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INTCSET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1094 (2021) 012074 doi:10.1088/1757-899X/1094/1/012074

Determination and Analysis of Residual Stress for AISI L2

Tool Steel in Electric Discharge Machine (EDM)

Shukry H Aghdeab, Raed R Shwaish and Tahseen M Salman

Production Engineering and Metallurgy Department, University of Technology,
Baghdad, Iraq

E-mail: Pme.19.02@grad.uotechnology.edu.iq

Abstract. Electric discharge machine is one of the most important non-traditional cutting
processes conducted without contact between the workpiece and tool electrode. Each cutting
process was associated with residual stresses, and these stresses are significant in determining
life and product performance. This study aimed to determine the residual stress produced in the
electric discharge machine (EDM) using the X-ray diffraction method. The used EDM
parameters in this study are current Ip (10, 20, 30) A, pulse on-time Ton (50, 100, 150) μs, and
pulse off-time Toff (6.5, 12,25) μs these parametric divided into 27 specimens. Full factorial
was used to analyze the result using Minilab 17 software. The result showed that
approximately between the experimentally and predict result. Also, the result illustrated that
the residual stress was increasing with increases in each parametric EDM used. Maximum
tensile residual stress is (838.86 Mpa) at a higher value of machine parameters, while the best
residual stress achieved is compressive residual stress at low machine parameters, and it
reaches 201 Mpa.
Keywords. Electrical discharge machining (EDM), Factorial, X-ray diffraction, Residual
stress.

1. Introduction
An electric discharge machine is a cutting process electric spark mechanism to convert electrical
energy to thermal energy to produce many sparks on the workpiece with a dielectric liquid. Resulting
from the high-temperature gradients, EDM produces residual stresses and metallurgical changes. Such
stresses are always generated where regions of material were non-homogeneous plastically deformed
in such a permanent way strain incompatibilities happen [1]. These stresses are contained much more
than the material's yield point and, depending on the crystal structure, causing severe slip, twining, and
cleavage [2]. The maximum value of residual stresses at the top surface decreases until it reaches zero
in the sub-surface [3]. Figure (1) explains the variation of residual stress by the plasma column; from
the figure, we can see that the residual stress is affected only on the heated affected zone. This means
that the residual stress in EDM is depended on the heated affected zone and is associated with depth
[4]. Residual stress can be classified into two types compressive residual stresses and tensile residual
stresses. The compressive residual stresses are more important for product performance and life,
promoting service and preventing crack nucleation. The compressive residual stress value takes a
negative signal [5]. Tensile residual stress increasing service stresses and leads to failure of
components, distortion, corrosion, and cracking. The tensile residual stress value is taken positive
signal [6]. Many types of research in this field is done. Mohanty showed that residual stress increased

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INTCSET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1094 (2021) 012074 doi:10.1088/1757-899X/1094/1/012074

sharply with increasing current and pulse on time, often slowly increasing residual stress and duty
factor [7]. S.N. Joshi and SD Pande showed high-temperature gradient zones and high residual stress
regions that reach the material yield strength. A large amount of compressive stress is generated inside
the crater zone; it decreased along with the depth of the work domain and transited into tensile stress
[8]. S. Saxena studied the thermal stress distribution for the electric spark process. It was found tensile
stress at the contact area between electrode and workpiece increased in depth, tensile stress converted
to comparison stress; this converting also connected with the cooling and heated cycle during the
process [9]. B. Nahak studied surface integrity in die-sinking EDM and showed the residual tensile on
the surface due to the abrupt surface temperature difference due to the fast thermal cycle and the
consolidated layer's thermal expansion [10].

Figure 1. Effect of plasma column on residual stress distributions[11].

2. Residual stress measurement

Residual stress was a crucial factor when assessing engineering components' integrity and
welded assemblies [12-13]. Residual stresses occur in many manufactured structures and
components. Over the years, various approaches have been developed to calculate residual
stress for different materials to achieve accurate evaluation. Numerous technical methods
have developed over many decades. Their practical implementations have greatly benefited
from the advancement of complementary technology, particularly in material cutting, full-
field deformation measuring techniques, computational methods, and computing power [14].
Many methods were used to measure residual stress, such as destructive, semi destructive, and
non-destructive techniques depending on their applications and the availabilities of those
techniques. X-ray diffraction method was used in this study on a device XRD-6000, which
was found in Structural Research and Development Laboratory/Baghdad/ Iraq. We use XRD
methods because it is used for ductile material and small components. Also, the XRD method
has good accuracy and inexpensive, and it is considered a non-destructive test.

3. Experimental procedure
In this study, pure copper is selected as a tool electrode and tool steel AISI L2 as a workpiece. The
tool electrode dimensions are 32x27x10 mm3, and the workpiece dimensions are 30x20x3 mm3. After
it was cut by water, it gets machined; 10 mm was cut from the end of the sample using EDM, as
shown in Figure (2). Chemical composition for the workpiece and electrode are shown in Table (1).

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INTCSET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1094 (2021) 012074 doi:10.1088/1757-899X/1094/1/012074

Figure 2. Electrode and workpiece shape.

Table 1. Chemical composition for AISI L2 tool steel and

copper electrode.
Element Weight (%) Element Weight (%)
C 0. 690 Al 0.0023
AISI L2 tool steel

Si 0.276 S 0.00006

Pure copper
Mn 0.406 Sn 0.0018
P 0.0091 P 0.0008
S 0.003 Fe 0.024
Mo < 0.002 Mn < 0.0004
Cr 0.585 Cr 0.0071
Ni 0.0305 Sb 0.0082
Cu 9999
The machine parameter can be classified into fixed parameters and changed parameters, such as
current, Ton, and Toff, as shown in Table (2).

Table 2. Machine parametric value in

this study.
Machining Parameters Values
Current 10 ,20 ,30 A
Ton 50, 100, 150μs
Toff 6.5 , 12 ,25μs
Polarity Positive
Dielectric fluid Transformer oil
(HV) 240 V 1.5 A
S code (S CODE) 20
Servo feed (SVO) 75 %
Working time (WT) 0.6 sec
Jumping time (JT) 0.8 mm
Gap code (GAP) 9
Depth of cut 1 mm

4. Results and discussion

The experiment and predicted results for the residual stress with machine parameters are shown in
Table (3). Design of experimental is done using full factorial to give (all prospects) 27 number of
experiment on program Minilab17 software. The found relationship between the input parameters and
the produced residual stress by using DOE is shown in Equation (1).
σrs = 255 - 26.53 Ip - 1.26 Ton + 34.9 Toff + 0.674( Ip )2 + 0.00596 ( Ton )2 -1.520 (Toff)2 - 0.0092 Ip*Ton
+ 0.957 Ip*Toff+ 0.0551 Ton*Toff (1)

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INTCSET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1094 (2021) 012074 doi:10.1088/1757-899X/1094/1/012074

Table 3. Experiment and predict value with machine parametric.

No. Exp. Residual Pred. Residual
Ip Ton Toff
Sample stress (Mpa) stress (Mpa)
1 11 01 590 -6659691 -6609561
6 11 01 16 -0029611 -0309399
0 11 01 60 -6509031 -6069051
5 11 111 590 -6119911 -6629520
0 11 111 16 0919111 0259063
5 11 111 60 6399025 6359311
3 11 101 590 6399911 6009925
2 11 101 16 5169109 0919600
9 11 101 60 0309091 0369235
11 61 01 590 6099003 6129990
11 61 01 16 5509109 5059605
16 61 01 60 0559952 0339055
10 61 111 590 6009101 6669651
15 61 111 16 5909611 5559356
10 61 111 60 0969101 0999590
15 61 101 590 6159063 6539009
13 61 101 16 5019560 5319552
12 61 101 60 0139039 5939551
19 01 01 590 0509911 0239161
61 01 01 16 0019039 0609020
61 01 01 60 3519001 3519325
66 01 111 590 5159621 0919020
60 01 111 16 0159111 0029116
65 01 111 60 3509511 3569900
60 01 101 590 5619111 5109525
65 01 101 16 0599005 0569119
63 01 101 60 2029253 2519111

Residual stress is increasing with an increase in MRR, EWR, and SR. So residual stress increasing
with an increase in current from 10 to 30A. This occurred because increasing the current leads to an
increase in spark energy between the electrodes. Residual stress also increases with Ton because
increasing in Ton leads to high temperature on the workpiece, so increasing in temperature leads to
increasing σrs. Also, the result shows the highest level of Toff gives maximum residual stresses because
higher Toff enhances the re-solidification time in the presence of dielectric medium and results in more
significant surface grains, causing higher residual stresses. The effect of current, Ton and Toff, on the
residual stress is shown in Figure (3).

Figure 3. The effect of Current (Ip), pulse on time (Ton), and pulse off time
(Toff) on residual stress (σrs).

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INTCSET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1094 (2021) 012074 doi:10.1088/1757-899X/1094/1/012074

The performance of variance analysis (ANOVA) is organized in Table (4), which includes variation
sources, degrees of freedom (DF), the total sum of squares (Adj SS), mean squares (Adj MS), F-
values, and P-values to determine whether the factors are significantly related to the response.
ANOVA results show that the current has the highest effect on the residual stresses.

Table 4. ANOVA table for σrs.

Source DF Adj SS Adj MS F-Value P-Value
Model 14 737874 52705 64.19 0.000
Linear 5 599871 99979 121.76 0.000
Current 6 348588 174294 212.26 0.000
Ton 6 14997 7499 9.13 0.004
Toff 6 236286 118143 143.88 0.000
2-Way Interactions 2 138003 17250 21.01 0.000
Current * Toff 5 126488 31622 38.51 0.000
Ton * Toff 5 11515 2879 3.51 0.041
Error 16 9853 821
Total 65 747728

5. Conclusion
The present study discussed the effect of electrical process parameters (Ip, Ton, Toff) on
the for tool steel AISI L2 when pure copper is used as a tool electrode. The full
factorial model has been proposed to estimate the residual stresses. The result showed that the
experimented and predicted values are approximately equal. From the result, it can be concluded that:
 Best residual stresses are compressive stress produced in samples 1, 2, 3, 4, which have
negative signals, and this stress appeared at low machine parameters current, pulse on time,
and pulse off time. Therefore, the researcher recommends using lower input parameters to
achieve safety residual stress.
 Residual stress increasing with increasing the current, pulse on time, pulse off time. The
maximum experimental residual stress was 838.9Mpa, and the predicted maximum residual
stress was 861Mpa.

Nomenclature
Ton Pulse on time (μs) Ip Current (A)
Toff Pulse off time (μs) σrs Residual stress (Mpa)
EDM Electric discharge machine XRD X-ray diffraction
SR Surface roughness MRR Material removal rate
EWR Electrode wear rate DOE Design of experimental

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[4] A Thesis, D O F Philosophy and S S Sidhu 2014 Study of Surface Properties and Residual
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INTCSET 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1094 (2021) 012074 doi:10.1088/1757-899X/1094/1/012074

p211
[7] C P Mohanty, J Sahu and S S Mahapatra 2012 Thermal-Structural Analysis of Electrical
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[8] S N Joshi and S D Pande 2013 Prediction of Thermal Residual Stresses with a Thermo ‐
physical Model of Electrical Prediction of Thermal Residual Stresses with a Thermo-
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[9] S Saxena 2016 Thermal Stresses due to Electrical discharge machining on AISI4340 vol 7 no 5
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[11] T Muthuramalingam and B M S Vignesh 2018 Performance Analysis of Pulse Generators on
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[13] B Ekmekci 2007 Residual Stresses and White Layer in Electric Discharge Machining (EDM)
(Appl. Surf. Sci.) vol 253 no 23 pp 9234–9240
[14] N S Rossini, M Dassisti, K Y Benyounis and A G Olabi 2012 Methods of Measuring Residual
Stresses in Components (Mater. Des.) vol 35 pp 572–588