (402 HV to 1166 HV) is enhanced by 3–4 times compared to the base material (299 HV) whereas the indentation depth has been reduced with the rise in WS2 concentration and lies within the RLT of the coated surface. The wear rate of the WS2 coated surface is drastically reduced compared to the base material with a lower value of coefficient of friction (COF). The coated surface became hydrophobic in nature with a contact angle of 109.6° compared to the hydrophilic base HC 276.

Electro discharge machining performance of cryogenic heat treated copper electrode

Abstract In this study, the EDM machining performance of a cryogenic heat treated copper electrode was investigated. Within the scope of the study, electrodes selected from copper material were subjected to cryogenic heat treatment with a cycle between [room temperature/ − 184 °C/room temperature]. In the experimental design, the electrode material was changed at two levels: copper electrode (Cu) and cryogenic copper electrode (CCu). Controllable machine parameters, peak current (Ip), active pulse duration (Ton), pulse gap duration (Toff) and gap voltage (Vg) were changed at three levels. The effects of these parameters on outputs such as recast layer thickness (RLT), material removal rate (MRR), electrode wear rate (EWR) and taper angle (TA), which are taken into consideration in determining the processing quality after EDM machining experiments, were taken into account. A total of 18 experiments were carried out on Ti–6Al–4V (Titanium alloy) workpiece with copper electrode. Lower YKTK with combinations of EDM process parameters such as cryogenic copper electrode (CCu), 4 A peak current (Ip), 110 µs active pulse duration (Ton), 72 µs pulse gap time (Toff) and 6 V gap voltage (Vg), It was observed that EWR and TA and higher MRR were obtained.

Exploring the machined surface characteristics of Haynes 25 superalloy: Cost mitigation and quality enhancement perspective

The current study investigates the surface characteristics and machining cost of electrical discharge machining (EDM) of Haynes 25 superalloy using tools made by additively manufactured CuCr1Zr, pure copper and graphite. Before assessing machinability, the workpiece and tool materials were characterized using Energy Dispersive Spectroscopy (EDS), X-ray Diffraction (XRD) and evaluations of tensile strength, micro-hardness, density and thermal conductivity. The effects of current (I), voltage (V), pulse duration (Ton), duty cycle (τ) and flushing pressure (Fp) is analyzed on surface characteristics viz. surface roughness (SR), surface crack density (SCD), recast layer thickness (RCT), heat-affected zone (HAZ), micro-hardness (MH) and machining cost (MC). Post machining XRD analysis revealed the formation of cobalt oxides like (CoO and Co3O4) affecting the micro-hardness of the machined surface. Alongside, a field emission scanning electron microscopy (FESEM) is carried out which confirms, the deposition of metal carbides and oxides on the EDMed surface. Current and pulse-on-time significantly influenced performance, with optimal EDM parameters identified and validated through confirmative experiments, resulting in a mean error of ∼2.84 %. It is seen that the use of additively manufactured CuCr1Zr tools resulted in improved machined surface characteristics and a more cost-effective approach for producing intricate profiles with minimal surface defects.

Assessment of Recast Layer while Machining Die Steel D3 on EDM

The material melted and quickly solidified on the surface, forming a Recast layer over the machined surface. The present experimental assessment measures the extent of influence of machine variables towards the deposition of recast material post-machining Die Steel D3. The microstructure of the recast layer is dendritic and columnar due to sudden quenching, causing complex phase transformation. Scanning Electron Microscopy is utilized to assess the range of recast deposition. The range of average recast deposition is between 32.7 to 68.5 µm. The sequential model and lack of fit tests depict that the EDM parameters and recast layer can be modeled using 2FI equations. The analysis apprised that peak current (p-value < 0.0001) has a crucial impact on recast deposition. The duration (p-value = 0.4694) was the minimal affecting factor amid selected variables for white layer thickness, which aligns with the previous literature. The impact of current and duration is almost linear towards recast layer thickness and higher deposits of recast layer (RL) are observed at higher levels of current and duration. Lower RL can only be attained by setting a lower current and on duration. The influence of lower voltage is not much on recast layer thickness at minimum value of peak current. The residual error of 3.13% during model validation illustrates the adequacy of the model.

IMPROVEMENT IN THE RECAST LAYER THICKNESS, CORNER RADIUS AND SURFACE ROUGHNESS OF MONEL K 400 THROUGH CFRP, NANO-SiC, AND ZrSiO4 PARTICLES ADDED WIRE EDM

IMPROVEMENT IN THE RECAST LAYER THICKNESS, CORNER RADIUS AND SURFACE ROUGHNESS OF MONEL K 400 THROUGH CFRP, NANO-SiC, AND ZrSiO₄ PARTICLES ADDED WIRE EDM

Experimental and numerical study of a lateral waterjet laser cutting of an SS304 brush seal.

This study explores the application of lateral waterjet laser cutting in the fabrication of brush seals for gas turbine engines, with the aim of optimizing process parameters to enhance cutting quality. Experimental and numerical analyses were conducted to assess the effects of laser power, scanning speed, waterjet velocity, and waterjet standoff distance on key outcomes, such as kerf width, heat-affected zone, and recast layer thickness. The findings indicate that a laser power of 500 W, scanning speed of 15 mm/s, waterjet velocity up to 10 m/s, and waterjet standoff distance of 1 mm are optimal for reducing thermal damage and achieving precise kerfs. Furthermore, numerical simulations highlight the significance of controlled molten flow in realizing these optimal results, providing a comprehensive understanding of the cutting mechanism. These findings position lateral waterjet laser cutting as a better technique for brush seal manufacturing, offering significant improvements over conventional methods.

Experimental Investigation on Wire Electric Erosion Behaviour of Silicon Dioxide Particulate Reinforced Composite

The intend of current study was focused on the prediction of material removal rate (MRR) and surface roughness (SR) for the AA7050-SiO2 composite during wire electric erosion or discharge machining (WEDM) process using a brass (Br) wire electrode. Here, stir casting process was employed to develop the AA7050 matrix composite with inclusion of 10wt.% SiO2 particle reinforcement. The multi-objective optimization method of Technique for order preference by similarity to ideal solution (TOPSIS) approach has been applied to find out the optimal setting of input machining parameters such as peak current (Ip), pulse-on time (Ton) and pulse-off time (Toff). Furthermore, the significant effects of parameters were identified by analysis of variance (ANOVA). Taguchi L9 (33) orthogonal design has been formulated to perform the experimental work. TOP SIS results stated that the optimal setting of Ip at 30 amps, Ton of 130 μs and Toff of 55 μs provide the better MRR with lesser SR. The ANOVA results noticed that Ip has the prime noteworthy parameter over the adopted responses having a contribution of 45.67%, followed by Ton (32.34%) and Toff (12.26%), respectively. The confirmation test was carried out by the optimal parameters setting to verify the predicted results. Finally, the scanning electron microscopy (SEM) test was carried out for the machined surface of the composite specimen and it was reveals that the formation of craters and recast layer thickness in the machined surfaces.

MULTI-OBJECTIVE OPTIMIZATION OF MACHINING PARAMETERS FOR EDM OF MAGNESIUM ALLOY- ZE41 USING MARCOS ALGORITHM AND DIFFERENT WEIGHING METHODS: SD, CRITIC AND MEREC

This paper presents multi-objective optimization of machining parameters, i.e., electrode materials, peak current, pulse on time and pulse off time in EDM of magnesium alloy-ZE41. The objectives such as metal removal rate, tool wear rate, surface roughness, recast layer thickness and radial overcut were optimized using MARCOS algorithm and three objective weighing methods, i.e., SD, CRITIC and MEREC. Taguchi’s L27(34) orthogonal array was used for conduction of experiments. ANOVA results showed that electrode material, interaction of electrode material and peak current and pulse on time were the most significant parameters for all weighing methods. Comparative study indicated that the percentage improvement in performance at optimal parameter setting were 37.21%, 32.30% and 10.68% for SD, CRITIC and MEREC respectively. Confirmation results indicated that all objectives except tool wear rate were improved positively for SD and CRITIC, but all objectives except metal removal rate deteriorated for MEREC.

Machining characteristics and optimization of 10CrNi3Mo alloy steel by WEDM

ABSTRACT 10CrNi3Mo alloy steel has the characteristics of high hardness and wear resistance, and is widely used in aircraft and spacecraft, shipbuilding and so on. However, its conventional processing method has high tool loss. Wire Electrical Discharge Machining (WEDM) technology is based on electrode pulse discharge to corrode materials. There is no direct contact between the tool and the workpiece, so it is suitable for processing materials with complex shapes, such as high hardness and high brittleness. The focus of this study is to investigate the effects of different electrical parameters such as pulse width, pulse gap, current, and wire feeding speed on the recast layer thickness (RCL) and surface roughness (SR) of 10CrNi3Mo alloy steel processed by wire discharge machining using orthogonal experiments. The gray correlation method was used to optimize the above two process indicators, and seeking optimal processing parameters. The optimized recast layer thickness was 8.65 μ m. The surface roughness is 1.932 μ m. Achieve expected goals.

Evaluation of the Surface Integrity and Recast Layer in Electrical Discharge Turning of WC-Co Composites.

Tungsten carbide (WC) and its composites are typically associated with high hardness and high wear resistance, posing challenges in conventional machining processes like turning. To address the machining difficulties of WC-Co, electrical discharge turning (EDT) was proposed. The rotational speed in EDT is a key factor influencing the machining results; however, conflicting reports exist about its impact on the EDT process. Therefore, the effect of rotational speed on three different machining regimes, including roughing, semi-finishing, and finishing, was investigated using energy-dispersive X-ray spectroscopy (EDX), SEM, and roughness tests. Additionally, elemental mapping was applied to illustrate the element distribution on the machined surface. The results indicated that increasing the rotational speed led to a 10% to 17% decrease in the recast layer thickness and a 14% to 54% reduction in the surface roughness (Ra).

Experimental Study on the Comparison between Network Microstructure Titanium Matrix Composites and Ti6Al4V on EDM Milling.

Network microstructure titanium matrix composites (NMTMCs), featuring Ti6Al4V as the matrix and network-distributed TiB whiskers (TiBw) as reinforcement, exhibit remarkable potential for diverse applications due to their superior physical properties. Due to the difficulty in machining titanium matrix composites, electrical discharge machining (EDM) stands as one of the preferred machining techniques for NMTMCs. Nevertheless, the compromised surface quality and the recast layer significantly impact the performance of the workpiece machined by EDM. Therefore, for the purpose of enhancing the surface quality and restraining the defects of NMTMCs, this study conducted comparative EDM milling experiments between NMTMCs and Ti6Al4V to analyze the effects of discharge capacitance, charging current, and pulse interval on the surface roughness, recast layer thickness, recast layer uniformity, and surface microcrack density of both materials. The results indicated that machining energy significantly influences workpiece surface quality. Furthermore, comparative experiments exploring the influence of network reinforcement on EDM milling revealed that NMTMCs have a higher melting point, leading to an accumulation phenomenon in low-energy machining where the reinforcement could not be completely removed. The residual reinforcement in the recasting layer had an adsorption effect on molten metal affecting the thermal conductivity and uniformity within the recasting layer. Finally, specific guidelines are put forward for optimizing the material's surface roughness, recast layer thickness, and uniformity, along with minimizing microcrack density, which attain a processing effect that features a roughness of Ra 0.9 μm, an average recast layer thickness of 6 μm with a range of 8 μm, and a surface microcrack density of 0.08 μm-1.

Nanopowder-mixed EDM on biodegradable Mg alloy AZ31B for improved surface characteristics and biocompatibility

Powder-mixed electrical discharge machining (PM-EDM) was conducted on biodegradable magnesium (Mg) alloys for biomedical applications. The Mg alloy AZ31B has shown outstanding mechanical properties, similar to human bone, and is lightweight. Efforts were made to enhance the EDM capabilities by a PM-EDM process using nanopowder mixed in the dielectric medium and copper tool electrode amid the machining of Mg alloy AZ31B, followed by investigating surface modification by minimum machining time, morphology, chemistry, topography and wettability of the surfaces. The surface produced by nano PM-EDM operation exhibits minimal cracks and craters, an acceptable range of recast layer thickness (2.4 − 2.7μm), satisfactory corrosion resistance and surface roughness (Ra = 2.87μm) as well as suitable hydrophobic behaviour (CA122q) and bioactivity with Ringer’s solution, suggesting an improvement in the degradation rate. Thus, PM-EDM-induced surface modification suggests the suitability of Mg alloy AZ31B as a biodegradable implant in adults and children.

Numerical simulation and experimental validation on the mechanism of crater evolution in electrical discharge micromachining

The plasma-material interaction and evolution mechanism of a solitary crater governs the nature of the surface, either plain or textured, created through the electrical discharge micromachining (EDMM) process. Therefore, it is indispensable to understand the fundamentals of a single crater evolution, which involves melt pool hydrodynamics and material vaporization under intense plasma pressure. The plasma pressure during the workpiece heating phase alters the vaporization phenomenon and melt ejection, warranting an in-depth understanding. In light of this, the current work proposes a two-dimensional (2-D) multiphysics numerical model of the melt pool hydrodynamics during EDMM. The model incorporates thermal evolution along with the effects of active plasma pressure during the heating phase of the substrate with the help of a coupled thermo-fluidic model. The simulation results reveal the predominant role of plasma pressure on the crater morphology evolution, plasma flushing efficiency (PFE) and recast layer thickness (RLT). The predicted single crater profile is validated using single-spark experiments with reasonable agreement. Thereafter, the formation mechanism of a single crater has been extended to multi-crater creation for textured surface generation.

Improving the Quality of Laser Drilling by Assisted Process Methods of Static Solution and Mist Blowing.

The use of static solution-assisted laser drilling can effectively improve hole roundness, decrease taper angle, and reduce recast layer thickness and hole wall slag adhesion. However, the enormous energy of the laser will evaporate the solution to form a suspension droplet and reduce the quality and efficiency of laser drilling. To deal with this defect, the mist-blowing method was used to reduce the influence of droplets on the taper angle and recast layer. In this work, the effect of wind speed on drilling quality was examined, and laser drilling in air, water, and NaCl solution was carried out to analyse the effect of solution composition on hole wall morphology. The results showed that a speed fan with a proper wind speed that disperses the droplets formed in the processing area can significantly reduce the refraction and scattering of the laser, and the taper angle and roundness of the drilling hole were also reduced by 15.6% and improved by 2.4%, respectively, under the wind speed of 2 m/s. The hole wall morphology showed a thicker recast layer and cracking in air, while it was thinner in water and there was little or no layer in the NaCl solution in the same current. When drilling in NaCl, the taper angle and roundness of the drilling hole were reduced by 4.13% and improved by 2.11%, respectively, compared to water. Due to the mechanical effect of the laser in the NaCl solution, the impact force on the material was much greater than that in water. The solution cavitation effect, generated by the absorption of laser energy, caused an explosive impact on the molten material adhered to the surface of the hole wall. Above all, drilling in the NaCl solution with a current of 200 A and a wind speed of 2 m/s was the optimal condition for obtaining the best processing quality.

Comparative performance evaluation and economic assessment between traditional and vibration assisted EDM during machining of Inconel 718

Nickel based superalloy, Inconel 718 offers extensive applications in aerospace and gas turbine industries because of its outstanding properties, enabling high performance in various critical components. Despite the wide application of electric discharge machining (EDM) for difficult-to-cut conductive materials, the process becomes less productive due to unstable arcing and inadequate debris flushing during machining, leading to reduced operational efficiency. This research focuses on comparative performance evaluation and economic assessment between conventional-EDM and vibration assisted EDM (VA-EDM) while machining Inconel 718 with copper electrode. The workpiece was excited to vibrate with low frequency by employing unbalanced mass attached in a rotary motor with the aim of enhancing EDM performance. Material removal rate MRR, surface integrity (surface crack density SCD, surface roughness Ra, white (recast) layer thickness WLT) and tool wear rate TWR are analyzed to determine machining performance in comprehensive analysis. The results of the performance comparison show that vibration assisted is superior to the conventional-EDM process concerning enhanced material removal rate, and surface morphology with minimum surface crack density, tool wear rate and white layer thickness. The mean value ratios for Ra EDM/ Ra VA-EDM, TWR EDM/ TWR VA-EDM, WLT EDM/ WLT VA-EDM, and SCD EDM/ SCD VA-EDM are 1.35, 1.52, 1.21, and 1.74, respectively. Additionally, the surface integrity was enhanced using vibration-assisted EDM because it (a) increases the plasma flushing efficiency and the gap pressure gradient; (b) raises the energy of electrically charged plasma particles; (c) increases the effective flow of dielectric in the gap; (d) minimizes the number of ineffective pulses (short-circuiting and arching) on the surface; and (e) improves the dielectric flushing conditions in sparking gap. According to the findings, the overall machining expenditure per part under VA-EDM in Indian rupees (INR) 534 is lowered by 8% than expenditure under conventional-EDM (INR 576.60). The outcomes of this research have the potential to benefit numerous industries that deal with difficult-to-cut materials.