A comparative study on the wear resistance of electrical discharge machined surfaces

The properties of the surface were affected by many factors such as the pulse parameters, tool electrode material, and dielectric liquid in electrical discharge machining. Austenitic, dual-phase, and ferritic steel work materials were electrical discharge machined using graphite and copper tool electrodes in hydrocarbon- based oil and water dielectric liquids. Then the surfaces were analyzed regarding sliding friction wear responses on a comparative basis. The results revealed that the surface wear responses are sensitive to the type of the tool electrode material when machining in water dielectric liquid. However, the use of hydrocarbon-based dielectric liquid substantiality suppresses the influence of tool electrode on surface wear response due to excessive carbon release from the cracked dielectric. The machined surface topographical features were also affected due to the used electrical parameters regarding crater size, globular attachments, and microcracks that led significant alterations in sliding friction response. Primarily, weakly bounded globular attachments on the machined surface were dislodged at the initial stages of the friction tests and led higher sliding distances to the steady friction conditions. Finally, the results were compared with the subsurface microstructural properties to comprehend the wear responses.