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This information is based on our present state of knowledge and is intended to provide general
notes on our products and their uses. It should not therefore be construed as a warranty of
specific properties of the products described or a warranty for fitness for a particular purpose.
Classified according to EU Directive 1999/45/EC
For further information see our “Material Safety Data Sheets”.
Edition 3, 08.2007
The latest revised edition of this brochure is the English version,
SS-EN ISO 9001
which is always published on our web site www.uddeholm.com
SS-EN ISO 14001
EDM OF TOOL STEEL
Contents
Introduction ............................................ 3
The basic principles of EDM ................ 4
The effects of the EDM process
on tool steels .......................................... 4
Measuring the effects ............................ 6
Achieving best tool performance ....... 9
Polishing by EDM .................................. 11
Summary ................................................. 11
3
EDM OF TOOL STEEL
Rehardened layer
Tempered layer
Unaffected matrix
200 X
Typical hardness distribution
in the surface layer
5
EDM OF TOOL STEEL
Thickness µm
Measuring 80
Graphite electrode
the effects 60 Fig. 4a. Layer thicknesses and
fissure frequency in the surface
40 Melted zone
The thicknesses of the heat- layer in electrical discharge
20 machining of hardened (52 HRC)
affected zones have been measured. Hardended zone
The hardnesses in these zones 0 Uddeholm Orvar Supreme at
Matrix different pulse durations.
have also been measured, as have
100 200 500 1000 ti µ sec
crack frequencies and crack 21 25 43(A)
depths. Strength values have – – 3(B)
– – –(C)
been obtained through bending
tests. No. of cracks per cm: (A) in melted zone
The layer thicknesses appear to (B) in hardened zone
(C) in matrix
be largely independent of both steel
grade and electrode material. On Thickness µm
the other hand, there is a definite
difference between the specimens Graphite electrode
60
which have been hardened and
40
those which were in the softanneal- Fig. 4b. As above, but for
ed condition. Figure 4 shows, in the 20 Melted zone
electrical discharge machining of
form of graphs, the layer thicknesses 0 Hardended zone Uddeholm Orvar Supreme in
Matrix the annealed condition.
and fissure frequency with different
100 200 500 1000 ti µ sec
pulse durations for Uddeholm 5 19 15(A)
Orvar Supreme. – – –(B)
– – –(C)
In the annealed material, the zones
are thinner and the fissures fewer. No. of cracks per cm: (A) in melted zone
(B) in hardened zone
The brittle, hardened zone is scar- (C) in matrix
cely present at all (figure 4b).
The layer thicknesses can vary
considerably, from 0 µm to maxi-
mum values slightly below the Rmax
specified in the machining directions.
In the rough-machining stages
(ti ≥100µ sec), the thicknesses of the
layers vary far more substantially
than in the fine-machining stages. Fig. 5. Fine-machined Uddeholm
The thickness of both the melted Rigor, pulse duration 10µ sec.
100 x
and the hardened zone increases
with spark duration, which appears the beneficial effect of “fine-finish-
to be the most important single ing”, i.e. to produce a very thin re-
controlling variable. Figure 5 shows melted and heat-affected zone.
6
EDM OF TOOL STEEL
1:1
ti = 10 µs. Magnification 500 x Figur 7. The suspected “pores” can
Figur 6b. Graphite electrode be seen on the surface of the tool
Graphite electrode
t = 200 µ sec
i
HV
1000
800
600
400
Hardness immediately
after EDM
Fig. 9. Typical hardness distribu-
200 Hardness after re- tion in hardened Uddeholm
tempering
Sverker 21 immediately after EDM
and then after re-tempering.
0
0 50 100 150 µm
8
EDM OF TOOL STEEL
400
This reduces the risk of crack
300 formation during heating and
Stress-relieved
Stress-relieved
9
EDM OF TOOL STEEL
Wire EDM These stresses take the form of In certain cases the risk can be
The observation made about the tensile stresses in the surface area reduced through different pre-
EDM surface in earlier pages are and compressive stresses in the cautions.
also mostly applicable to the wire centre and are in opposition to each 1: To lower the overall stress level
EDM-process. other. During the wire erosion pro- in the part by tempering at a high
The affected surface layer, how- cess a greater or lesser amount of temperature. This assumes the use
ever, is relatively thin (<10 µm) and steel is removed from the heat- of a steel grade with high resistance
can be compared more to “fine- treated part. Where a large volume to tempering.
sparking” EDM. Normally there are of steel is removed, this can some-
2: By drilling several holes in the
no observable cracks in the eroded times lead to distortion or even
area to be removed and to connect
surface after wire erosion. But in cracking of the part. The reason is
them by saw-cutting, before harden-
certain cases another problem has that the stress balance in the part is
ing and tempering. Any stresses
been experienced. disturbed and tries to reach an
released during heat treatment are
After heat treating a through equilibrium again. The problem of
then taken up in the pre-drilled and
hardening steel the part contains crack formation is usually only
sawn areas, reducing or eliminating
high stresses (the higher the tem- encountered in relatively thick cross
the risk of distortion or cracking
pering temperature, the lower the section, e.g. over 50 mm (2") thick.
during wire-erosion. Fig. 13 illu-
stresses). With such heavier sections, correct
strates how such pre-cutting may
hardening and double tempering is
be done.
important.
10
EDM OF TOOL STEEL
Wire erosion layer produced is very thin and in connection with the working
of cutting punches equal in the these grades. The thick- performance of spark-machined
ness is about 2–4 µm. Since there is tools should arise, however, there
When producing a cutting punch
no sign of any heat-affected layer, are some relatively simple extra
by wire erosion, it is recommended
the influence of the EDM on me- operations that can be employed, as
(as with conventional machining) to
chanical properties is negligible. indicated above.
cut it with the grain direction of the
A slightly striped appearance has
tool steel stock in the direction of
been re-ported in materials rich in
the cutting action. This is not so
carbides, such as high-carbon cold-
important when using PM steels
due to their non-directional grain
Summary work steels and high-speed steels,
In summing up it can be said that where there is always a certain
structure.
properly executed electrical dis- amount of carbide segregation or in
charge machining, using a rough and material with high sulphur content.
a fine machining stage in accordance The difference in bending strength
Polishing by EDM with the manufacturer’s instruction, between rough-spark-machined and
Today some manufacturers of EDM- eliminates the surface defects ob- fine-spark-machined test pieces is
equipment offer, by a special tech- tained in rough machining. Naturally, largely due to the difference in the
nique, possibilities to erode very certain structural effects will always distribution of the cracks and to the
fine and smooth surfaces. It is pos- remain, but in the vast majority of presence of the in spots distributed
sible to reach the surface finish of cases these are insignificant, pro- white layer on the fine-spark-
about 0,2–0,3 µm. Such surfaces are vided that the machining process machined specimens. The rougher
sufficient for most applications. The has otherwise been normal. Struc- surface finish of the rough-machined
greatest advantages are when com- tural effects, more-over, need not specimen has not really been signi-
plicated cavities are involved. Such necessarily be regarded as entirely ficant. Regardless of circumstances,
cavities are difficult, time consuming negative. In certain cases the surface such surface irregularities are rela-
and therefore expensive to polish structure, i.e. the rehardened layer, tively harmless as crack initiators
manually, but can be conveniently has—on account of its high hard- compared with the solidification
done by the EDM- machine during a ness—improved the resistance of cracks. During the polishing of the
night-shift, for example. the tool to abrasive wear. In other fine-machined test piece which was
Investigations made on our grades cases it has been found that the carried out, the depth of the white
Uddeholm Impax Supreme, Udde- cratered topography of the surface and rehardened layer was merely
holm Orvar Supreme, Uddeholm is better able to retain lubricant reduced and not completely elimi-
Stavax ESR and Uddeholm Rigor than conventional surfaces, resulting nated. Further polishing would
show that the hard re-melted white in a longer service life. If difficulties probably result in complete restora-
tion of the bending strength.
Highly stressed tools and parts
thereof, e.g. very thin sections that
are far more liable to bending, can
justify an extra finishing operation.
The lower the hardness in the
matrix, the less sensitive the mate-
rial will be to adverse effects on the
strength as a result of electrical
discharge machining. Lowering of
the hardness level of the entire tool
can, therefore, be another alterna-
tive.
Fig. 14. This Uddeholm Stavax ESR mould insert was finished
by EDM “polishing”.
11
EDM OF TOOL STEEL
12
EDM OF TOOL STEEL
13
EDM OF TOOL STEEL
Pakistan Taiwan
ASSAB International AB
Head office
P.O. Box 17595
Jebel Ali ASSAB Steels (Taiwan) Co Ltd
AE-Dubai No. 112 Wu Kung 1st Rd.
Telephone: +971 488 12165 Wu Ku Industry Zone
www.assab.se TW-Taipei 248-87, Taiwan (R.O.C.)
Telephone: +886 2 2299 2849
www.assabsteels.com
14
Network of excellence
Uddeholm is present on every continent. This ensures you
high-quality Swedish tool steel and local support wherever you
are. Assab is our wholly-owned subsidiary and exclusive sales
channel, representing Uddeholm in various parts of the world.
Together we secure our position as the world’s leading supplier
of tooling materials.
www.assab.com www.uddeholm.com
HAGFORS KLARTEXT U0708XX
Uddeholm is the world’s leading supplier of tooling materials. This
is a position we have reached by improving our customers’ everyday
business. Long tradition combined with research and product develop-
ment equips Uddeholm to solve any tooling problem that may arise.
It is a challenging process, but the goal is clear – to be your number one
partner and tool steel provider.
Our presence on every continent guarantees you the same high quality
wherever you are. Assab is our wholly-owned subsidiary and exclusive
sales channel, representing Uddeholm in various parts of the world.
Together we secure our position as the world’s leading supplier of
tooling materials. We act worldwide, so there is always an Uddeholm
or Assab representative close at hand to give local advice and support.
For us it is all a matter of trust – in long-term partnerships as well as in
developing new products. Trust is something you earn, every day.