PARAMETRIC APPROACH MODEL FOR DETERMINING ELECTRICAL DISCHARGE MACHINING (EDM) CONDITIONS: EFFECT OF CUTTING PARAMETERS ON THE SURFACE INTEGRITY

摘要

Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. The EDM process is based on thermoelectric energy between the work piece and an electrode. There are various types of products which can be produced by using EDM, such as dies and moulds. Today, many parts used in the aerospace and automotive industries and in the final processes of surgical components can be finished by the EDM process. A simple and easily understandable model was proposed for predicting the relative importance of different factors (composition of the steel and Electro Discharge Machining processing conditions) in order to obtain efficient pieces. A detailed application on the tool steel machined by EDM was given in this study. This model is based on thermal, metallurgical, mechanical, and in situ test conditions. It gives detailed information on the effects of electrochemical parameters on the surface integrity and sub-surface damage of the material (Heat Affected Zone, HAZ), the level of residual stresses, and the surface texture. This approach is an efficient way to separate the responsibilities of the steel maker and machining process designer for increasing the reliability of the machined structures.