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

Abstract

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.

Evaluating machining performance of acrylonitrile-butadiene-styrene (ABS) based electrical discharge machining (EDM) electrodes fabricated by fused deposition modelling (FDM) followed by a novel metallization method

“…9 AM can even machine customized and complex shapes on hard material with better workpiece surface characteristics. 10,11 AM techniques used for electrode production can be categorized into two groups: one using conductive material like selective laser sintering (SLS) and the other using non-conductive materials such as fused deposition modelling (FDM). Use of AM for EDM electrode production using conductive material is more explored.…”

Green Approach for Electropolishing Surface Treatments of Additive Manufactured Parts: A Comprehensive Review

“…Furthermore, this technique is disadvantaged by using toxic and dangerous reagents and, therefore, has a negative impact from the environmental point of view [19]. Electrical discharge machining is another technique proposed to improve the surface quality of the AM parts [20], but this technique based on the removal of asperity via heat from rapid electrical discharge requires high potential values, and involves continuous tool wear and thermal-related stress on samples. In the literature, some review papers presented the electropolishing treatment as a post-processing treatment using DESs on conventionally produced components, as Smith [21].…”

Simulation of flow-field and debris temperature analysis in micro-electrical discharge milling using slotted tools

“…In this aspect, a simple cylindrical tool is modified to improve flushing and machining performance. Various types of tool geometry used by researcher are foil, 10 slotted, 11,12 stepped, 13 peripheral slots, 14 bunched, 15 tubular, 16 semi-cylindrical, 17 inclined micro-slots, 18 helical slots, 19 single and double-helical, 20 and 3D printed complex profile 21 to improve machining performance. However, all the study was focused on the experimentation to enhance material removal rate and reduce tool wear rate.…”