Investigation of complex rapid EDM electrodes for rapid tooling applications

Dimla, Eric; Hopkinson, Neil; Rothe, H.

doi:10.1007/s00170-003-1709-8

Cited by 49 publications

(29 citation statements)

References 6 publications

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“…When the layer is completed, the platform is levelled in the z-axis allowing a new layer to be added on top of the previous one. Wire Electrical Discharge Machining (EDM) is a precise cutting technique that minimizes the need for excessive post processing machining and was used to breakaway support and remove the specimens from the platform [60]. Lastly, the edges were then polished using an emery cloth of grades 120 and 220 [61].…”

Section: Specimens Manufacturingmentioning

confidence: 99%

Effects of Ultrasonic Impact Treatment on the Stress-Controlled Fatigue Performance of Additively Manufactured DMLS Ti-6Al-4V Alloy

et al. 2019

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Additive manufacturing (AM) offers many advantages for the mechanical design of metal components. However, the benefits of AM are offset to a certain extent by the poor surface finish and high residual stresses resulting from the printing process, which consequently compromise the mechanical properties of the parts, particularly their fatigue performance. Ultrasonic impact treatment (UIT) is a surface modification process which is often used to increase the fatigue life of welds in ship hulls and steel bridges. This paper studies the effect of UIT on the fatigue life of Ti-6Al-4V manufactured by Direct Metal Laser Sintering (DMLS). The surface properties before and after the UIT are characterized by surface porosity, roughness, hardness and residual stresses. Results show that UIT enhances the fatigue life of DMLS Ti-6Al-4V parts by suppressing the surface defects originating from the DMLS process and inducing compressive residual stresses at the surface. At the adopted UIT application parameters, the treatment improved the fatigue performance by 200%, significantly decreased surface porosity, reduced the surface roughness by 69%, and imposed a compressive hydrostatic stress of 1644 MPa at the surface. methodology, P.W., S.M., E.T. and S.N.; software, E.T.; validation, E.T., P.W.; formal analysis, E.T. and P.W.; investigation, P.W., S.M., E.T. and S.N.; resources, M.S.A.E.; data curation, E.T, P.W.; writing-original draft preparation, E.T., P.W. and S.N.; writing-review and editing, P.W. and M.S.A.E.; visualization, E.T., P.W. and S.N.; supervision, M.S.A.E.; project administration, M.S.A.E.; funding acquisition, M.S.A.E.

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Section: Specimens Manufacturingmentioning

confidence: 99%

Effects of Ultrasonic Impact Treatment on the Stress-Controlled Fatigue Performance of Additively Manufactured DMLS Ti-6Al-4V Alloy

et al. 2019

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“…In National University of Singapore (NUS), efforts were made [12] to fabricate metal electrodes by DMLS by using the powder metal comprising of copper, tin, nickel and phosphorus. In the University of Bournemouth researchers [13] concentrated on the shell thickness of copper shell electroplated DLMS electrodes. The shape of the component was complex with sloped surfaces, deep slots which is not easy to be machined by CNC milling.…”

Section: Literature Review and Motivation Of The Present Researchmentioning

confidence: 99%

PCA based hybrid Taguchi philosophy for optimization of multiple responses in EDM

2018

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The present study is aimed at a multi-response optimization problem by applying Principal Component Analysis (PCA) combined with Taguchi method. The investigation has been carried out through a case study in Electric Discharge Machining (EDM) of D2 steel by using copper, brass and Direct Metal Laser Sintered (DMLS) electrode produced by direct metal laser sintering using Directmetal20. The research work has been carried out to evaluate the best parametric combination which could fulfill multiple responses like lower Tool Wear Rate (TWR), higher Material Removal Rate (MRR) and lower Surface Roughness (R a). Unlike the use of single-objective optimization problem in traditional Taguchi method, a hybrid Taguchi method has been developed in combination with PCA to solve multi-objective problem. Taguchi method assumes that the quality characteristics should be uncorrelated or independent which is not always fulfilled in actual condition. PCA is applied to remove response correlation and to calculate independent (uncorrelated) quality indices known as principal components. These principal components combined with weighted principal component analysis (WPCA) are used to calculate overall quality index denoted as Multi-response Performance Index (MPI). This investigation combines WPCA and Taguchi method for forecasting optimal setting. The predicted result by this method was validated through confirmatory test proving the efficacy of the process. Out of five input process parameters considered, tool electrode has been found to be the most significant factors through the Analysis of Variance (ANOVA).

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“…The preferable surface finish of a cavity can be acquired using roughening or semi-finish machining parameters with this kind of electrode. Dimla et al [83] have described a collaborative research program aimed at investigating the use of quick EDM electrodes obtained via appropriate rapid prototyping techniques in finishing laser-sintered tools. Two methods were employed in obtaining the EDM electrodes: copper coating of stereo lithography models and copper coating of direct metal laser sintered (bronze) models.…”

Section: Electrode Manufacturing Using Rapid Prototyping and Rapid Tomentioning

confidence: 99%

An overview of technology and research in electrode design and manufacturing in sinking electrical discharge machining

Jha¹,

Ram²,

Rao³

2011

JESTR

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Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes, based on thermoelectric energy between the workpiece and an electrode. In this process, the material is removed electro thermally by a series of successive discrete discharges between two electrically conductive objects, i.e., the electrode and the workpiece. The performance of the process, to a large extent, depends on the material, design and manufacturing method of the electrodes. Electrode design and method of its manufacturing also affect on the cost of electrode. Researchers have explored a number of ways to improve electrode design and devised various ways of manufacturing. The paper reports a review on the research relating to EDM electrode design and its manufacturing for improving and optimizing performance measures and reducing time and cost of manufacturing. The final part of the paper discusses these developments and outlines the trends for future research work.

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Investigation of complex rapid EDM electrodes for rapid tooling applications

Cited by 49 publications

References 6 publications

Effects of Ultrasonic Impact Treatment on the Stress-Controlled Fatigue Performance of Additively Manufactured DMLS Ti-6Al-4V Alloy

Effects of Ultrasonic Impact Treatment on the Stress-Controlled Fatigue Performance of Additively Manufactured DMLS Ti-6Al-4V Alloy

PCA based hybrid Taguchi philosophy for optimization of multiple responses in EDM

An overview of technology and research in electrode design and manufacturing in sinking electrical discharge machining

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