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Experimental investigation and 3D finite element prediction of the white layer thickness, heat affected zone, and surface roughness in EDM process

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Abstract

An axisymmetric three-dimensional model for temperature distribution in the electrical discharge machining process has been developed using the finite element method to estimate the surface integrity characteristics of AISI H13 tool steel as workpiece. White layer thickness, depth of heat affected zone, and arithmetical mean roughness consisting of the studied surface integrity features on which the effect of process parameters, including pulse on-time and pulse current were investigated. Additionally, the experiments were carried out under the designed full factorial procedure to validate the numerical results. Both numerical and experimental results show that increasing the pulse on-time leads to a higher white layer thickness, depth of heat affected zone, and the surface roughness. On the other hand, an increase in the pulse current results in a slight decrease of the white layer thickness and depth of heat affected zone, but a coarser surface roughness. Generally, there is a good agreement between the experimental and the numerical results.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Tabriz, Tabriz, Iran

    Mohammadreza Shabgard, Mirsadegh Seyedzavvar & Ahmad Najadebrahimi

  2. Department of Mechanical Engineering, Middle East Technical University, Ankara, Turkey

    Samad Nadimi Bavil Oliaei

Authors
  1. Mohammadreza Shabgard
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  2. Samad Nadimi Bavil Oliaei
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  3. Mirsadegh Seyedzavvar
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  4. Ahmad Najadebrahimi
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Corresponding author

Correspondence to Samad Nadimi Bavil Oliaei.

Additional information

This paper was recommended for publication in revised form by Associate Editor In-Ha Sung

Mohammadreza Shabgard received his PhD in manufacturing and production engineering at University of Tabriz, and currently is an associate professor at this university. His research interests mainly include advanced manufacturing methods.

Samad Nadimi Bavil Oliaei received his MSc in manufacturing and production engineering at University of Tabriz, and currently is a PhD student at the Middle East Technical University. He is doing research in micro-mechanical machining.

Mirsadegh Seyedzavvar received his MSc in manufacturing and production engineering at University of Tabriz under supervision of Professor M. Shabgard. His research interests mainly include advanced manufacturing methods.

Ahmad Najadebrahimi received his MSc in manufacturing and production engineering at University of Tabriz, and currently is a researcher at the research center of East Azerbaijan branch of Iran Khodro Co. His research interests mainly include the utilization of FEM in welding and machining methods.

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Shabgard, M., Oliaei, S.N.B., Seyedzavvar, M. et al. Experimental investigation and 3D finite element prediction of the white layer thickness, heat affected zone, and surface roughness in EDM process. J Mech Sci Technol 25, 3173–3183 (2011). https://doi.org/10.1007/s12206-011-0905-y

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  • DOI: https://doi.org/10.1007/s12206-011-0905-y

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