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EDM of Tool Steel

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.
EDM OF TOOL STEEL

Contents
Introduction ............................................. 3
The basic principles of EDM ..................... 3
The effects of the EDM process
on tool steels ........................................... 3
Measuring the effects .............................. 5
Achieving best tool performance ............. 8
Polishing by EDM .................................... 10
Summary ................................................ 10

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.

2
EDM OF TOOL STEEL

Introduction The basic may be necessary to subordinate the


first three factors, when choosing ma-
The use of Electrical Discharge Machin- principles of EDM chining parameters, in order to optimize
ing (EDM) in the production of forming the fourth.
Electrical discharge machining (spark
tools to produce plastics mouldings, die
erosion) is a method involving electrical
castings, forging dies etc., has been
discharges between an anode (graphite
firmly established in recent years. Devel-
or copper) and a cathode (tool steel or
opment of the process has produced
other tooling material) in a dielectric
The effects of
significant refinements in operating
technique, productivity and accuracy,
medium. The discharges are controlled the EDM process
while widening the versatility of the
in such a way that erosion of the tool or
work piece takes place. During the op-
on tool steels
process. The influence of spark erosion on the
eration, the anode (electrode) works
Wire EDM has emerged as an effi- machined material is completely differ-
itself down into the workpiece, which
cient and economic alternative to con- ent to that of conventional machining
thus acquires the same contours as the
ventional machining of apertures in methods.
former.
many types of tooling, e.g. blanking As noted, the surface of the steel is
The dielectric, or flushing liquid as it
dies, extrusion dies and for cutting ex- subjected to very high temperatures,
is also called, is ionized during the
ternal shapes, such as punches. causing the steel to melt or vaporize.
course of the discharges. The positively
Special forms of EDM can now be The effect upon the steel surface has
charged ions strike the cathode, where-
used to polish tool cavities, produce been studied by Uddeholm Tooling to
upon the temperature in the outermost
undercuts and make conical holes using ensure that the tool maker may enjoy
layer of the steel rises so high (10–
cylindrical electrodes. the many benefits of the EDM process,
50,000°C / 18–90,000°F) as to cause
EDM continues to grow, therefore, as while producing a tool that will have a
the steel there to melt or vaporize, form-
a major production tool in most tool satisfactory production life.
ing tiny drops of molten metal which
making companies, machining with In the majority of cases, it has been
are flushed out as “chippings” into the
equal ease hardened or annealed steel. impossible to trace any influence at all
dielectric. The craters (and occasionally
Uddeholm Tooling supplies a full also “chips” which have not separated on the working function of the spark-
range of tool steels noted for consist- completely) are easily recognized in a eroded tool. However, it has been
ency in structure. This factor, coupled cross section of a machined surface. See observed that a trimming tool, for ex-
with very low sulphur levels ensures Fig. 1. ample, has become more wear resistant,
consistent EDM performance. while in some cases tool failure has
Four main factors need to be taken
This brochure gives information on: occurred prematurely on changing from
into account when considering the
• The basic principles of EDM conventional machining to EDM. In
operating parameters during an EDM
• The effects of the EDM process other cases, phenomena have occurred
operation on tool steel:
on tool steels during the actual electrical discharge
• the stock-removal rate
machining that have caused unexpected
• Achieving best tool performance. • the resultant surface finish defects on the surface of the tool. This
• electrode wear due to the fact that the machining has
• the effects on the tool steel. been carried out in an unsuitable man-
The influence of the EDM operation ner.
on the surface properties of the ma-
chined material, can in unfavourable
circumstances jeopardize the working
performance of the tool. In such cases it

Fig.1. A “rough-machined” EDM


surface with a cross section through
chips and craters.
Material: Orvar 2 Microdized.

3
EDM OF TOOL STEEL

“SURFACE STRENGTH”— REHARDENED LAYER In order to study the structural


AN IMPORTANT FACTOR In the rehardened layer, the tempera- changes incurred with different machin-
All the changes that can be observed ture has risen above the austenitizing ing variables, different tool steels—see
are due to the enormous temperature (hardening) temperature and martensite table 1—were “rough-machined” and
rise which occurs in the surface layer. has been formed. This martensite is hard “fine-machined” with graphite elec-
and brittle. trodes.
In the surface layer, it has been ob-
served that the four (main) factors asso-
ciated with the all-important “surface
strength” of the steel are affected by
this temperature increase:
• the microstructure
• the hardness
• the stress condition
• carbon content.
Fig. 2 shows a section from a normal
rough-spark-machined surface with the
typical, different structural changes.

MELTED AND RESOLIDIFIED LAYER


The melted and resolidified layer
produced during the EDM process is
also referred to as the “white zone”, 1000 x
since generally no etching takes place in Fig. 3. Pillar crystals formed during solidification.
these areas during metallographic
preparation. Fig. 3, nevertheless, shows
clearly that it is a rapidly solidified layer,
where long pillar crystals have grown TEMPERED LAYER
straight out from the surface of the In the tempered layer, the steel has
metal during solidification. A fracture not been heated up so much as to reach
occurring in this layer invariably follows hardening temperature and the only
the direction of the crystals. In normal thing that has occurred is tempering-
rough machining, this layer has a thick- back. The effect naturally decreases
ness of about 15–30 µm. towards the core of the material – see
The carbon content in the surface the hardness curve in Fig. 2.
layer can also be affected, for instance,
by carburization from the flushing liquid
or from the electrode, but decar-
burization can also occur.

400 600 800 1000


H
v
Melted and
resolidified layer

Rehardened layer

Tempered layer

Unaffected matrix

200 X
Typical hardness distribution
in the surface layer.

Fig. 2. Section from a spark-machined surface showing changes in structure.


Material: Rigor, hardened to 57 HRC.
4
EDM OF TOOL STEEL

Austenitizing Tempering
Time 20 min Time 2 x 30 min Hardness
Steel grade AISI Temperature Temperature Hardened Annealed
°C °F °C °F HRC HB

ARNE O1 810 1490 220 430 60 190


CALMAX – 960 1760 200 392 58 200 Note: As Corrax is a precipitation hardening
RIGOR A2 940 1725 220 430 60 – steel the EDM surface has different charac-
SVERKER 21 D2 1020 1870 250 480 60 220 teristics. The “white layer” consists of
GRANE (L6) 840 1540 250 480 54 melted and resolidified material with a
IMPAX SUPREME P20 850 1560 580 1075 30 – hardness of approx. 34 HRC. There will be
ORVAR SUPREME H13 1025 1875 560 1040 50 180 no other heat affected zone of importance.
Table 1. The tool steels were tested in the hardened and tempered condition, and some of them
also in the annealed condition.

Measuring Thickness µm
80
the effects 60
Graphite electrode

The thicknesses of the heat-affected Fig. 4a. Layer thicknesses and fissure
40 Melted zone frequency in the surface layer in
zones have been measured. The hard-
20 electrical discharge machining of
nesses in these zones have also been Hardended zone
hardened (52 HRC) Orvar Supreme at
measured, as have crack frequencies 0
Matrix different pulse durations.
and crack depths. Strength values
100 200 500 1000 t µ sec
i
have been obtained through bending 21 25 43(A)
tests. – – 3(B)
– – –(C)
The layer thicknesses appear to be
largely independent of both steel grade No. of cracks per cm: (A) in melted zone
and electrode material. On the other (B) in hardened zone
(C) in matrix
hand, there is a definite difference be-
tween the specimens which have been
Thickness µm
hardened and those which were in the
softannealed condition. Fig. 4 shows, in Graphite electrode
60
the form of graphs, the layer thicknesses
and fissure frequency with different 40
pulse durations for Orvar Supreme. 20 Melted zone Fig. 4b. As above, but for electrical
In the annealed material, the zones Hardended zone discharge machining of Orvar
0
are thinner and the fissures fewer. The Matrix Supreme in the annealed condition.
brittle, hardened zone is scarcely present 100 200 500 1000 t µ sec
i
at all (Fig. 4b). 5 19 15(A)
– – –(B)
The layer thicknesses can vary consid- – – –(C)
erably, from 0 µm to maximum values
No. of cracks per cm: (A) in melted zone
slightly below the Rmax specified in the (B) in hardened zone
machining directions. In the rough- (C) in matrix
machining stages (ti ≥100µ sec), the
thicknesses of the layers vary far more
substantially than in the fine-machining
stages.

The thickness of both the melted and


the hardened zone increases with spark
duration, which appears to be the most
important single controlling variable.
Figure 5 shows the beneficial effect
of “fine-finishing”, i.e. to produce a
100 x very thin remelted and heat-affected
Fig. 5. Fine-machined Rigor.
Pulse duration 10µ sec.
zone.

5
EDM OF TOOL STEEL

STRUCTURES OF THE CAUSE OF “ARCING”


SPARK-MACHINED LAYERS Short off-times, or pause times, give
With longer pulse duration, the heat is more sparks per unit of time and thus
conducted more deeply into the mate- more stock removal. During the off-time,
rial. Higher current intensity and density the dielectric fluid must have time to
(and thus spark energy) do, indeed, give become de-ionized. Too short an off-
a higher “amount of heat” in the sur- time can result in double sparking “igni-
face, but the time taken for the heat to tions” which lead to constantly burning
diffuse, never-theless, appears to have arcs between the electrode and the
the greatest significance. The pictures work piece, resulting in serious surface
below show how the surface zones are defects. The risk of arcing is increased if
ti = 200 µs. Magnification 500 x
changed in Sverker 21 (in hardened flushing conditions for the dielectric
Figur 6d. Copper electrode
and tempered condition) with different fluid are difficult.
pulse durations and electrode materials. As a result of “arcing”, i.e. a condi-
tion in which arcs are formed between
local parts of the electrode and the
workpiece, large craters or “burns” are
formed in the surface. These have fre-
quently been confused with slag inclu-
sions or porosity in the material. Figs. 7
and 8 show the surface of a tool with a
section through one of the suspected
“pores”.
One of the primary causes of this
type of defect is inadequate flushing, or
machining of narrow slots, etc., result-
ti = 10 µs. Magnification 500 x ti = 500 µs. Magnification 500 x
ing in chips and other loose particles
Figur 6a. Copper electrode Figur 6e. Graphite electrode
forming a bridge between the electrode
and the workpiece. The same effect can
be obtained with a graphite electrode
which bears traces of foreign material.
On modern machines featuring so-
called adaptive current control, the risk
of “arcing” has been eliminated.

ti = 10 µs. Magnification 500 x Figur 7. The suspected “pores” can 1:1


Figur 6b. Graphite electrode be seen on the surface of the tool.

ti = 100 µs. Magnification 500 x 65 x


Figur 8. A section through one of the
Figur 6c. Graphite electrode suspected “pores”.

6
EDM OF TOOL STEEL

Fissure frequency also increases Melted Hardened


with pulse duration zone zone Matrix
With times in excess of 100µ sec, all
High-alloy
steels reveal several cracks in the cold-work steel
melted layer. High-carbon and/or air- SVERKER type 20–50 2–10 0–5
hardening steels show the highest fre- Hot-work steel
ORVAR type 10–40 2–5 0–2
quency of fissures. The annealed speci- Cold-work steels
mens contain no cracks at all in the RIGOR, ARNE types 10–30 0–5 0–2
matrix. Plastic-moulding
steels IMPAX
The number of cracks which continue SUPREME type 0–5 0–2 0
down into the hardened zone is roughly
20%, while only a very few cracks pen- Table 2. The table shows the occurrence rate of fissures
etrate into the matrix. In the matrix, the
fissure depth is seldom more than about
some tens of a µm. Here too, it applies
that cracks in the matrix are mainly Renewed tempering (235°C/455°F
encountered in the highly-alloyed cold- 30 min) of the specimen in figure 9
working steels. Table 2 shows the occur- resulted in lowering of the hardness
rence rate of fissures in a number of level to the curve drawn with a broken
tested tool steels. line.
The difference in stock-removal If electrical discharge machining is
rate amounts to a maximum of approx. properly performed with a final fine-
15% between the different grades of machined stage, surface defects are
tool steel with the same machine set- largely eliminated. If this is not possible
ting data. for one reason or another, or if it is
The hardnesses in the different necessary for all effects to be eliminat-
layers can also vary considerably, but in ed, some different related operations
principle the same pattern applies to all can be used:
grades. Fig. 9 shows a typical hardness • Stress-relief tempering at a tem-
distribution. The difference in hardness pering temperature approx. 15°C
and volume between the layers gives (30°F) lower than that previously
rise to stresses which, upon measure- used tempering temperature, lowers
ment, have been found to have the the surface hardness without influ-
same depth as the affected surface encing the hardness of the matrix.
layers. These stresses can be substan- • Grinding or polishing will remove
tially reduced by extra heat-treatment both the surface structure and cracks,
operations. depending of course on how deeply
it is done (approx. 5–10 µm in fine-
Graphite electrode machining).
t = 200 µ sec
i
HV

1000

800

600

400
Hardness immediately
after EDM
200 Hardness after Fig. 9. Typical hardness distribution in
retempering
hardened Sverker 21 immediately after
EDM and then after re-tempering.
0
0 50 100 150 µm

7
EDM OF TOOL STEEL

BENDING TEST BACKGROUND TO


THE BENDING TEST RESULTS
Achieving best
To evaluate the likely effect of the
remelted layer, surface irregularities and The hard, re-solidified rehardened layers tool performance
cracks produced in the EDM process on cause, in the first instance, those cracks EDM USING SOLID ELECTRODES
the strength of a tool, a bending test which are formed upon application of (COPPER/GRAPHITE)
was carried out. Various combinations the load and in the second instance
As noted, in most cases where the EDM
of EDM surface finish and post treat- those which were already present to act
process has been carefully carried out
ments, e.g. stress-relieving/polishing, as initiators of failure in the matrix. At
no adverse effect is experienced on tool
were tested on 5 mm square test pieces 57 HRC, the matrix is not tough enough
performance. As a precautionary
of Rigor at 57 HRC. The test pieces were to stop the cracks from growing and
measure, however, the following steps
spark-machined on one face to different consequently the failure occurs already
are recommended:
EDM stages and bent severely, with the on the elastic part of the load curve.
EDM surface on the outside of the bend. Normally, there should have been a
EDM of hardened and
Fig. 10 shows that the sample with a certain amount of plastic bending of a
tempered material
fine-spark machined finish which had test bar in this material.
been polished afterwards gave the best A Conventional machining
result. The rough spark-machined sam-
B Hardening and tempering
ple, without any post treatment, had the
C Initial EDM, avoiding “arcing” and
lowest bending strength. excessive stock removal rates.
Finish with “fine-sparking”, i.e. low
current, high frequency.
Bending strength
N/mm2 D (i) Grind or polish EDM surface
1200
or D (ii) Temper the tool at 15°C (30°F)
1100 lower than the original tem-
1000 pering temperature.
900 or D (iii) Choose a lower starting
hardness of the tool to improve
800 overall toughness.
700
Fine spark-machined, Polished

600

500 EDM of annealed material


Rough spark-machined
Rough spark-machined

Fine spark-machined
Fine spark-machined

400
300 A Conventional machining
Stress-relieved
Stress-relieved

200 B Initial EDM, as C above.


100 C Grind or polish EDM surface.
This reduces the risk of crack forma-
0 tion during heating and quenching.
Fig. 10. Bending strength at different EDM stages and with Slow pre-heating, in stages, to the
hardening temperature is recom-
different subsequent operation. Material Rigor 57 HRC. The mended.
shaded areas show the spread of the results measured.

Note: When EDM’d in solution annealed


condition the toughness of Corrax is not
affected.
It is recommended that all EDM’ing
of Corrax is done after aging since an
aging after EDM’ing will reduce the
toughness.
It is recommended that the “white
layer” is removed by grinding, stoning
or polishing.

8
EDM OF TOOL STEEL

WIRE EDM in the centre and are in opposition to In certain cases the risk can be
The observation made about the EDM each other. During the wire erosion reduced through different precautions.
surface in earlier pages are also mostly process a greater or lesser amount of 1: To lower the overall stress level in
applicable to the wire EDM-process. steel is removed from the heat-treated the part by tempering at a high tem-
The affected surface layer, however, is part. Where a large volume of steel is perature. This assumes the use of a steel
relatively thin (<10 µm) and can be removed, this can sometimes lead to grade with high resistance to temper-
compared more to “fine-sparking” distortion or even cracking of the part. ing.
EDM. Normally there are no observable The reason is that the stress balance in 2: By drilling several holes in the area
cracks in the eroded surface after wire the part is disturbed and tries to reach to be removed and to connect them by
erosion. But in certain cases another an equilibrium again. The problem of saw-cutting, before hardening and
problem has been experienced. crack formation is usually only encoun- tempering. Any stresses released during
After heat treating a through harden- tered in relatively thick cross section, heat treatment are then taken up in the
ing steel the part contains high stresses e.g. over 50 mm (2") thick. With such pre-drilled and sawn areas, reducing or
(the higher the tempering temperature, heavier sections, correct hardening and eliminating the risk of distortion or
the lower the stresses). These stresses double tempering is important. cracking during wire-erosion. Fig. 13
take the form of tensile stresses in the illustrates how such pre-cutting may be
surface area and compressive stresses done.

Fig. 13. Pre-drilled holes connected by a


saw-cut, before hardening and tempering,
will help to prevent distortion or cracking
when wire eroding thick sections.

Fig. 12. This block of D2 steel, approx. 50 x


50 x 50 mm (2" x 2" x 2"), cracked during the
wire EDM operation.

Fig. 11. Wire erosion of a hardened and tempered tool steel


blanking die.

9
EDM OF TOOL STEEL

WIRE EROSION
OF CUTTING PUNCHES
Summary The difference in bending strength
between rough-spark-machined and
In summing up it can be said that prop- fine-spark-machined test pieces is
When producing a cutting punch by
erly executed electrical discharge ma- largely due to the difference in the
wire erosion, it is recommended (as
chining, using a rough and a fine ma- distribution of the cracks and to the
with conventional machining) to cut it
chining stage in accordance with the presence of the in spots distributed
with the grain direction of the tool steel
manufacturer’s instruction, eliminates white layer on the fine-spark-machined
stock in the direction of the cutting
the surface defects obtained in rough specimens. The rougher surface finish of
action. This is not so important when
machining. Naturally, certain structural the rough-machined specimen has not
using PM steels due to their non-direc-
effects will always remain, but in the really been significant. Regardless of
tional grain structure.
vast majority of cases these are insig- circumstances, such surface irregulari-
nificant, provided that the machining ties are relatively harmless as crack
process has otherwise been normal. initiators compared with the solidifica-
Polishing by EDM Structural effects, more-over, need not tion cracks. During the polishing of the
Today some manufacturers of EDM- necessarily be regarded as entirely fine-machined test piece which was
equipment offer, by a special technique, negative. In certain cases the surface carried out, the depth of the white and
possibilities to erode very fine and structure, i.e. the rehardened layer, rehardened layer was merely reduced
smooth surfaces. It is possible to reach has—on account of its high hardness— and not completely eliminated.
the surface finish of about 0,2–0,3 µm. improved the resistance of the tool to Further polishing would probably
Such surfaces are sufficient for most abrasive wear. In other cases it has been result in complete restoration of the
applications. The greatest advantages found that the cratered topography of bending strength. Highly stressed tools
are when complicated cavities are in- the surface is better able to retain lubri- and parts thereof, e.g. very thin sections
volved. Such cavities are difficult, time cant than conventional surfaces, result- that are far more liable to bending, can
consuming and therefore expensive to ing in a longer service life. If difficulties justify an extra finishing operation.
polish manually, but can be conven- in connection with the working per- The lower the hardness in the matrix,
iently done by the EDM- machine during formance of spark-machined tools the less sensitive the material will be to
a night-shift, for example. should arise, however, there are some adverse effects on the strength as a
Investigations made on our grades relatively simple extra operations that result of electrical discharge machining.
Impax Supreme, Orvar Supreme, Stavax can be employed, as indicated above. Lowering of the hardness level of the
ESR and Rigor show that the hard re- A slightly striped appearance has entire tool can, therefore, be another
melted white layer produced is very thin been re-ported in materials rich in car- alternative.
and equal in the these grades. The thick- bides, such as high-carbon cold-work
ness is about 2–4 µm. Since there is no steels and high-speed steels, where
sign of any heat-affected layer, the in- there is always a certain amount of
fluence of the EDM on mechanical prop- carbide segregation or in material with
erties is negligible. high sulphur content.

Fig. 14. This Stavax ESR


mould insert was finished
by EDM “polishing”.

10
EDM OF TOOL STEEL
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9331 Santa Fe Springs Road
77bis, rue de Vesoul PL-05-092 Lomianki ASSAB Pacific Pte. Ltd
Santa Fe Springs, CA 90670
La Nef aux Métiers Telephone: +48 22 751 5675 171, Chin Swee Road
Telephone: +1 562 946 65 03
F-25000 Besançon Telefax: +48 22 751 5670 No. 07-02, San Centre
Telefax: +1 562 946 77 21
Telephone: +33 381 53 12 19 Singapore 169877
Telefax: +33 381 53 13 20
PORTUGAL UDDEHOLM
F RAMADA Aços e Industrias S.A. Telephone: +65 534 56 00
7900 Hub Parkway Telefax: +65 534 06 55
GERMANY P.O. Box 10 Cleveland OH 44125
UDDEHOLM P-3881 Ovar Codex Telephone: +1 216 524 87 70 Subsidiaries
Hansaallee 321 Telephone: +351 56 58 61 11 Telefax: +1 216 642 10 42 China, Hong Kong, Indonesia, Japan,
D-40549 Düsseldorf Telefax: +351 56 58 60 24 Korea, Malaysia, Philippine Islands,
Telephone: +49 211 535 10 CANADA Singapore, Taiwan, Thailand
Telefax: +49 211 535 12 80
ROMANIA
UDDEHOLM LIMITED
BÖHLER Romania SRL
Branch offices 2595 Meadowvale Blvd.
Uddeholm Branch
UDDEHOLM Mississauga, Ontario L5N 7Y3
Str. Atomistilor Nr 14A
Falkenstraße 21 Telephone: 905 812 9440
077125 Magurele Jud Ilfov
D-65812 Bad Soden/TS. Telefax: 905 812 8659
Telephone: +40 214 575007
Telephone: +49 6196 659 60 Telefax: +40 214 574212 MEXICO
Telefax: +49 6196 659 625 UDDEHOLM
RUSSIA
UDDEHOLM Calle Ocho no 2, Letra "C"
UDDEHOLM TOOLING CIS
Albstraße 10 Fracc. Industrial Alce Blanco
25 A Bolshoy pr PS
D-73765 Neuhausen 53370 Naucalpan de Juarez
197198 St. Petersburg
Telephone: +49 715 898 65-0 Estado de Mexico
Telephone: +7 812 233 9683
Telefax: +49 715 898 65-25 Telephone: +52 5-576 5422
Telefax: +7 812 232 4679
Telefax: +52 5-576 2139
GREAT BRITAIN, IRELAND SLOVAKIA
UDDEHOLM UK LIMITED UDDEHOLM
UDDEHOLM Slovakia Lerdo de Tejada No.542
European Business Park Nástrojové ocele, s.r.o
Taylors Lane, Oldbury Colonia Las Villas
KRÁCINY 2 66420 San Nicolas de Los Garza, N.L.
West Midlands B69 2BN 036 01 Martin
Telephone: +44 121 552 55 11 Telephone: +52 8-352 5239
Telephone: +421 842 4 300 823 Telefax: +52 8-352 5356
Telefax: +44 121 544 29 11 Telefax: +421 842 4 224 028
Dublin Telephone: +353 1 45 14 01

When the first idea pops into your head, throughout the development
process to the release of the new product, we’ll be your partner.
As the world’s leading supplier of tooling materials and related services,
we can be trusted. Meet us under the Uddeholm and ASSAB brands,
wherever in the world you have your business. 11
Edition: 2, 01.2005

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