Effects of primary and secondary metallization techniques on the performance of electric discharge machining (EDM) electrode produced by additive manufacturing and composite coating

Shaikh, Mohemmed Suleman Noor Mohemmed.; Ahuja, B. B.

doi:10.1016/j.matpr.2020.09.441

Cited by 6 publications

(1 citation statement)

References 44 publications

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“…The coating of the aluminium in the electrode increases the material removal rate significantly; the coated electrode produces 24 % less TWR than the uncoated electrode does. Shaikh and Ahuja [9] conducted the experiments with electrodes, such as silver coated tungsten and electroless nickel coated electrodes, in the EDM process. They noted that the electroless nickel-coated electrode has a20 % higher machining rate than the silver-coated tool, which is because the electroless nickel coating increases the current distribution on the electrode.…”

Section: Introductionmentioning

confidence: 99%

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Saminatharaja¹,

Periyakgounder²,

Selvaraj³

et al. 2021

SV-JME

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Electrical discharge machines (EDM) are widely employed in machining components containing complex profiles of hard-to-cut and machining materials. However, the fabrication-of-tool time for the EDM process is excessively high in the traditional machining method, which significantly affects the machining rate. Therefore, in this paper, a powder metallurgy (PM) technique is employed to fabricate the tool electrode using copper (Cu), titanium carbide (TiC), and zirconium silicate (ZrSiO4) for different combinations. An L18 orthogonal array (OA) is planned using the following input parameters: three types of tools (Cu, Cu90, Cu80), peak current (PC) [A], pulse on time (PT) [µs], and gap voltage (GV) [V]. The performance of EDM is evaluated through the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). The process parameters are optimized using two different techniques: the technique for order of preference by similarity to the ideal solution (TOPSIS) and grey relational analysis (GRA). TOPSIS and GRA optimization techniques produce the same optimal parametric solution for less TWR, SR, and higher MRR with the combination of the Cu90 tool, E8 APC, 15 µs pulse PT, and 75 V GV. Based on the ANOVA table of TOPSIS, pulse on time plays a major role, contributing 46.8 % of the machining performance; peak current shows the most significant contribution of 39.3 % of the machining performance using GRA values. Furthermore, the scanning electron microscope (SEM) image analyses are carried out on the machined workpiece surface to understand the effect of tools on machining quality.

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Section: Introductionmentioning

confidence: 99%

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Saminatharaja¹,

Periyakgounder²,

Selvaraj³

et al. 2021

SV-JME

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A comprehensive review on surface modifications of polymer‐based 3D‐printed structures: Metal coating prospects and challenges

Gautam,

Gogoi,

Kongnyui

et al. 2024

Polymers for Advanced Techs

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The production of complex structures out of a variety of materials has undergone a revolution due to the rapid development of additive manufacturing (AM) technology. Initially confined to applications such as magnetic actuators and two‐dimensional electric or electronic circuits, the convergence of 3D printing and metallization methods has emerged as a revolutionary approach. This synergy facilitates the creation of functional and customizable metal‐polymer hybrid structures characterized by high strength, lightweight properties, intricate geometric designs, and superior surface finish. These structures also exhibit enhanced electrical and thermal conductivity, as well as optical reflectivity. This paper reviews techniques to improve the effectiveness of 3D‐printed polymer antennas and structures by using various techniques of metallization. The metallization processes are examined, and a classification based on the materials employed is presented to facilitate comparisons that highlight the optimal utilization of materials for the fabrication of 3D‐printed polymer structures. The main emphasis here is on the effectiveness of different processes in terms of deposition, bonding strength, electrical conductivity, and various characteristics of metallic coatings developed on polymers. This review contributes an in‐depth analysis of the latest developments in 3D printing and metallization techniques specifically applied to polymer antennas and structures. The exploration extends to potential applications, challenges encountered, and future prospects within this dynamic field. As AM and metallization continue to evolve, this study aims to provide a comprehensive understanding of the state‐of‐the‐art methodologies and their implications for the future of polymer‐based structures and antennas.

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Optimization of electro-discharge machining process using rapid tool electrodes via metaheuristic algorithms

Sahu,

Mahapatra,

Thomas

et al. 2023

J Braz. Soc. Mech. Sci. Eng.

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Effects of primary and secondary metallization techniques on the performance of electric discharge machining (EDM) electrode produced by additive manufacturing and composite coating

Cited by 6 publications

References 44 publications

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

A comprehensive review on surface modifications of polymer‐based 3D‐printed structures: Metal coating prospects and challenges

Optimization of electro-discharge machining process using rapid tool electrodes via metaheuristic algorithms

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