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Journal of Mechatronics and Automation

An Experimental Study to Determine Optimum Machining Conditions for Electrical Discharge Machining of the Heat Treatable Steel 42CrMo4 (Din 1.7225)

  1. Soheil Mohtaram
  2. Reza Gheisari

Abstract

Electric discharge machining (EDM) is a well-established machining option and a non-traditional machining process, in many manufacturing-related industries worldwide. It is found to be capable of machining geometrically complex or hard material components, which are specific and difficult-to-machine. In this study, the electrical discharge machining of 42CrMo4 with different electrode materials namely, copper, aluminum and tungsten carbide and process parameters was performed to explore the influence of EDM parameters on the machining characteristics of 42CrMo4. The efficiency of the EDM process is studied in terms of the material removal rate, the tool wear rate and the surface roughness of the work piece. The experimental results reveal that for machining of 42CrMo4, the optimum condition of machining rate and tool wear rate takes place at a discharge current of 25 A, pulse duration of 200 µs, pulse interval of 100 µs, sparking voltage of 80 V and copper (Cu) as the tool electrode material with positive polarity. However, to obtain a high-precision surface finish, the conditions may vary.

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