Abstract
Electro discharge machining process (EDM) is frequently used when machining of high complex and accurate features is required. Indeed, it is specially recommended for hard materials and micro-machined features. However, due to the process nature, there is still incomprehension on process parameters influence at the final quality features, ending up by lower productivity and quality ratios. On the other hand, fashioning and re-shaping of required electrodes for each feature are time consuming phases and the number of stored electrodes is very high. Therefore, in order to increase the global EDM process productivity, quality and flexibility, standardized simple electrode shapes, capable to machine different features, must be found. This study presents the influence of the main EDM process parameters and different tool geometries on basic process performance measures. A set of designed experiments with varying parameters such as pulsed current, open voltage, pulse time and pulse pause time are carried out in H13 steel using different geometries of copper electrodes. In addition, material removal rate , surface roughness and different dimensional and geometrical micro-accuracies are analyzed through statistical methods. Results help to select appropriate EDM process parameters to machine parts depending on product requirements.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Das S., Klotz M., Klocke F. (2003) EDM simulation: Finite element-based calculation of deformation, microstructure and residual stresses. Journal of Materials Processing Technology 142: 434–451. doi:10.1016/S0924-0136(03)00624-1
Fenggou C., Dayong Y. (2004) The study of high efficiency and intelligent optimization system in EDM sinking process. Journal of Materials Processing Technology 149(1): 83–87. doi:10.1016/j.jmatprotec.2003.10.059
Ferreira J. C. (2007) A study of die helical thread cavity surface finish made by Cu-W electrodes with planetary EDM. International Journal of Advanced Manufacturing Technology 34(11–12): 1120–1132. doi:10.1007/s00170-006-0687-z
García Navas V., Ferreres I., Marañón J. A., Garcia-Rosales C., Gil Sevillano J. (2008) Electro-discharge machining (EDM) versus hard turning and grinding-comparison of residual stresses and surface integrity generated in AISI O1 tool steel. Journal Materials Processing Technology 195(1–3): 186–194
Ghoreishi M., Tabari C. (2007) Investigation into the effect of voltage excitation of pre-ignition spark pulse on the electro-discharge machining (EDM) process. Materials Manufacturing Processes 22(7): 833–841
Groover M. P. (1996) Fundamentals of modern manufacturing. Prentice-Hall, NJ
Guu Y. H., Hou M. T. (2007) Effect of machining parameters on surface textures in EDM of Fe-Mn-Al alloy. Materials Science Engineering 466(1–2): 61–67
Ho K. H., Newman S. T. (2003) State of the art electrical discharge machining (EDM). International Journal of Machine Tools and Manufacture 43(12–13): 1287–1300
Ho K. H., Newman S. T., Rahimifard S., Allen R. D. (2004) State of the art in wire electrical discharge machining (WEDM). International Journal of Machine Tools and Manufacture 44: 1247–1259
Jeong Y. H., Min B. (2007) Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation. International Journal of Machine Tools and Manufacture 47(12–13): 1817–1826
Khanra A. K., Sarkar B. R., Bhattacharya B., Pathak L. C., Godkhindi M. M. (2007) Performance of ZrB2–Cu composite as an EDM electrode. Journal of Materials Processing Technology 183: 122–126
Kiyak M., Çakır O. (2007) Examination of machining parameters on surface roughness in EDM of tool steel. Journal of Materials Processing Technology 191(1–3): 141–144
Kumar P. D. (2008) Study of thermal stresses induced surface damage under growing plasma channel in electro-discharge machining. Journal of Materials Processing Technology 202(1): 86–95
Lin Y., Cheng C., Su B., Hwang L. (2006) Machining characteristics and optimization of machining parameters of SKH 57 high-speed steel using electrical-discharge machining based on Taguchi method. Materials Manufacturing Processes 21(8): 922–929
Liu K., Ferraris E., Peirs J., Lauwers B., Reynaerts D. (2008) Micro-EDM process investigation of Si3N4-TiN ceramic composites for the development of micro-fuel-based power units. International Journal of Manufacturing Research 3(1): 27–47
Liu H., Yan B., Chen C. L., Huang F. Y. (2006) Application of micro-EDM combined with high-frequency dither grinding to micro-hole machining. International Journal of Machine Tools and Manufacture 46(1): 80–87
Liu H., Yan B., Huang F., Qiu K. (2005) A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications. Journal of Materials Processing Technology 169(3): 418–426
Logothetis N., Wynn H. P. (1989) Quality through design: Experimental design, off-line quality control and Taguchi’s contributions. Clarendon Press, Oxford
Mahardika M., Tsujimoto T., Mitsui K. (2008) A new approach on the determination of ease of machining by EDM processes. International Journal of Machine Tools and Manufacture 48: 746–760
Markopoulos A. P., Manolakos D. E., Vaxevanidis N. M. (2008) Artificial neural network models for the prediction of surface roughness in electrical discharge machining. Journal of Intelligent Manufacturing 19: 283–292
Özgedik A. (2006) An experimental investigation on tool wear in electric discharge machining. International journal of advanced manufacturing technology 27: 488–496
Pham D. T., Dimov S. S., Bigot S., Ivanov A., Popov K. (2004) Micro-EDM—recent developments and research issues. Journal of Materials Processing Technology 149(1–3): 50–57
Pradhan, B. B., Masanta, M., Sarkar, B. R., Bhattacharyya, B. (2008). Investigation of electro-discharge micro-machining of titanium super alloy. International Journal Advanced Manufacturing Technologies 1–13
Puertas I., Luis C. J. (2004) A study of optimization of machining parameters for electrical discharge machining of boron carbide. Materials Manufacturing Processes 19(6): 1041–1070
Salman Ö., Kayacan M. C. (2008) Evolutionary programming method for modeling the EDM parameters for roughness. Journal of Materials Processing Technology 200(1–3): 347–355
Singh S., Maheshwari S., Pandey P. C. (2004) Some investigations into the electric discharge machining of hardened tool steel using different electrode materials. Journal of Materials Processing Technology 149: 272–277
Sundaram M. M., Pavalarajan G. B., Rajurkar K. P. (2008) A study on process parameters of ultrasonic assisted micro EDM based on Taguchi method. Journal of Materials Engineering Perform 17(2): 210–215
Tsai K. M., Wang P. J. (2001) Predictions on surface finish in electrical discharge machining based upon neural network models. International Journal of Machine Tools and Manufacture 41: 1385–1403
Wansheng Z., Zhenlong W., Shichun D., Guanxin C., Hongyu W. (2002) Ultrasonic and electric discharge machining to deep and small hole on titanium alloy. Journal of Materials Processing Technology 120(1–2): 101–106
Yan B. H., Huang F. Y., Chow H. M., Tsai J. Y. (1999) Micro-hole machining of carbide by electric discharge machining. Journal of Materials Processing Technology 87(1–3): 139–145
Yan B. H. (2000) Machining characteristics of Al2O3/6061Al composite using rotary EDM with a disklike electrode. International journal of advanced manufacturing technology 16(5): 322–331
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Pellicer, N., Ciurana, J. & Delgado, J. Tool electrode geometry and process parameters influence on different feature geometry and surface quality in electrical discharge machining of AISI H13 steel. J Intell Manuf 22, 575–584 (2011). https://doi.org/10.1007/s10845-009-0320-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10845-009-0320-8