摘要
放電加工法特別適用於高強度、高硬度材料的加工。本研究以不同的電極尺寸，電極直徑由9.5mm至0.5mm、300mm與26mm，以傳統放電加工機與微細放電加工機，對工具鋼SKD11與SKD61進行加工，探討電極尺寸與放電加工參數對加工表層特性的影響。
研究結果顯示，微細放電加工表面與傳統放電加工的表層特性是一樣，不同在於微細放電加工表面全被淺坑參差任意覆蓋，每個淺坑都可以清楚被辨識，都代表每一個電弧柱的時間順序與位置，若其與加工參數迴歸分析，可以得到淺坑直徑與放電電壓、放電電流與放電持續時間之經驗公式。
在電極尺寸大於500mm的傳統放電加工中，擴孔量、消耗比、表面粗糙度與白層厚度，皆受放電電流與放電持續時間要影響，而電極尺寸不影響其他表層特性，只影響表面裂紋生成。在電極尺寸小於500mm的微細放電加工中，放電電壓與放電電容對表層特性的影響，則大過於其他加工參數，過小的放電電壓將導致加工不穩定，過大的放電電壓則將惡化放電加工表層特性，而降低放電電容雖可以提升放電加工表層特性，但當放電電容小於20pF時，由於電路中遊浮電容將導致連續電弧與加工短路，也將惡化放電加工表層特性。
在放電加工參數對放電裂紋影響方面，發現當放電電流增大時，白層厚度歧異度增大，厚度大的白層所佔比例少，因此可以降低裂紋生成，而當放電持續時間增大時，由於白層整體厚度提昇與引入更多應力，因此也助於裂紋開展。在電極尺寸方面對於裂紋影響方面，當電極尺寸減少時，由於電極中心到電極中間的距離縮短，導致溫度梯度變化小，因此表面裂紋不易生成。本研究以裂紋臨界界線預測裂紋生成與否，在裂紋臨界界線上方為裂紋生成區，在下方則為無裂紋區，發現加工材料的熱傳導係數將影響曲線斜率，當熱傳導係數增大時可增加其斜率，而電極尺寸則使裂紋臨界界線產生平移位移，電極尺寸縮小可增大無裂紋區之區域。

Abstract
EDM is a high-technology process particularly suitable for the machining of materials with high strength and toughness properties. In this study, tool steel SKD11 and SKD61 are machined with varying electrode size, from 9.5mm to 0.5mm, 300mm and 26mm, covering the fields of conventional and micro EDM. Effects of electrode size and working parameters upon surface integrity are analyzed.
The results reveal that the surface topography of the micro-EDM process exhibits similar features to those associated with the conventional EDM process. However, the Micro-EDMed surface shows the presence of an evenly distributed series of randomly overlapping craters. Each crater may be individually identified, and indicates the exact position and chronological sequence of a series of discrete discharges. A regression equation related diameter of crater and working parameters could be further established.
Electrode size larger than 500mm belongs to conventional EDM. The results indicate that enlargement, wear ratio, surface roughness and the thickness of white layer are affected by pulse-on duration and pulse current. Electrode size affects only the formation of surface crack. Electrode size smaller than 500mm belongs to micro-EDM. Pulse voltage and capacity have the most significant influence on surface integrity. A Small voltage leads to unstable of the process and a large voltage deteriorates the surface roughness. Although reducing capacitance will promote the surface, when capacitance reduced to 20pF, the stray capacitance will cause the continuous arc and short circuit. This also does damage to the surface integrity.
Surface crack is affected by both working parameters and electrode size. An increasing pulse-on duration will increase both the average white layer thickness and the induced stress. These two conditions tend to promote the crack formation. When the pulse current is increasing, the material removal rate will increase but with a deviation of thickness of the white layer and a less tendency to crack. When the electrode size is reduced, the temperature gradient of the dielectric is not serious because of the distance from the center to edge of the electrode is decreased, and this can prevent the surface crack. When crack critical line is performed to predict the formation of surface crack, the slope increased as the thermal conductivity of the working material increased. Changing the electrode diameter causes a parallel shift of the crack critical line location within the crack distribution map. When small diameter electrodes are employed in the machining process, the location of the line shifts upwards. This causes the no-crack zone to enlarge, and therefore permits a wider choice of machining parameters to be adopted.

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