Electron microprobe study of deposition and diffusion of tool material in electrical discharge machining

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Abstract
Electron microprobe analysis for the surface deposition and diffusion of tool material was carried out on mild steel (MS), high-carbon steel (HCS) and high-speed steel (HSS) work samples, machined by an electrical discharge process using a relaxation circuit in distilled water and kerosene at 225 and 56·25 mJ pulse energy, with copper and brass as tools. It was observed that high-energy machining results in lower surface deposition but more depth of diffusion. MS-HCS-HSS showed increasing surface deposition but decreasing depth of diffusion in the same order. Machining in distilled water at high-pulse energy resulted in lower surface deposition and depth of diffusion as compared to machining in kerosene. At low-pulse energy kerosene showed similar results. Tool material was found to deposit preferentially along the crater rims. The possibility of a certain typical geometry of crater formation in multi-spark machining is concluded. It is felt that each large crater is a result of three to four small craters, the size of which is about one-fourth of that of a large crater.

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