Multi-pass EDM process planning for the surface treatment of powder-bed-fusion AM CORRAX mold steel

Abstract

Abstract Although it is time-consuming to perform multi-pass electrical discharge machining (EDM) processes, EDM is exceedingly feasible for processing the partially unmelt profile of Powder-Bed-Fusion additive manufacture mold steel. This study is based on the principle of removing three times the thickness of the recast layer and reducing the EDM processes depth. And then, the surface quality and the processing time with EDM passes are decreased by adjusting the EDM passes suggested by the machine builder. Secondly, reduction of four more passes and the predetermined depth of processing so that the total processing time can be reduced further. Finally, the efficiency is increased by more than 77% compared to machine builder’s processes, and the final surface roughness reaches the specification of 0.17 μm Ra. The HAZ and recast layer thickness are also reduced drastically and distributed uniformly. Therefore, a new version of the EDM process planning suitable for AM CORRAX mold surface treatment is proposed, and its processing efficiency and surface integrity are investigated.