A comparison between micro milling pure copper and tungsten reinforced copper for electrodes in EDM applications

Büttner, H.; Vieira, Gabriel de Deus; Hajri, Melik; Vögtlin, M.; Kuster, Friedrich; Stirnimann, Josef; Wegener, Konrad

doi:10.1016/j.precisioneng.2019.08.018

Cited by 11 publications

(5 citation statements)

References 35 publications

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“…Pure copper has excellent electrical and thermal conductivity, high elasticity, high ductility, and good corrosion resistance. Hence, it has been widely used in automobile industry manufacturing, electronic communication, aerospace, and many other fields [ 1 , 2 , 3 ]. Higher demands are placed on the cutting process and the machining quality of pure copper material in the actual machining process.…”

Section: Introductionmentioning

confidence: 99%

Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper

Lai

Kun

et al. 2023

Micromachines

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In this paper, the responses of machined surface roughness and milling tool cutting forces under the different milling processing parameters (cutting speed v, feed rate f, and axial cutting depth ap) are experimentally investigated to meet the increasing requirements for the mechanical machining of T2 pure copper. The effects of different milling processing parameters on cutting force and tool displacement acceleration are studied based on orthogonal and single-factor milling experiments. The three-dimensional morphologies of the workpieces are observed, and a white-light topography instrument measures the surface roughness. The results show that the degree of influence on Sa (surface arithmetic mean deviation) and Sq (surface root mean square deviation) from high to low level is the v, the f, and the ap. When v = 600 m/min, ap = 0.5 mm, f = 0.1 mm/r, Sa and Sq are 1.80 μm and 2.25 μm, respectively. The cutting forces in the three directions negatively correlate with increased cutting speed; when v = 600 m/min, Fx reaches its lowest value. In contrast, an increase in the feed rate and the axial cutting depth significantly increases Fx. The tool displacement acceleration amplitudes demonstrate a positive relationship. Variation of the tool displacement acceleration states leads to the different microstructure of the machined surfaces. Therefore, selecting the appropriate milling processing parameters has a positive effect on reducing the tool displacement acceleration, improving the machined surface quality of T2 pure copper, and extending the tool’s life. The optimal milling processing parameters in this paper are the v = 600 m/min, ap = 0.5 mm, and f = 0.1 mm/r.

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Section: Introductionmentioning

confidence: 99%

Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper

Lai

Kun

et al. 2023

Micromachines

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“…Comparatively unique and advanced solid condition of welding methodology namely friction stir welding (FSW), in which a non-esculent welding tool accomplishes both the heat (due to friction) and mechanical deformation concurrently, seems to be suitable for joining alloys of Cu [16][17][18]. Reasons for preferring the process of FSW for joining Cu are that the higher amount of input of heat required for joining alloys of Cu can be easily met by employing the FSW process.…”

Section: Introductionmentioning

confidence: 99%

Impact of speed of traverse during joining of CDA101 plates by FSW process

Kumar¹,

Sevvel²

2022

Scientia Iranica

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An experimental investigation was carried out to comprehend the impact of speed of traverse of tool on tensile strength and micro-structural peculiarities of attained joints during friction stir welding of Cu alloy namely CDA 101 flat plates, with other parameters namely spinning speed of tool (1100 rpm) and downward force (6kN) being constant. A tool with cylindrical tapered pin geometry was made to traverse at distinctive speeds from 20 mm/min to 45 mm/min. It was observed that, the CDA 101 joints fabricated at 20 mm/min was found to be entirely free flaws, with joints fabricated at other speeds of tool traverse possessing several weld flaws. Grains in the center of the zone of stir of the joints obtained at 20 mm/min was uniformly distributed and homogeneous, due to the experience of the exemplary volume of frictional heat and sufficient amount of stirring force. Highest tensile strength of 200.65 MPa (nearly 85.38% of base metal)was exhibited by joint attained at 20 mm/min.

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“…Brass provided a better surface quality than copper electrode. Büttner et al [15] explored the key factors of micro-features of electrodes which have to be considered in the micro-milling of pure copper and tungsten-reinforced copper. Bai et al [16] found that, when using brass and copper electrode to process 45-carbon steel and W18Cr4V, brass electrode were able to achieve higher MRR compared to copper electrode.…”

Section: Introductionmentioning

confidence: 99%

Study on the micro-EDM processing characteristics of Ti-6Al-4V alloy with different electrode materials

Chen

Lian

et al. 2021

Int J Adv Manuf Technol

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Functional-surface microstructures are widely used in industrial practice. During the fabrication of microstructures in micro-electrical discharge machining (micro-EDM), the thermal and physical characteristics of both workpieces and electrode materials at room temperature and high temperatures have an important in uence on surface quality and distribution of recast layer. In order to study the in uence of different electrode material characteristics on the surface integrity of microstructures machined using micro-EDM, red copper, brass, copper-tungsten and tungsten electrode were used to perform micro-EDM on both Ti-6Al-4V alloy and 304 stainless steel. In the experiment, electrode with groove arrays featuring high copying accuracy and surface quality was designed to carry out powder mixed electrical discharge machining (PMEDM) on Ti-6Al-4V alloy, and the machining results were evaluated based on four indicators: microstructure morphology, tool electrode wear (TEW), material removal rate (MRR), and recast layer thickness (RLT). Simultaneously, the surface morphology and recast layer thickness changes of 304 stainless steel workpieces machined using the above four types of electrodes, using both normal polarity and negative polarity micro-EDM were quantitatively analyzed. The results showed that copper-tungsten electrode is recommended to machine Ti-6Al-4V alloy because it has a smaller TEW (139 µm), the highest MRR (255.39 mm 3 /min), and a thinner recast layer thickness (3.35 µm). This was followed by copper electrode, which featured good machining performance and machinability. When machining 304 stainless steel with negative polarity, the TEW of copper electrode and tungsten electrode was the smallest, and the thickness of recast layer was able to be effectively reduced to about 3 µm.

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A comparison between micro milling pure copper and tungsten reinforced copper for electrodes in EDM applications

Cited by 11 publications

References 35 publications

Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper

Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper

Impact of speed of traverse during joining of CDA101 plates by FSW process

Study on the micro-EDM processing characteristics of Ti-6Al-4V alloy with different electrode materials

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