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To cite this article: Wujun Feng, Xuyang Chu, Yongqiang Hong & Li Zhang (2017): Studies on
the surface of high-performance alloys machined by micro-EDM, Materials and Manufacturing
Processes, DOI: 10.1080/10426914.2017.1364758
Download by: [Wilfrid Laurier University] Date: 11 August 2017, At: 20:04
Studies on the surface of high-performance alloys machined
by micro-EDM
Wujun Feng
Xuyang Chu*
Yongqiang Hong
Li Zhang
ABSTRACT
SUS304, and SKH59 alloys, which are important aviation materials EDM influences the surface
morphologies of these materials and directly affects their reliability during use. However, current
surface evaluation parameter such as Ra cannot describe the surface morphology machined by
1
micro-EDM precisely. Therefore, systematic research on surface morphology of the
aforementioned alloys is presented in the study. Based on a novel evaluation method combining
fractal theory with wavelet filters, first, comparative experiments on surface morphology
evaluations of different materials were conducted and discussed. Second, two different pulse
power supplies were studied to explore the effect of pulse power on the high-performance alloy
surface. Third, three different micro-EDM processing methods were compared to study their
effects on the surfaces of high-performance alloys. Finally, different machining parameters such
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as discharging energies, rotation speeds of the tool electrode, and gap voltages were set to
investigate their effects on the surface morphology. The results showed that different materials,
pulse power supplies, processing methods, and machining parameters greatly influence the surface
Introduction
Titanium alloys, stainless steels, and high-speed steels are three types of high-performance
alloys that are widely used in the aerospace industry. Titanium alloys are characterized by low
density, high-temperature strength, and endurance strength; therefore, they have been used to
replace aluminum alloys in fabricating the shells of aircraft engines. Stainless steel is another type
of material applied extensively to space launch vehicles and exhaust passages around rocket
engines because it possesses good plasticity and toughness. High-speed steel is mainly employed
in high-speed cutting of aircraft parts because it has high hardness and good wear resistance. In
aerospace materials, surface accuracy is extremely important; low-quality surfaces can have
serious consequences in many cases. Because the abovementioned three types of materials are
2
difficult to machine, the selection of suitable machining methods for these types of intractable
of high accuracy and non-contact machining render it suitable for machining difficult-to-process
materials, and it can produce high-precision surfaces. Surface accuracy is an important factor in
determining component reliability, and surfaces machined by micro-EDM are often used as final
surface forms, so the analysis of this type of surface morphology is a focus in intractable materials.
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series of experiments based on response surface methodology (RSM) and Box–Behnken statistical
design. Surface morphology and the quality of machined surfaces were crucial components of the
study.[4] Moses and Jahan presented several comparative experiments between Ti–6Al–4V and
brass to investigate the different microscale features of the metals; surface morphology was one of
these, judged intuitively based on the observation of debris.[5] Koyano et al. studied the decrease
of energy to improve the quality of surfaces machined on stainless steel, using the average surface
parameters on machining stainless steel shim, investigating Ra, metal removal rate, and the tool
wear ratio; among these features, surface morphology was an essential reference.[7] Das et al.
studied the surface integrity of SUS 304 sheet machined by micro-EDM; surface integrity mainly
consists of surface morphology, recast layers, and white layer thicknesses, so they discuss surface
morphology extensively.[8] D’Urso et al. studied stainless steel grinding using different micro-
EDM electrodes, judging electrode effectiveness based on the surface morphology of inner
microscale holes.[9] These studies show that surface morphology is an indispensable factor
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reflecting the machining quality of intractable materials such as titanium alloys, stainless steels,
surface evaluation methods cannot describe the surface morphology machined by micro-EDM
because of the random discharging process, which creates many peaks and craters on the surface,
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different from surfaces formed by traditional machining methods. Moreover, few researchers have
conducted systematic studies on the surface morphology of intractable materials. The object of the
study presented is the systematic investigation of surface morphology utilizing different processing
methods, materials, pulsed power supplies, and machining parameters, using a novel evaluation
method.
Fractal theory is usually used to depict the morphologies of mountains and rivers which
evaluation parameter of fractal theory is concise. Therefore, it is suitable for evaluating the micro-
EDM surface.
Because the sample data of surface morphology is dispersed, the correct calculation method
of fractal theory should be chosen. The sample property can be described as having a Fractional
B t1 – B t2
2 2
t 1 –t 2 (1)
4
Where B(t) is the location of the particles in Brownian motions, α is the index of Hurst. For
a random surface profile S(τ), its incremental variance can be defined as a structure function, and
1 L
S Z x Z Z x Z ( ) C 42D (2)
2 2
x0
L
Where τ is the increment of the process, L is the length of the sample, D is the fractal
dimension, and C is a constant. Combining structure function with Fractional Brownian Motions,
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S
2
(3)
As the data of sample are discrete, the heights of the profile are set to x[i] (i = 0, 1, …, N-
1), where N is the sample number. The expression of its discrete form can be written as follows:[19]
N 1n
x i n x i
2
S n i 0
(4)
N n
According to expression (3), expression (4) can be simplified to the following expression:
S n G n42D (5)
slope of the curve, the fractal dimension can be calculated using the following equation:
D 2 k / 2 (6)
Hence, the structure function method is suitable for the fractal dimension calculation,
Regarding the filter of the profile curve, because the surface morphology machined by
micro-EDM has high precision, the wavelet filter method can filter high frequency noise and then
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retain low frequency signals as much as possible, it is the filter method chosen in this study.
According to Parseval theorem, if there are two signals f1(x) and f2(x), the relationship between the
1
f1 x f2* x dx F1 w F2* w dw (7)
2
1
f1 x dx F w dw F f df (8)
2 2 2
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2
Expression (8) shows that the energy of signal is conserved. Suppose that f1(x), f2(x)
andψ∈L2(R),W f1(a,b) and W f2(a,b) is the wavelet transformation of f1(x) and f2(x), then the
da
Wf1 a, bWf2 a, b db C f1 x , f2 x (9)
0 a2
w
Where C dw , w is obtained by a Fourier transform of x .
0
w
Wf a, b
2
1
f1 x
2
dx dadb (11)
0 C 0 a2
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The information in the original signal is retained effectively after orthogonal
transformation. Hence, wavelet method is an ideal solution for filters. For the choice of wavelet
basis, eight orders of Daubechies wavelet are chosen as the wavelet basis.
Above all, the novel surface-evaluation method combining fractal theory with wavelet
filters is applied in the study based on previous work.[20] The detailed procedure is shown in Figure
1. According to the evaluation rule, surface morphologies of high fractal dimension represent high-
quality surfaces. the experiments in the study tested the following four aspects: 1) materials; 2)
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Titanium alloys, stainless steels, and high-speed steels were chosen as the workpieces to
investigate the distinctions of surface morphology from the different materials. Table 1 shows the
main properties of the three selected materials. These were machined by the same discharging
Two types of pulsed power supply were used in micro-EDM: RC and transistor pulse
power supplies. The discharging process of the RC pulse power supply features high voltages and
high currents, while that of the transistor pulse power supply is the opposite, as Figure 2 shows.
Therefore, the discharging process of RC-type pulse power supplies is more severe than that of
transistor pulse power supplies. The surface morphologies of the same material machined by
different pulse power supplies may therefore differ.[21] The differences were investigated by using
The three types of mainstream processing methods used were micro-EDM grinding, micro-
EDM milling, and micro-wire EDM (WEDM). Micro-EDM grinding is necessary when high-
precision surfaces are needed;[22,23] micro-EDM milling is widely used in the fabrication of
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microscale complex 3D structures and various elaborate surfaces.[24–26] Micro-WEDM is a special
machining type derived from micro EDM. In micro-WEDM, the tool electrode is replaced by a
wire electrode to cut extremely tapered and complex geometries and molds; it is usually used in
the fabrication of 2D structures.[27–29] Schematics of the three processing methods and machining
The machining parameters investigated were the voltage and the capacitance as they are
the two main factors influencing the surface quality machined by an RC-type pulse power supply.
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For the transistor-type pulse power supply, the two factors are the current and pulse width. In
addition, the rotation speed of the electrode and the gap voltage cause discrepancies in the surface
The results and mechanism are discussed based on the four aspects mentioned above: 1)
First, Figure 4, Figure 5 and Table 6 show the experimental results under the condition
of the same discharging energy. And it can be concluded from these results that Ti-6Al-4V has the
lowest surface roughness, corresponding to the smoothest surface, and the highest fractal
dimension, SUS304 takes second place, and SKH59 has the coarsest surface and the lowest fractal
dimension. The carbon levels in Ti-6Al-4V, SUS304, and SKH59 increase by 180%, 98%, and
85%, respectively. Regarding the brass levels, the brass increases on the surfaces of all three
materials after micro-EDM processing, but the increases of brass among the three types of surfaces
differ.
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Because the discharging energy is the same, the discharging channels during the machining
process are the same too.[23] When the discharging channel featuring a high temperature is
established, the surface materials of the workpiece are melted and the weld pool consisting of
gasification and liquefaction of workpiece materials is formed. However, the size of the weld pool
is determined by the specific heat and heat conductivity of the materials. Among the alloys
investigated in this study, Ti-6Al-4V has the highest specific heat and lowest heat conductivity,
since the discharging energy during machining of the three materials is the same. Because of the
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high specific heat, the highest energy is required to melt the surface of Ti-6Al-4V and the diameter
of the weld pool is the smallest, compared to the other materials. Moreover, because of the low
heat conductivity of Ti-6Al-4V, very less energy spreads to other part of the workpiece due to
thermal effects. As a result, the depth of the weld pool is relatively shallow and the molten
materials are less, forming the surface with the best quality. For the same reason, the surface
morphology quality of SUS304 is the second best and that of SKH59 is the poorest.
As to the increase of the carbon, in terms of the mechanism, there are gap breakdowns,
discharging channel establishment and discharging channel extensions during the machining
process, causing the decomposition of the kerosene which contains carbon. However, Ti-6Al-4V
has the highest fusion point and lowest heat conductivity, leading to the severest decomposition of
kerosene during processing. Therefore, the carbon increase rate of Ti-6Al-4V is the highest.
SUS304 and SKH59 have the intermediate and lowest carbon increase rate, respectively.
The increase in the brass can be attributed to the wear in the tool electrode during
machining.[30–32] However, the degree of growth is different, because the crater diameter in Ti–
6Al–4V is the smallest, the weld pool in the machining process is small and the solidification rate
is rapid. Therefore, the quantity of adhered brass melted from the tool electrode is the smallest
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among the three materials. In much the same way, the brass adhesion quantity of SKH59 is the
highest because it has the largest crater dimensions and lowest fusion point. In other words, the
weld pool in the machining process is large and the solidification rate is slow. The situation of
No.1 in Table 3 and experiment No. 1 in Table 4. According to the figure and the fractal dimension,
it can be concluded that with the same discharging energy, the surface morphology machined by
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a RC type power supply is poorer than that machined by a transistor type power supply.
because the two types of pulse power supply have different circuit configurations and therefore
different discharge phenomena. Both pulse power supplies experience RC discharging; thereafter,
the discharge voltage of the RC-type pulse declines exponentially with a sine wave-shaped current
waveform, so the discharging time of the RC-type supply is shorter than that of the transistor type.
However, the discharging energy of the RC type is more concentrated, and the discharging energy
is different each time. Meantime, the high-energy density results in severe discharge, more
materials on the surface are molten, and craters and peaks characterized by larger diameter and
depth are formed, resulting in inconsistent and poor surface morphology. For the transistor-type
pulse power supply, it maintains a constant voltage after RC discharging and the discharging time
of the transistor type is obviously longer than that of the RC type. Its voltage is also lower than
that of the RC type, causing less concentrated energy and low-energy density. These make less
molten surface materials with small craters and peaks and the consistency of the surface
morphology machined by the transistor-type power supply is greater than that of the RC type,
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In the machining process, if an intricate surface is needed, the transistor-type pulse power
supply is ideal; otherwise, the RC-type pulse power supply is more suitable for surfaces with less
Third, based on the machining conditions shown in Table 2, Figure 7(a–c) show the
and micro-EDM milling. For a constant discharging energy, the surface morphology machined by
micro-EDM milling is the smoothest, that by micro-EDM grinding is at the mid-level, and that by
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micro-WEDM is the coarsest. In terms of the fractal dimension and Ra, Figure 7(d, e) show all
values of Ra and fractal dimensions. The value of Ra does not reflect the variation of the surface
morphology accurately.
from the wire electrode. Moreover, the speed of the wire electrode is slow and the discharging gap
is too narrow. Ablation products from the workpiece surface during machining are difficult to
expel, resulting in a surface morphology at the bottom that is covered by the surface morphology
at the top along the direction of processing,[33,34] showing a clear cascading phenomenon. The
above factors lead to the poorest surface morphology among the three processing methods.
electrode. Further, the vibration of the wire electrode is eliminated. During the machining process,
the discharging channel is established, under a high temperature, the surface materials of the
workpiece and tool electrode are melted or gasified. Then dielectric, workpiece materials and tool
electrode materials are mixed together, forming metallic compounds. At the later stage of
processing, plasma in the discharging channel expands rapidly. Most of the metallic compounds
are expelled into the dielectric, while the rest of them are condensed, forming peaks on the
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workpiece surface. The gasified dielectric attached to the surface of the workpiece is transformed
to surface bubbles after processing. Cracks and craters on the surface are created because of the
thermal stress and a high-energy intensity discharge. Moreover, the cascading phenomenon that
grinding. However, in the process of micro-EDM milling, the movement speed of the tool
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electrode is slower and most of the surface is polished multiple times, because the tool electrode
is moved back and forth. Therefore, the total discharging time in the discharging channels and the
quantity of material removed are larger than those in micro-EDM grinding. Under the machining
condition, more of the metallic compounds discussed above are expelled and part of the residual
bubbles on the surface are eliminated, resulting in a surface featuring gentle peaks and few bubbles.
Finally, Figure 8(a–d) show the corresponding fractal dimensions according to the
machining conditions shown in Table 3 and Table 4. The variation of the capacitance and voltage
in the RC type and the variation of the pulse width and current in the transistor type can be
simplified as the discharge energy paired with the speed of the tool electrode. They show that,
regardless of the material, larger discharging energies and faster electrode rotation speed correlate
to lower fractal dimensions, indicating that the surface morphology is rougher. Simultaneously,
the discharge rate of a tool electrode rotating at high speed is lower than that of one at low speed,
as Figure 8(e) shows. Finally, Figure 8(f) shows that when the machining voltage is 80V, the gap
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With the increase in discharging energy, the surface quality becomes poor according to the
fractal dimension. The diameter of discharging channel will expand along with an increase in
discharging energy during the machining process. For the same material surface, a wider
discharging channel will result in more melted metallic alloys on the surface being expelled and
the formation of wider and deeper craters. The alloys unable to be expelled are solidified to higher
peaks on the surface. The altitude intercept between the higher peaks and deeper craters makes the
As to the rotation speed of the tool electrode, high-speed tool electrode rotation will easily
cut off the discharging channels. Once the channel is cut off, the discharging process is insufficient,
resulting in the surface materials that are not yet fully melted. Moreover, the discharging channel
cut off halfway cannot produce enough pressure to expel the melted surface materials. Therefore,
the semi-molten state and undischarged metal compounds re-cover on the surface of the workpiece,
causing a cascading phenomenon which affects the processing quality of the workpiece surface.
Therefore, if most of the molten materials can be expelled smoothly, the rotation speed of the tool
Different gap voltages correspond to different gaps between the tool electrode and the
workpiece. In the present study, gap voltages of 20V or 30V use relatively small gaps, where short
circuits may occur quickly. Meanwhile, the breakdown delay is also short. These hinder the
complete discharge process seriously. Most of the metal compounds that should have been
removed cannot be expelled smoothly. At the end of the machining process, they are solidified on
the surface of the workpiece, resulting in serious height differences and surfaces that are usually
coarser. When the gap voltage is 60V or 70V, the gap is relatively large. open circuits may occur
frequently, along with a longer breakdown delay, under these circumstances, parts of the mental
13
compounds are expelled, but frequent open circuit phenomenon makes another part of the surface
materials that should be removed not processed, what's more is that the surface not processed is
coarse originally, the surface consistency is greatly affected, causing poor-quality surface.
Conclusion
In the present study, systematic research on the surface morphologies of three high-
method combining fractal theory and wavelet filter was described. The following conclusions can
1) Titanium alloys are more suitable for applications in aviation and aerospace industries because
they have higher fusion points and lower heat conductivities. The surface morphology of
the Ti–6Al–4V alloy machined by micro-EDM is better than that of stainless steel and
high-speed steel.
2) The RC-type supply is suitable for machining high-performance alloy surfaces where machining
efficiency is a priority, while the transistor-type supply is suitable for machining high-
3) Using the same high-performance alloy and machining parameters, the use of micro-EDM
milling obtains the best surface morphology. Micro-EDM grinding creates surfaces of
4) Smaller discharge energy creates smaller craters and peaks, thus obtaining a finer surface and
higher fractal dimension. Slower rotation speed of the tool electrode should be applied
under the condition of smooth chip evacuation. In this way, a fine surface morphology and
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high fractal dimension can be obtained. Both higher and lower gap voltages create coarse
5) In evaluating the surface morphology machined by micro-EDM, it is found that the new
presented method combining fractal theory with wavelet filters is more suitable than the
Acknowledgement
This work was supported by the National Nature Science Foundation of China for Young
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Scientists under Grant No.51505400; the Fundamental Research Funds for the Central Universities
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Table 1. The property of three types of intractable materials
18
Table 2. Experimental conditions for different micro EDM processing methods
speed
(r/m)
3 2500 90 10.125
4 4000 90 16.2
19
Table 3. Experimental conditions for the investigation of surface morphology machined by RC
type pulse power supply
ging
energy
(μJ)
2 10000 80 4V / 32
4 10000 120 72
20
Table 4. Experimental conditions for the investigation of surface morphology machined by
transistor type pulse power supply
(ns) energy
(μJ)
4 0.2 4000 96
21
Table 5. Experimental conditions for the investigation of surface morphology machined by
different gap voltage
(V) speed
(r/m)
2 30~40
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3 40~50
4 50~60
5 60~70
22
Table 6. Comparison of important parameters from three materials
23
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24
Figure 1. The schematic diagram of the evaluation rule.
Figure 2. The discharging waveform of RC type (left) and transistor type pulse power supplies
(right).
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Figure 3. The schematics of three machining types.
Figure 4. The surface morphology of Ti-6Al-4V (left), SUS304(middle) and SKH59(right)
machined by same discharging energy.
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27
Figure 5. The energy spectrum analysis of surface morphology before and after machining.
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Figure 6. Fractal dimensions of Ti-6Al-4V surface morphology machined by different pulse
power supply under same discharging energy.
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Figure 7. The surface morphology of different machining types under the same discharging
energy.
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Figure 8. The affection of different machining parameters onto the surface fractal dimensions.
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31