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<p>The work focuses on achieving a high-quality machined surface on an AISI D3 workpiece using a high-speed Electrical Discharge Machining (EDM) process, along with analysing its morphology. In this process, a dielectric fluid medium with a specific electric conductivity (714µsec/cm) was utilized, along with an electrolyte copper rod of diameter 20&#xa0;mm as the high-speed rotary tool electrode (RTE). The primary objective of the study was to examine the influence of pulse-on time on surface integrity, specifically regarding the formation of the recast layer during high-speed Electrical Discharge Machining processes. The investigation revealed a direct correlation between pulse-on time and recast layer thickness: as the pulse-on time increased, so did the thickness of the recast layer. Furthermore, it was noted that the microstructure of the recast layer was affected by the cooling rate and flushing pressure of the dielectric fluid. These factors play a crucial role in determining the final characteristics of the recast layer, highlighting the importance of controlling process parameters for achieving desired surface quality in high-speed EDM applications. The study assessed the recast layer (RL) and surface roughness (SR) as response parameters and correlated them with various analytical techniques such as X-ray Diffraction (XRD), residual stress analysis, oscilloscope (DSO) readings, Scanning Electron Microscopy (SEM), Energy-dispersive X-ray spectroscopy (EDS), and its spectra results. The results indicated the formation of various inter-metallic compounds on the machined surface, suggesting an improvement in surface quality compared to conventional Electric Discharge Machining (EDM) processes. In summary, the research demonstrates the effectiveness of high-speed EDM in producing high-finished machined surfaces on AISI D3 steel, with detailed analysis and characterization of the surface morphology and recast layer formation mechanism. This could potentially lead to advancements in manufacturing processes, particularly in industries where precise surface finishing is critical.</p>

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Role of Pulse-Duration in Characterization of Surface Integrity in High Speed EDM of AISI D3 Steel

  • 期刊论文

  • 发表日期：

    2025年9月1日

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  • Mukesh Kumar,
  • Vipin,
  • Mohammad Sakib Perwez Khan

摘要

The work focuses on achieving a high-quality machined surface on an AISI D3 workpiece using a high-speed Electrical Discharge Machining (EDM) process, along with analysing its morphology. In this process, a dielectric fluid medium with a specific electric conductivity (714µsec/cm) was utilized, along with an electrolyte copper rod of diameter 20 mm as the high-speed rotary tool electrode (RTE). The primary objective of the study was to examine the influence of pulse-on time on surface integrity, specifically regarding the formation of the recast layer during high-speed Electrical Discharge Machining processes. The investigation revealed a direct correlation between pulse-on time and recast layer thickness: as the pulse-on time increased, so did the thickness of the recast layer. Furthermore, it was noted that the microstructure of the recast layer was affected by the cooling rate and flushing pressure of the dielectric fluid. These factors play a crucial role in determining the final characteristics of the recast layer, highlighting the importance of controlling process parameters for achieving desired surface quality in high-speed EDM applications. The study assessed the recast layer (RL) and surface roughness (SR) as response parameters and correlated them with various analytical techniques such as X-ray Diffraction (XRD), residual stress analysis, oscilloscope (DSO) readings, Scanning Electron Microscopy (SEM), Energy-dispersive X-ray spectroscopy (EDS), and its spectra results. The results indicated the formation of various inter-metallic compounds on the machined surface, suggesting an improvement in surface quality compared to conventional Electric Discharge Machining (EDM) processes. In summary, the research demonstrates the effectiveness of high-speed EDM in producing high-finished machined surfaces on AISI D3 steel, with detailed analysis and characterization of the surface morphology and recast layer formation mechanism. This could potentially lead to advancements in manufacturing processes, particularly in industries where precise surface finishing is critical.