Development and application of new composite materials as EDM electrodes manufactured via selective laser sintering

Czelusniak, Tiago; Amorim, Fred L.; Higa, Camila F.; Lohrengel, Armin

doi:10.1007/s00170-014-5765-z

Cited by 36 publications

(9 citation statements)

References 17 publications

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“…Czelusniak et al. 13 fabricated copper nickel–titanium/zirconium boride composite electrodes using the SLS process. The process was optimized to fabricate high densified electrode and utilized for the EDM process.…”

Section: Introductionmentioning

confidence: 99%

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Singh

Pandey

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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The present investigation addresses the machining outcome of electric discharge machining using a rapid manufactured complex shape copper electrode. Developed rapid manufacturing technique using an amalgamation of polymer 3D printing and pressureless sintering of loose powder as rapid tooling has been used to fabricate copper electrode from the computer-aided design model of the desired shape. The fabricated electrode was used for the electric discharge machining of the D-2 steel workpiece. Central composite design was employed to study the electric discharge machining parameters (pulse duration, duty cycle and peak current) effect on the electric discharge machining characteristics such as material removal rate, electrode wear rate and cavity dimensional deviation as overcut from electrode computer-aided design model. Analysis of variance was executed to attain significant parameters along with interactions. Peak current was found to be the utmost dominating parameter for three responses. The high percentage of carbon was observed on the electrode surface after electric discharge machining at the high level of pulse duration and resulted in low electrode wear rate. The high percentage of dimensional deviation was noticed at the maximum duty cycle and maximum peak current by the substantial interactions. Genetic algorithm-based multi-objective optimization was employed for the electric discharge machining parameters optimization to maximize material removal rate, minimize electrode wear rate and dimensional deviation. The multi-feature complex copper electrode was fabricated and used for electric discharge machining as the case study to check the efficacy of the optimized process. It was witnessed that the process was competent to fabricate complex shape cavity as per the desired computer-aided design model shape with efficient material removal rate and electrode wear rate.

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Section: Introductionmentioning

confidence: 99%

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Singh

Pandey

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…However, the EDM performance using fabricated electrodes was reduced as compared to the solid copper electrode. Czelusniak et al 23 used copper nickel–titanium/zirconium boride composite electrodes fabricated by SLS for the EDM process. The electrodes resulted in low EWR as compared to solid copper.…”

Section: Introductionmentioning

confidence: 99%

Electric discharge machining using rapid manufactured complex shape copper electrode with cryogenic cooling channel

Singh

Pandey

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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In this study, a rapid manufacturing process based on the combination of polymer three-dimensional printing and pressureless loose sintering was explored for the fabrication of complex shape electric discharge machining pure copper electrodes with the cryogenic cooling channel. The fabricated electrodes were used to perform electric discharge machining on D2 steel workpiece. The comparative study was performed on material removal and electrode wear rates between the solid copper electrode, rapid manufactured electrode without cryogenic cooling and with cryogenic cooling. Also, the surface characteristics of the worn electrode and the machined workpiece were studied with and without cryogenic cooling. The significant effect of the cryogenic cooling on the electrode wear rate and the surface roughness was observed. Better surface finish, small cracks and less debris were notified on the workpiece surface machined with rapid manufactured electrode with cryogenic cooling due to rapid dissipation of the heat from the surface of the electrode after machining. Similarly, few cracks and low carbon deposition was observed on the rapid manufactured electrode with cryogenic cooling surface after machining as compared to rapid manufactured electrode without cryogenic cooling. The sharp corner edges of the complex shape tool in rapid manufactured electrode with cryogenic cooling were retained after machining due to low melting and vaporization of the electrode material. The dimensional deviation of the machined surface with respect to computer-aided design model was compared. The rapid manufactured electrode with cryogenic cooling was found to machine the more accurate complex shape features in terms of dimensions on the workpiece as compared to rapid manufactured electrode without cryogenic cooling.

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“…Такие материалы, обладая превосходными механическими свойствами [1], весьма перспективны в современной авиационной и ракетно-космической технике в качестве различных узлов и деталей, а также для изготовления жаростойких тиглей для расплавов и, кроме того, применяются как высокотемпературные электродные материалы для электроэрозионной обработки [2][3][4][5][6][7]. Основными методами получения компактных изделий такого класса являются горячее прессование и искровое плазменное спекание (ИПС) порошков ZrB 2 и легирующих добавок [1][2][3][4][5][6][7][8]. Тем не менее, ввиду сильной ковалентной связи, низкой объемной и зернограничной диффузии в кристаллической решетке ZrB 2 , существует проблема уплотнения порошка ZrB 2 при проведении процесса ИПС и горячего прессования [9].…”

Section: Introductionunclassified

Features of Production and High-Temperature Oxidation of SHS Ceramics Based on Zirconium Boride and Zirconium Silicide

Iatsyuk

Pogozhev

Левашов

et al. 2016

Russ. J. Non-ferrous Metals

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Национальный исследовательский технологический университет (НИТУ) «МИСиС», г. Москва Институт структурной макрокинетики и проблем материаловедения РАН (ИСМАН), г. Черноголовка Статья поступила в редакцию 04.07.16 г., доработана 30.09.16 г., подписана в печать 03.10.16 г. Работа посвящена исследованию кинетики и механизма горения реакционных смесей в системах Zr-Si-B и Zr-B, получению по технологии силового СВС-компактирования компактных керамических материалов, а также изучению их жаростойкости. Показано, что для составов в системе Zr-Si-B зависимости температуры и скорости горения от начальной температуры (T 0) имеют линейный характер, т.е. с ростом T 0 стадийность химических реакций образования диборида и дисилицида циркония не меняется. Рассчитаны значения эффективной энергии активации СВС-процесса, свидетельствующие о ведущей роли реакционного взаимодействия циркония с бором и кремнием в расплаве. Изучена стадийность химических превращений в волне горения смеси Zr-Si-B: первоначально путем кристаллизации из расплава образуется фаза ZrB 2 , затем с запаздыванием в 0,5 с появляется фаза ZrSi 2 ; спустя 1 с кристаллизуется непрореагировавший Si. Изучен фазовый состав продуктов синтеза, в которых основным компонентом является диборид ZrB 2 , а также, в зависимости от состава исходной реакционной шихты, содержатся дисилицид циркония ZrSi 2 , Si и борид ZrB 12. По технологии силового СВС-компактирования получены компактные образцы, характеризующиеся высокой твердостью и низкой остаточной пористостью. В результате высокотемпературного окисления СВС-образцов в зависимости от состава на их поверхности формируются оксидные пленки SiO 2-ZrO 2-B 2 O 3 , а также сложный оксид ZrSiO 4 , служащие эффективным диффузионным барьером и снижающие скорость окисления. Ключевые слова: керамика, композиционные материалы, диборид циркония, дисилицид циркония, окисление, жаростойкость. Яцюк И.В.-аспирант кафедры порошковой металлургии и функциональных покрытий (ПМиФП) НИТУ «МИСиС», инженер научно-учебного центра (НУЦ) СВС МИСиС-ИСМАН (119049, г. Москва, Ленинский пр-т, 4).

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Development and application of new composite materials as EDM electrodes manufactured via selective laser sintering

Cited by 36 publications

References 17 publications

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Electric discharge machining using rapid manufactured complex shape copper electrode with cryogenic cooling channel

Features of Production and High-Temperature Oxidation of SHS Ceramics Based on Zirconium Boride and Zirconium Silicide

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