Residual Stress Modeling in Electric Discharge Machining (EDM) by Incorporating Massive Random Discharges

EDM induced residual stress is a great concern for product performance. Current modeling methods of EDM are limited to a single discharge. However, a single discharge simulation is far from the reality to predict the residual stress due to the accumulating effect of massive random discharges. In this study, a new modeling method accounting for massive random discharges has been developed to simulate residual stress formation in die-sinking EDM of the ASP 23 tool steel. Both local residual stress and average residual stress characteristics in the subsurface have been investigated. The effects of discharge voltage on residual stresses are also studied.