Influence of machining parameters on the surface integrity in electrical discharge machining

Purpose: The aim of this research is to make a study of the influence of machining parameters on the surface integrity in electrical discharge machining. The material used for this study is the X200Cr15 and 50CrV4 steel for dies and moulds, dies castings, forging dies etc.Design/methodology/approach: The methodology consists of the analysis and determination of the white layer thickness WLT, the material removal rate MRR, the electrode wear ratio EWR and the micro hardness of each pulse discharge energy and parameters of electrical discharge machining.Findings: The Results of the tests undertaken in this study show that increasing energy discharge increase instability and therefore, the quality of the workpiece surface becomes rougher and the white layer thickness increases. This is due to more melting and recasting of material.With the increase of the discharge energy, the amount of particles in the gap becomes too large and can form electrically conducting paths between the tool electrode and the workpiece, causing unwanted discharges, which become electric arcs (arcing). these electric arcs damage the electrodes surfaces (tool and workpiece surfaces) and can occur microcracks.Research limitations/implications: A possible future work would be the development of a general the phenomenal of the residual stress of the wire electrical discharge machining in titanium alloys. The behavior is of the residual stress studies are planed in the future.Practical implications: The relationship found between the total energy of discharge pulses, composition of the steels and the type of machining on the surface integrity (the surface texture, the metallurgical surface aspect, the microhardness in the heat affected zone, HAZ) of different workpiece materials has an important practical implication since it allows selecting the best cutting condition combination from the points of view both the security and the economy for the established requirements in each case. Results are of great importance for aerospace and automotive industry.Originality/value: The paper is original since the bibliographical review has allowed testing that, although works about these themes exist, none approaches the problem like it has been made in this work. The paper could be an interesting source of information for engineers and researchers who work with machining dies and also significant complex parts in aeronautics.