Analysis of the relationship between the properties of selected materials and the parameters of the EDD process

Analysis of the relationship between the properties of selected materials and the parameters of the EDD process


download PDF

Abstract. The thermophysical properties of the electrodes material significantly impact performance of the electrical discharge machining (EDM). The aim of this article was to investigate the influence of thermophysical properties of selected materials on the EDM process. The effect of the thermophysical properties of these materials on process efficiency factors (material removal rate, linear tool wear) and hole geometry (aspect ratio, radial overcut) was analyzed. The results showed that selected thermophysical properties of the workpiece, such as thermal conductivity, melting point, have the most significant impact on the electro-erosion process. Optimal result parameters (material removal rate: 2.58 mm3/min, linear tool wear: 4.95 mm, aspect ratio: 8.00, radial overcut: 0.046 mm) and no presence of “bottom cone” were obtained for EDM drilling in Inconel 718 and similarly for AISI 1045 steel. On the other end were high resistance alloys such as tungsten carbide and copper alloy.

Electrical Discharge Drilling (EDD), Micro-Hole, Difficult-To-Cut Material

Published online 4/19/2023, 12 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: TRAJER Marcin, CZESZKIEWICZ Adrian, MACHNO Magdalena, Analysis of the relationship between the properties of selected materials and the parameters of the EDD process, Materials Research Proceedings, Vol. 28, pp 1747-1758, 2023


The article was published as article 189 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] B.M. Schumacher, R. Krampitz, J.-P. Kruth, Historical phases of EDM development driven by the dual influence of “Market Pull” and “Science Push”, Procedia CIRP 6 (2013) 5-12.
[2] J.E. Abu Qudeiri, A. Saleh, A. Ziout, A.-H.I. Mourad, M.H. Abidi, A. Elkaseer, Advanced electric discharge machining of stainless steels: assessment of the state of the srt, gaps and future prospect, Materials 13(6) 907 (2019) 2-48.
[3] T. Chwalczuk, A. Felusiak, M. Wiciak-Pikuła, Influence of electrode material on surface roughness during die-sinking electrical discharge machining of Inconel 718, Mat. Res. Proc. 17 (2020) 138-145.
[4] E. Franczyk, M. Machno, W. Zębala, Investigation and optimization of the SLM and WEDM processes’ parameters for the AlSi10Mg-sintered part, Materials 14 (2021) 1-16.
[5] D. Kumar, N.K. Singh, V. Bajpai, Recent trends, opportunities and other aspects of micro-EDM for advanced manufacturing: a comprehensive review, J. Braz. Soc. Mech. Sci. Eng. 42 (2020).
[6] K.H. Ho, S.T. Newman, State of the art electrical discharge machining (EDM), Int. J. Mach. Tools Manuf. 43 (2003) 1287-1300.
[7] R. Świercz, D. Oniszczuk-Świercz, Experimental investigation of surface layer properties of high thermal conductivity tool steel after electrical discharge machining, Metals 7 (2017) 1-16.
[8] T. Musazawa, State of the art of micromachining, CIRP Ann. 49 (2000) 473-488.
[9] S. Thirumalai Kumaran, T.J. Ko, M. Uthayakumar, M.A. Khan, M. Niemczewska-Wójcik, Surface texturing by dimple formation in TiAlSiZr alloy using μ-EDM, J. Aust. Ceram. Soc. 53 (2017) 821-828.
[10] M. Trajer, Ł. Pyclik, J.R. Sobiecki, The nickel aluminide coatings obtained on small holes produced with the EDD method, Stroj. Vestn./J. Mech. Eng. 68) (2022) 623-634.
[11] B.K. Sahu, S. Datta, S.S. Mahapatra, On electro-discharge machining of Inconel 718 super alloys: an experimental investigation, Mater. Today 5 (2018) 4861-4869.
[12] L. Zhang, H. Tong, Y. Li, Precision machining of micro tool electrodes in micro EDM for drilling array micro holes, Precis. Eng. 39 (2015) 100-106.
[13] D. Reynaerts, P.-H.’s Heeren, H. van Brussel, Microstructuring of silicon by electro-discharge machining (EDM)-part I: theory, Sens. Actuators A: Phys. 60(1-3) (1997) 212-218.
[14] G. Maccarini, G. Pellegrini, C. Ravasio, Effects of the properties of workpiece, electrode and dielectric fluid in micro-EDM drilling process, Procedia Manuf. 51 (2021) 834-841.
[15] M. Machno, Investigation of the machinability of the Inconel 718 superalloy during the electrical discharge drilling process, Materials 13 (2020) 1-20.
[16] B. Khosrozadeh, M. Shabgard, Effects of hybrid electrical discharge machining processes on surface integrity and residual stresses of Ti-6Al-4V titanium alloy, Int. J. Adv. Manuf. Technol. 93 (2017) 1999-2011.
[17] A. Gholipoor, H. Baseri, M.R. Shabgard, Investigation of near dry EDM compared with wet and dry EDM processes, J. Mech. Sci. Technol. 29 (2018) 2213-2218.
[18] A.A. Khan, Electrode wear and material removal rate during EDM of aluminum and mild steel using copper and brass electrodes, Int. J. Adv. Manuf. Technol. 39 (2008) 482-487.
[19] Suhardjono, Characteristics of electrode materials on machining performance of tool steel SKD11 with EDM shinking, ARPN J. Eng. Appl. 11 (2016) 986-991.
[20] Z. Pan, Y. Feng, T.P. Hung, Y.C. Jiang, F.C. Hsu, L.T. Wu, C.F. Lin, Y.C. Lu, S.Y. Liang, Heat affected zone in the laser-assisted milling of Inconel 718, J. Manuf. Process. 30 (2017) 141-147.
[21] M. Hernándes, R.R. Amriz, R. Cortès, C.M. Gómora, G. Plascencia, D. Jaramillo, Assessment of gas tungsten arc welding thermal cycles on Inconel 718 alloy, T. Nonferr. Metal. Soc. 29 (2019) 579-587.
[22] J. Selech , D. Ulbrich, D. Romek, J. Kowalczyk, K. Włodarczyk, Nadolny, Experimental study of abrasive, mechanical and corrosion effects in ring-on-ring sliding contact, Materials 13 4950 (2020).
[23] J. Ma, N.H. Duong, Sh. Lei, Numerical investigation of the performance of microbump textured cutting tool in dry machining of AISI 1045 steel, J. Manuf. Process. 19 (2015) 194-204.
[24] R. Velavan, S. Nandhakumar, P. Vijayakumar, Experiment in EDM process by using brass electrode with Inconel material in nano powder mixed dielectric medium, Pakistan J. Biotechnol. 14 (2017) 50-53.
[25] Y. Zhang, Z. Xu, Y. Zhu, D. Zhu, Effect of tube-electrode inner structure on machining performance in tube-electrode high-speed electrochemical discharge drilling, J. Mater. Process. Technol. 231 (2016) 38-49.
[26] S. Vidya, P. Mathiyalangan, R. Wattal, A review on research aspects and trends in micro-electrical discharge machining (micro-EDM), Int. J. Eng. Technol. Sci. Res. 5 (2018) 581-590.
[27] E. Bamberg, S. Heamawatanachai, Orbital electrode actuation to improve efficiency of drilling micro-holes by micro-EDM, J. Mater. Process. Technol. 209 (2009) 1826-1834.