Effect of magnetic field intensity on deposition of copper tool in electro discharge deposition

Abstract

The fabrication of micro products is gradually expanding due to their need in micro feature-based frameworks, which require a multitude of functions to be integrated. Electro discharge deposition (EDD) is an emerging additive manufacturing process to create micro products. In the present paper, simulation of an EDD process has been investigated in the presence and absence of maximum magnetic flux density. In the first stage of simulation, a thermo–physical model has been developed to find the melt volume in single pulse discharge. In the second stage, initially the optimum orientation and location of the magnet to be placed around the EDD plasma are identified, and subsequently, in the presence of maximum magnetic flux density, heavy species transport is used to study the impact of the process on the height and weight of deposition. Experiments are carried out to validate the simulation results. From the results obtained it is observed that the height of deposition is increased by 23.5% in the presence of the magnetic field.

Electric discharge coating process: a critical review with potential application

“…Shirguppikar S et al [66] made a grey fuzzy optimization of process parameters for dry EDM, showing that peak current and pulse on-time influence material removal rate. Muralidharan et al [67][68][69] analyzed the continuous coating process, single spark coating with air as a dielectric medium, and critically studied the effect of magnetic field and shielding gas on coat quality. Dry EDC requires a separate chamber to circulate the shielding gas.…”

A thermophysical modelling of electric discharge coating process

“…All experimental literature reported shows EDC attempt were made for selected toolwork piece combination and corresponding parameter optimation and subsequent result analysis. Some of the researchers Muralidharan B et al [28][29][30] developed simulation model for electro discharge deposition (EDD) process and experimentally evaluated by using thin metal wires of few microns in diameter with different environmental conditions and magnetic field. The simulation methodologies are derived from the literature and used appropriately for the current research work.…”