Experimental Analysis of the Machinability of AISI 1.2738 Steel by Sinking EDM Based on Voltage, Pulse-Off Time, and Tool Feed Rate

Öz

The aim of this study is to investigate the effects of voltage, pulse-off time (Toff), and tool feed rate on the machinability of AISI 1.2738 mold steel in die-sinking electrical discharge machining (EDM). Experimental studies were carried out using a full factorial design with 3³ = 27 test conditions, and the material removal rate (MRR) and surface roughness (Ra) were evaluated as the main performance indicators. The results showed that increasing the voltage raised the MRR from 6.29 g/min to 9.13 g/min (approximately 45% improvement), while Ra increased from 5.19 µm to 8.88 µm, indicating a deterioration in surface quality. Increasing the pulse-off time improved the surface roughness by about 25% but caused an 18% reduction in MRR. Raising the tool feed rate from 6 mm/s to 10 mm/s had a limited influence, with a 6% increase in MRR and a 4% improvement in Ra. The findings revealed that MRR reached a saturation level at higher voltage values, with the optimum machining performance achieved around the 2–3 V range. These results provide an original contribution to the literature as one of the few systematic studies focusing on the effect of tool feed rate in the EDM processing of AISI 1.2738 steel.

Anahtar Kelimeler

• Electrical discharge machining
• AISI 1.2738
• Voltage
• Tool feed rate
• Pulse-off time
• Material removal rate
• Surface roughness

AISI 1.2738 Çeliğinin Dalma Erozyonla İşlenebilirliğinin Voltaj, Darbesiz Süre ve Takım İlerleme Hızına Bağlı Deneysel Analizi

Öz

Bu çalışmanın amacı, AISI 1.2738 kalıp çeliğinin dalma erozyonla işlenmesinde voltaj, darbesiz geçen süre (Toff) ve takım ilerleme hızının işlenebilirlik üzerindeki etkilerini belirlemektir. Deneysel çalışmalar, 3³ = 27 koşuldan oluşan tam faktöriyel tasarım yöntemiyle gerçekleştirilmiş ve malzeme işleme hızı (MİH) ile yüzey pürüzlülüğü (Ra) ana performans kriterleri olarak değerlendirilmiştir. Sonuçlar, voltaj artışının MİH değerini 6.29 g/dk’dan 9.13 g/dk’ya yükselttiğini (%45 artış), buna karşılık Ra değerinin 5.19 µm’den 8.88 µm’ye çıkarak yüzey kalitesini olumsuz etkilediğini göstermiştir. Toff süresinin artışı yüzey pürüzlülüğünde yaklaşık %25 iyileşme sağlarken MİH’te %18 azalmaya neden olmuştur. Takım ilerleme hızının 6 mm/sn’den 10 mm/sn’ye çıkarılması, MİH’te %6 artış ve Ra’da %4 iyileşme ile sınırlı bir etki yaratmıştır. Bulgular, voltaj artışına bağlı olarak MİH değerlerinin yüksek seviyelerde doyuma ulaştığını ve optimum işlem koşulunun 2–3 V aralığında elde edildiğini ortaya koymuştur. Bu sonuçlar, AISI 1.2738 çeliğinin DEİ ile işlenebilirliğinde takım ilerleme hızının etkisini sistematik biçimde inceleyen nadir çalışmalardan biri olarak literatüre özgün bir katkı sunmaktadır.

Anahtar Kelimeler

• Dalma erozyon
• AISI 1.2738
• Voltaj
• Takım ilerleme hızı
• Darbesiz geçen süre
• Malzeme işleme hızı
• Yüzey pürüzlülüğü

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