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Experimental investigation of the effect of EDM parameters and dielectric type on the surface integrity and topography

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Abstract

The electrical discharge machining (EDM) process is mostly used in conditions that complex and intricate shapes need to be machined on very hard metals. However, the process leaves behind some undesirable properties such as high surface roughness, rough topography, high residual tensile stresses, micro-cracks, heat-affected zone (HAZ), and recast layer. This paper investigates the effects of different output parameters on the properties listed above. The input parameters studied include current, pulse-on time, and the type of dielectric; and the material being machined is AISI 1045 steel. Results show that the deionized water improved the output variables in EDM. The use of deionized water as the dielectric, not only improved the machined surfaces’ topography but also lowered the micro-cracks and HAZ thickness. The experiments also show how the pulse-on and current time affect the outcome of EDM machining of AISI 1045 steel.

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Acknowledgements

The authors would like to thank Dr. Ghanbari form University of Kashan for providing the 3D optical microscope in order to surface topography measurement.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran

    Hasan Rahimi

  2. Young Researchers and Elite Club, Najafabad Branch, Islamic Azad University, Najafabad, Iran

    Soroush Masoudi

  3. School of Engineering, Edith Cowan University, Joondalup, WA, 6027, Australia

    Soroush Masoudi & Majid Tolouei-Rad

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  1. Hasan Rahimi
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  2. Soroush Masoudi
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  3. Majid Tolouei-Rad
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Contributions

Experiments performed by Mr. Hasan Rahimi and he provided the conception and design of the study. Mr. Soroush Masoudi supervised development of work and performed analysis and interpretation of data, wrote manuscript, and acted as corresponding author. Mr. Majid Rad helped in data interpretation and manuscript evaluation.

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Correspondence to Soroush Masoudi.

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Rahimi, H., Masoudi, S. & Tolouei-Rad, M. Experimental investigation of the effect of EDM parameters and dielectric type on the surface integrity and topography. Int J Adv Manuf Technol 118, 1767–1778 (2022). https://doi.org/10.1007/s00170-021-08040-z

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