Analysis of Material Removal and Surface Integrity in the EDM Process
doi.org/10.63339/FME20250904
Keywords:
Electrical Discharge Machining, Material removal rate, Surface integrity, Recast layer, Pulse parametersAbstract
Electrical Discharge Machining (EDM) is prevalently applied in the shaping of hard to machine material, but thefundamentals of this process are complicated thermo-electric events that affect material removal as well as the integrity ofthe surfaces. This research examines how discharge parameters; pulse current, pulse duration, duty factor and dielectricflushing relate to and affect the combination of discharge parameters in determining the rate of material removal (MRR), tool wear, surface roughness as well as metallurgical changes in machined zone. A high-strength alloy was experimented with the help of controlled EDM conditions and then microcracks and surface topography were detailed throughcharacterization of the recast layer, heat-affected zone, and microcracks of the material. Its findings indicate that pulsecurrent and pulse-on time improvements are both effective in raising MRR and worsening surface defects such as recast layers and microcracks. On the other hand, enhanced lower-energy pulses enhance surface quality at reduced materialremoval speed. Thermal gradients during repetitive discharges can be studied microscopically to observe rapid melting and quenching to form globule debris, crater clusters, and modified microstructures. The paper establishes a window ofoperation that reduces the amount of damage caused on surfaces and also attains acceptable machining performance. The results add to the better insight of EDM mechanisms and give a practical advice on how to choose the process parameters when the surface integrity is the important factor of a component performance.References
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