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 (T_off), 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.