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<p>Electrical discharge machining (EDM) has been extensively used for manufacturing functional parts in aerospace, automobile, energy and mould-making industries due to its distinctive capability of machining geometrically complex with high dimensional accuracy in difficult-to-machine materials. However, non-uniform heating and cooling during EDM typically generate significant residual tensile stress fields in the machined surface layer, which induce micro-cracks and promote their propagation, thus seriously deteriorating the surface/sub-surface integrity and mechanical properties of the end-use component. A large number of investigations have been carried out on residual stress (RS) induced by EDM, which have revealed some important relationships, yet there is no review that summarizes this information. This paper surveys and assembles the current research status on RS in EDM. First, the formation mechanism of RS in EDM and the measurement methods are discussed. Then, the distribution of RS in EDM surface layers is classified into three categories, followed by a detailed analysis and summary of the influence of processing parameters, workpiece and tool electrode, and dielectric on the RS. Also, the research progress in numerical simulation of EDM-induced RS is summarized. Furthermore, modification strategies for EDM-induced RS are discussed in depth, including hybrid-EDM, powder additives, roughing-finishing sequence strategy, and various post-processing techniques. Finally, a micro-foil bending technique based on RS generated by EDM is introduced. This work systematically summarizes the formation mechanism, distribution, and modification strategies of RS caused by EDM, which can benefit future process optimization and control for minimizing RS and improving EDM surface integrity.</p>

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Residual stress and its modification strategies in the surface/sub-surface layer of components machined by electrical discharge machining: a review

  • 期刊论文

  • 发表日期：

    2025年6月16日

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  • Xiaoming Duan,
  • Krishna Kumar Saxena,
  • Jun wang,
  • Muhammad Hazak Arshad,
  • Izaro Ayesta,
  • Yifan Wang,
  • Dominiek Reynaerts,
  • Xiaodong Yang

摘要

Electrical discharge machining (EDM) has been extensively used for manufacturing functional parts in aerospace, automobile, energy and mould-making industries due to its distinctive capability of machining geometrically complex with high dimensional accuracy in difficult-to-machine materials. However, non-uniform heating and cooling during EDM typically generate significant residual tensile stress fields in the machined surface layer, which induce micro-cracks and promote their propagation, thus seriously deteriorating the surface/sub-surface integrity and mechanical properties of the end-use component. A large number of investigations have been carried out on residual stress (RS) induced by EDM, which have revealed some important relationships, yet there is no review that summarizes this information. This paper surveys and assembles the current research status on RS in EDM. First, the formation mechanism of RS in EDM and the measurement methods are discussed. Then, the distribution of RS in EDM surface layers is classified into three categories, followed by a detailed analysis and summary of the influence of processing parameters, workpiece and tool electrode, and dielectric on the RS. Also, the research progress in numerical simulation of EDM-induced RS is summarized. Furthermore, modification strategies for EDM-induced RS are discussed in depth, including hybrid-EDM, powder additives, roughing-finishing sequence strategy, and various post-processing techniques. Finally, a micro-foil bending technique based on RS generated by EDM is introduced. This work systematically summarizes the formation mechanism, distribution, and modification strategies of RS caused by EDM, which can benefit future process optimization and control for minimizing RS and improving EDM surface integrity.