Effect of Pulse Repetition Frequency on Crater Evolution and Surface Integrity in Finishing EDM of 4Cr13 Steel: Numerical and Experimental Investigation

Pulse repetition frequency (PRF) controls pulse off-time and, therefore, the extent of thermal accumulation, melt expulsion, and dielectric recovery in finishing electrical discharge machining (EDM). This study clarifies how PRF modifies crater evolution and surface integrity in finishing EDM of 4Cr13 martensitic stainless steel, a corrosion-resistant mold steel used in precision dies and molds. A 2D axisymmetric electro-thermo-fluid model was established in COMSOL, where Gaussian current density, heat-flux, and plasma pressure were periodically imposed at PRFs of 25–100 kHz, while pulse-on time (6 μs) and peak current (8 A) were kept constant. The simulations tracked the transient pressure, heat-flux, velocity, and temperature fields over a common elapsed time of 25 μs. Finishing experiments were then carried out on flat 4Cr13 coupons at 50, 75, and 100 kHz using a copper electrode and deionized water, followed by characterization by laser confocal microscopy, SEM/EDS, and X-ray diffraction using the cosα method. Increasing PRF localized the coupled pressure-heat-flow fields near the crater rim, but shortened off-time and intensified inter-pulse heat accumulation. Accordingly, the surface roughness decreased from Ra = 1.18 μm at 50 kHz to 0.63 μm at 75 kHz, and then slightly increased to 0.71 μm at 100 kHz because of crater overlap, re-melting, and incomplete gap recovery. SEM observations confirmed large irregular craters with cracks at 50 kHz, more uniform fine craters at 75 kHz, and overlapping re-solidified traces at 100 kHz. The residual stress remained compressive for all tested conditions (−341 to −409 MPa). Overall, 75 kHz offers the best compromise between crater uniformity, roughness, and compressive stress for finishing EDM of 4Cr13 steel.