Analysis of micro-cracks on machined surfaces in dry electrical discharge machining

Micro-crack formation in the heat affected zone in EDM is a common phenomenon and many measures have been perceived to minimize their occurrence. This paper presents a comprehensive and quantitative analysis of micro-crack formation, in terms of length, number and orientation of micro-cracks formed on the machined surfaces. The influence of processing conditions on crack formation is studied using the observations under scanning electron microscope (SEM). The results indicate that the micro-crack formation is the best represented in terms of average crack length. Statistical analysis of the results shows that pulse off-time (Toff), current (I), voltage (V) and electrode rotation speed (N) significantly influence the average crack length in both wall and bottom regions of the machined hole. In dry EDM, micro-crack formation occurs due to segregation of elements in the work surface and inter-diffusion of elements between work, and shield. A comparison of crack formation with the liquid dielectric EDM shows that average length and number density of micro-cracks were lower in the dry EDM than those in the liquid dielectric EDM.