Journal of Mechanical Science and Technology 29 (9) (2015) 1~7

www.springerlink.com/content/1738-494x(Print)/1976-3824(Online)

DOI 10.1007/s12206-013-0913-y

Experimental investigation of the process parameters in

cryogenic cooled electrode in EDM
Vinoth Kumar. S* and Pradeep Kumar. M
Department of Mechanical Engineering, CEG, Anna University, Chennai-600 025, India.
(Manuscript Received 000 00, 2015; Revised 000 00, 2015; Accepted 000 00, 2015)
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Abstract
Investigations were conducted on the machining of AISI D2 tool steel via conventional electrical discharge machining (CEDM) and
cryogenic cooled electrode in electrical discharge machining (CCEDM). Machining parameters, including discharge current, pulse on
time, and gap voltage, were varied to investigate their effects on machining performance such as on electrode wear ratio (EWR), surface
roughness (Ra), microstructure, surface morphology, and elemental composition. Experimental results showed that EWR was reduced by
20% in CCEDM compared with in CEDM. Moreover, the Ra in CCEDM decreased by approximately 19% compared with that in
CEDM. The results also indicated that the surface morphology of the workpiece machined via CCEDM was better than that of the workpiece machined via CEDM. Lastly, the damaged layer and microcracks were less in the workpiece machined via CCEDM than those in
the workpiece machined via CEDM.
Keywords: Cryogenic cooling; Electrical discharge machining; Electrode wear ratio; SEM; Surface roughness
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1. Introduction
Electrical discharge machining (EDM) is a widely used
process in manufacturing high-precision components from
extremely hard and exotic metals. EDM is frequently used in
mold- and die-making industries [1]. Haron et al. [2] reported
that the highest material removal rate (MRR) was achieved at
6.5 A when machining AISI 1045 steel with an electrode diameter of 20 mm. Ozgedik et al. [3] conducted an experimental investigation on tool wear in EDM on an AISI 1040 steel
workpiece with cylindrical copper as the tool electrode. The
experimental results indicated that the metal removal rate increased with pulse duration. Amorim et al. [4] examined the
behavior of copper and graphite electrodes during the machining of AISI P20 tool steel; according to their observation,
copper and graphite presented similar MRR trends at positive
polarity. Furthermore, when the discharge current was high,
MRR was high, electrode wear was low, and surface roughness (Ra) was improved with the copper electrode under negative polarity.
Batish et al. [5] investigated the effects of the process parameters and the mechanism of material deposition in EDM
on the surface properties of EN31,H11 and high-carbon highchromium die steel materials. The material transfer mecha*

Corresponding author. Tel.: +919994757258, Fax.: +

E-mail address: svkceg@gmail.com,pradeep@annauniv.edu

Recommended by Associate Editor

KSME & Springer 2015

nism involved in EDM was discussed. Die steel was machined

effectively with a copper tool electrode via EDM. Guu [6]
investigated surface morphology and microcracks in AISI D2
steel under EDM. Based on the report, a low discharge current
should be used to avoid the formation of microcracks. Chen et
al. [7] studied the influences of kerosene and distilled water as
dielectric fluids in machining Ti-6Al-4V. Carbide was formed
on the workpiece surface when kerosene was used as a dielectric fluid, whereas oxide was produced on the workpiece surface when distilled water was utilized. Kiyak et al. [8] investigated the influences of machining parameters on roughness
and reported that surface quality could be improved with a
low discharge current and pulse on time. Fonda et al. [9] attempted to measure temperature using a K-type thermocouple
on a Ti-6Al-4V workpiece with various duty factors and reported that internal workpiece temperature increased with duty
factor.
Popa et al. [10] demonstrated that optimizing process parameters could influence the performance of EDM. An equation for crater depth was formulated in terms of discharge
energy or EDM. Based on the equation, crater depth increased
with the discharge current flowing through the workpiece and
the tool electrode.
Hyeon Kyu Yoo et al. [11] performed an experiment on a
new electrode for micro-EDM using Ti(C,N)-based cement.
The result indicated that electrode wear ratio (EWR) improved
by 35% when a Ti-based solid solution carbonitrate electrode

Vinoth Kumar. S and Pradeep Kumar. M / Journal of Mechanical Science and Technology 29 (9) (2015) 1~9

was used compared with that of a WC-Co electrode. Lin et al.

[12] developed a hybrid EDM process. Investigations were
performed on an SKD 61 tool material with different process
parameters; the results showed that MRR increased with current. Tzeng and Chen [13] studied the multi-optimization
technique in EDM using response surface methodology and a
genetic algorithm . This approach is the most suitable optimization technique for industrial applications. Puthumana and
Josh [14] investigated the performance of dry EDM using a
slotted electrode. The experiment results revealed that the
slotted electrode reduced EWR.
Many researchers have attempted to investigate the benefits
of using cryogenic coolants to evaluate machining performance. Most cryogenic cooling applications in machining studies have been examined under turning operations although
cryogenic cooling is also applied in other machining operations such as grinding and milling. Abdulkareem et al. [15, 16]
investigated the effect of cooling a copper electrode on machining titanium alloy by EDM. Responses such as EWR,
MRR, and Ra were investigated. The results indicated that
EWR was reduced by approximately 27% when titanium alloy
was machined with an LN2-cooled copper electrode compared
with machining a similar material without cooling the electrode. Srivastava and Pandey [17, 18] evaluated the performance of the cryogenic cooling of a copper electrode on M2
grade high-speed steel workpiece machined via EDM. The
results revealed that electrode wear was reduced by 20%,
whereas Ra decreased by 27% when the electrode was cryogenically cooled. A summary of the literature that studied the
effects of cryogenic cooling on EDM is provided in Table 1.
Except for the two studies on EDM operations, no research
has yet focused on AISI D2 steel under cryogenic cooled
EDM.
The present work investigates the influence of cryogenic
cooled electrode in EDM (CCEDM) on the machining of AISI
D2 tool steel with a copper electrode and different discharge
currents, pulses on time, and gap voltages. It then compares
the effectiveness of conventional EDM (CEDM) with that of
CCEDM. Output responses, such as EWR, Ra, electrode temperature, microstructure, surface morphology, and elemental
composition of the workpiece, are measured.

2. Experimental setup
The experiments were performed on an ELECTRONICA
XPERT 1 EDM machine. The dimensions of the square copper electrode and workpiece are 19 mm 19 mm 140 mm
and 22 mm 22 mm 10 mm, respectively, for all work
combinations. The chemical composition and material properties of AISI D2 tool steel are provided in Tables 1 and 2, respectively.
2.1 Modified tool electrode
Fig. 1 shows the modified tool electrode setup for EDM.

Table 1. Composition of AISI D2 tool steel.

Elements

Mn

Si

Cr

Ni

Mo

Fe

Weight %

1.4

.60

0.6

11

.30

0.7

0.7

Balance

Table 2. Mechanical properties of AISI D2 tool steel.

Properties

Conditions (C)

Density ( 1000 kg/m3)

7.7

25

Poissons ratio

0.27-0.30

25

Elastic modulus (GPa)

190-210

25

Thermal expansion
(10-6/C)

10.4

20-100

Fig. 1. Modified tool electrode.

(a)

(b)

Fig. 2. EDM tool electrode: (a) conventional electrode; (b) modified

electrode.

The electrode was modified to allow LN2 to flow in from the

lower region and exit at the upper region of the electrode. The
electrode was 140 mm long. It had an inlet hole with a diameter of 12 mm that was located 90 mm from its top surface. The
bottom 12 mm was solid, and a hole with a diameter of 3 mm
was made at a depth of 0.08 mm at the center of the solid end.
The outlet for LN2 was a 5 mm-hole located opposite the inlet
hole.
Figs. 2(a) and (b) show the conventional and modified tool
electrodes, respectively.

Vinoth Kumar. S and Pradeep Kumar. M / Journal of Mechanical Science and Technology 29 (9) (2015) 1~9

Table 3. Experimental details of EDM operations.

Workpiece material and electrode

AISI D2 tool steel and copper

Current (A)

9, 12, and 15

Pulse on time (ms)

100, 200, and 300

Gap voltage (V)

45, 55, and 65

Dielectric fluid

IPOL spark oil

Polarity

Workpiece (+ ve), electrode (ve)

Machining environments

(i) CEDM
(ii) CCEDM

Fig. 3. Electrode temperature measurement using a K-type thermocouple.

2.2 Temperature measurement in the electrode

Type K is the most commonly used thermocouple; it has a
sensitivity of approximately 41 V/C. This product is inexpensive. A wide variety of probes are available from 200C
to 1250C /330F to 2460F.
2.3 Cryogenic cooling setup
The electrode was modified to allow LN2 to flow in from
the lower region and exit at the upper region of the electrode.
The electrode was 140 mm long. It had an inlet hole with a
diameter of 12 mm that was located 90 mm from its top surface. The bottom 12 mm was solid, and a hole with a diameter
of 3 mm was made at a depth of 0.08 mm at the center of the
solid end. The outlet for LN2 was a 5 mm-hole located opposite the inlet hole. Fig. 2 shows the electrode setup for the
machining process. The electrode was clamped to the rotatable z axis machine ram. The barricade stainless steel hose
pipe for the LN2 was connected to the lower part of the electrode through a brass adaptor.
LN2 was stored in a container. A compressed air pressure of
2-3 bar was supplied by the compressor. This pressure could
be regulated using a pressure regulator. The compressed air
was dried using a drier. After drying, the compressed air was
sent to the container through the inlet pipe. The compressed
air started to force down the fluid. The outlet pipe was placed
at the bottom of the container. Liquid nitrogen started rising
through the outlet pipe because of the air pressure inside the
container. Liquid nitrogen was then sent to the machining
zone through the flexible hose attached with a nozzle that was
connected to the EDM electrode, as shown in Fig. 4.
The K- type thermocouple was inserted at the bottom face
of the electrode and the edge of the workpiece. EWR and
MRR were measured by weight. Ra was evaluated using
Surftronic 3+ roughness measuring instrument. Input process
parameters included discharge current, pulse on time, and gap
voltage. The surface morphology of the machined workpiece
was studied using a scanning electron microscope. The experimental setup is shown in Fig. 5. Table 3 provides the experimental details of EDM operations

Fig. 4. Schematic of the cryogenic electrode cooling setup.

Fig. 5. Experimental setup of the cryogenic cooling of the electrode.

3. Results and discussion

3.1 EWR
Fig. 6 shows the effects of pulse on time and discharge current on EWR. EWR increased with discharge current and
pulse on time, as reported in the work of Puertas et al. [1].
Electrode wear increased with discharge current in both
CEDM and CCEDM. Gap voltage increased with decreasing
spark intensity in working gap voltage and reduced EWR in
CEDM and CCEDM. An increase in discharge current increased the amount of spark energy transferred into the machining gap, and consequently, increased electrode wear [1418]. A reduction of 20.59% in electrode wear was observed at
a discharge current of 9A, pulse on time of 100 ms, and gap
voltage of 65 V in CCEDM compared with in CEDM. The
minimum EWR was determined to be 7.41% for a pulse on
time of 300 ms, a discharge current of 12 A, and a gap voltage
of 55 V. EWR reduction in CCEDM was 7%-20.9% relative
to CEDM. Discharge current increased with pulse on time,

Vinoth Kumar. S and Pradeep Kumar. M / Journal of Mechanical Science and Technology 29 (9) (2015) 1~9

Fig. 6. Effects of pulse on time and discharge current on EWR: (a) gap
voltage 45 V; (b) gap voltage 55 V; (c) gap voltage 65 V.

Fig. 7. Effects of pulse on time and discharge current on Ra: (a) gap
voltage 45 V; (b) gap voltage 55 V; (c) gap voltage 65 V.

which increased heat energy at the electrode-workpiece interface and resulted in the rapid melting and vaporization of the
electrode. In CCEDM, however, the LN2-cooled electrode
exhibited enhanced thermal conductivity, and thus, reduced
the melting and vaporization of the electrode. Consequently,
EWR was reduced in CCEDM compared with in CEDM.
3.3 Ra
Fig. 7 shows the effects of pulse on time and discharge current on Ra. As indicated in the figure, Ra increased with discharge current and slightly decreased in both processes. This
finding could be attributed to the presence of a sufcient
amount of machining debris in the dielectric fluid that modified and widened the plasma channel. The application of LN2
cooling improved the thermal conductivity of the electrode
and ensured a stable spark, which reduced electrode wear,
melting, and vaporization, and resulted in a smooth surface.
The Ra value of the work surface was 8.7 mm and 7.0 mm
for a current of 9 A, a pulse on time 300 ms, and a gap voltage
of 55 V in CEDM and CCEDM, respectively. Ra under the
LN2 cooling of the electrode was reduced by 20% compared
with that in CEDM.
3.3 Electrode temperature
Fig. 8 shows the effects of pulse on time and discharge cur-

Fig. 8. Effects of pulse on time and current on electrode temperature:

(a) gap voltage 45 V; (b) gap voltage 55 V; (c) gap voltage 65 V.

rent on electrode temperature. Discharge current and electrode

temperature increased in both CEDM and CCEDM. Discharge current increased the discharge energy that would be
transferred in the machining gap, which raised electrode temperature in the plasma channel. The application of cryogenic
LN2 cooling of the electrode significantly reduced electrode
temperature and minimized electrode wear. Discharge current
and electrode temperature increased in both CEDM and
CCEDM. The increase in discharge current raised the amount
of electrical discharge energy transferred into the machining
gap, and thus, increased temperature in the plasma channel. A
reduction of approximately 8%-18% in electrode temperature
was observed in CCEDM compared with in CEDM. Pulse on
time increased temperature at different discharge currents in
machining AISI D2 steel in both CEDM and CCEDM. Electrode temperature increased with pulse on time and discharge
current. The rise in temperature caused electrode wear. Electrode temperature for a low discharge current of 9 A, a pulse
on time of 100 ms, and a gap voltage of 45 V was determined
to be 186C and 136C, in CEDM and CCEDM, respectively.
Furthermore, electrode temperature for a discharge current of
15 A, a pulse on time of 300 ms, and a gap voltage of 65 V
was found to be 488C and 365C in CCEDM and CEDM,
respectively. The reduction in electrode temperature with LN2
cooling of the electrode was 29% higher than that in CEDM.
3.4 Effect of cryogenic cooling on the microstructure of
AISI D2 tool steel
Figs. 9(a)-(c) show the cross-sectional view of the machined
surface under CEDM and CCEDM. Low current and pulse on
time reduced re-solidification layers and microcracks. However, at high current and pulse on time, resolidification layers
and microcracks were observed in both CEDM and CCEDM.
Resolidification layers and microcracks in CEDM were less
than those in CCEDM. A marginal difference in microhardness was observed in CCEDM compared with in CEDM.
A discharge current of 9 A, a pulse on time of 100 ms, a gap
voltage of 55 V, and hardness ranging from 217 H.V to 220
H.V increased discharge current to 15 A, pulse on time to 300
ms, gap voltage to 65 V, and hardness range to 234 H.V and

Vinoth Kumar. S and Pradeep Kumar. M / Journal of Mechanical Science and Technology 29 (9) (2015) 1~9

Conventional EDM
(CEDM process)

Cryogenic electrode EDM

(CCEDM process)

(a) Current 9 A, Pulse on time 100 m s and gap voltage of 45 V

(b) Current 12 A, Pulse on time 200 m s and gap voltage of 55 V

Conventional EDM
(CEDM process)

Cryogenic electrode EDM

(CCEDM process)

(a) Current 9 A, Pulse on time 100 m s and gap voltage of 45 V

(b) Current 12 A, Pulse on time 200 m s and gap voltage of 55 V

(c) Current 15 A, Pulse on time 300 m s and gap voltage of 65 V

(c) Current 15 A, Pulse on time 300 m s and gap voltage of 65 V
Fig. 9. (a)-(c) Microstructure cross-sectional view of the EDM of AISI
D2 tool steel with various levels of current, pulse on time, and gap
voltage.

236 H.V in CEDM and CCEDM. At low to high discharge

current and pulse on time settings, no significant difference
was observed in the hardness distribution and depth of the
samples in both CEDM and CCEDM. However, the hardness
of the samples produced in CEDM was lower than that of the
samples produced in CCEDM. This observation could be
attributed to the penetration of some ions and atoms present in
the plasma channel such as copper, carbon, and other materials released by the evaporation of the tool electrode and the
breakage of the dielectric hydrocarbon molecules. High numbers of resolidification layers and microcracks were observed
in CEDM because the electrical spark energy transferred onto
the workpiece surface increased, and thus, the number of uneven craters, resolidification layers, and microcracks also increased. In CCEDM, the application of LN2 cooling of the
electrode produced a stable spark. Thus, less resolidification
layers and microcracks were observed on the workpiece. The
base metal continued to harden, and the hardening rate was
high compared with in CEDM.
3.5 Effect of cryogenic cooling on the surface morphology of
AISI D2 tool steel
Figs. 10(a)-(d) shows the AISI D2 tool steel workpiece sur-

(d) Current 15 A, Pulse on time 300 m s and gap voltage of 65 V

Fig. 10. (a)-(d) SEM images of the workpiece surface of the AISI D2
tool steel under CEDM and CCEDM.

face under CEDM and CCEDM. At low discharge current and

pulse on time, resolidification layers and microcracks were
few. However, at high discharge current and pulse on time,
resolidification layers and microcracks increased in both
CEDM and CCEDM. Resolidification layers and microcracks
were less in CEDM than in CCEDM.
Fig. 10(a) shows a discharge current of 9 A, a pulse on time
of 100 ms, and a gap voltage of 45 V. Based on the workpiece
surface recast layer, globules and pockmarks were observed
under CEDM and CCEDM. Discharge current, pulse on time,
and gap voltage increased the width of crack per unit area and
facilitated the formation of visible surface cracks in both
CEDM and CCEDM. However, the width of crack per unit
area increased with discharge current and pulse on time because of the high spark energy between the workpiece and the
electrode. Less resolidification layers and pockmarks were
observed in CCEDM than in CEDM at low discharge current
and pulse on time, as shown in Figs. 10(a) and (b). A dis-

Vinoth Kumar. S and Pradeep Kumar. M / Journal of Mechanical Science and Technology 29 (9) (2015) 1~9

(a) CEDM

(b) CCEDM

(a) CEDM

(b) CCEDM

Fig. 11. EDAX analysis of the workpiece surface of AISI D2 tool steel
at a current of 9 A, a pulse on time of 100 s, and a gap voltage of 45
V: (a) CEDM; (b) CCEDM.

Fig. 12. EDAX analysis of the workpiece surface of AISI D2 tool steel
at a current of 15 A, a pulse on time of 300 ms, and a gap voltage of 65
V: (a) CEDM; (b) CCEDM

charge current of 15 A, a pulse on time of 100 ms, and a gap

voltage of 65 V increased discharge current, pulse on time,
microcracks, and globule size in CEDM compared with in
CCEDM, as shown in Fig. 10(c).
A discharge current of 15 A, a pulse on time of 300 ms, a
gap voltage of 65 V, globule sizes between 45.6 mm and 9.83
mm, and crack widths between 1.98 mm and 1.71 mm were
compared under CEDM and CCEDM. The depth of the damaged layer, as well as the number of microcracks and cracks,
increased with discharge current and pulse on time. Microcracks and subsurface damage were less in CCEDM than in
CEDM, as shown in the Fig. 10(d). Crack width reduction
could be attributed to the cryogenic cooling of the electrode.
The temperature in the plasma channel and dielectric fluid
decreased within the vicinity of the tool tip. Considerable
crack formation was observed with the development of high
thermal stress that exceeded the fracture strength of the material. These cracks were formed because of high thermal stress.
In general, the density of cracks increased with discharge current and pulse on time.

specimen because of the cryogenic cooling of the electrode.

3.6 Effect of cryogenic cooling on the elemental composition

analysis of AISI D2 tool steel
The elemental composition of the workpiece surface was
examined via energy-dispersive X-ray spectroscopy (EDAX).
The details are shown in Fig. 11. The elements in the specimen were indicated by the pecks that conformed to their energy levels. Iron, oxygen, vanadium, and chromium are the
main elements in the machined surface region.
Figs. 11(a) and (b) show the locations marked on spectra 8
and 9 under CEDM and CCEDM, respectively. Based on the
spectrum analysis of the workpiece surface region, elemental
composition peaks correspond to their energy levels; moreover, vanadium, chromium, oxygen, and iron are present in
both CEDM and CCEDM.
Figs. 12(a) and (b) indicate the presence of carbon in the
workpiece in both processes at a discharge current of 15 A and
a pulse on time of 300 ms. The amounts of carbon observed in
CEDM and CCEDM are 18.79% and 16.57%, respectively. A
reduction of 11% in carbon was observed on the workpiece

4. Conclusion
Experiments were performed on AISI D2 steel under
CEDM and CCEDM. The conclusions drawn from the investigation are as follows.
(1) The results indicate that wear is reduced by 10%-21%
under LN2 cooling of the electrode compared with under
CEDM.
(2) The average surface roughness in LN2 cooling of the
electrode is reduced by 5%-10% compared with that in
CEDM.
(3) Electrode temperature decreases by 25% at a discharge
current of 15 A and a pulse on time of 300 ms in CCEDM
compared with in CEDM.
(4) The width of microcracks increases with peak current
and pulse on time in both cases, whereas globules and recast
layers are less in CCEDM than in CEDM.
(5) The depth of the damaged layer, as well as the width and
number of microcracks and cracks, increases with discharge
current and pulse on time. The subsurface damage layer and
microcracks are less at low discharge current and pulse on
time. Damaged layers and microcracks are less in CCEDM
than in CEDM.
(6) Carbon is reduced by 11% in the elemental composition
of the workpiece specimen because of the cryogenic cooling
of the electrode.

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Vinoth Kumar is a research scholar at

Anna University. He obtained his B.E.
and M.E. in Mechanical Engineering at
Anna University, Chennai, India. His
research interests include nontraditional
machining, cryogenic machining, and
optimization techniques.

Pradeep Kumar holds a Ph.D. in Mechanical Engineering and works as an

Associate Professor at the Department
of Mechanical Engineering, Anna University, Chennai, India. He has been
involved in teaching and research for
nearly 14 years. Dr. Kumar has published numerous research papers in international and national journals.