Performance of sinking EDM electrodes made by selective laser sintering technique

Amorim, Fred L.; Lohrengel, Armin; Müller, Norbert; Schäfer, Guenter; Czelusniak, Tiago

doi:10.1007/s00170-012-4267-0

Cited by 34 publications

(12 citation statements)

References 9 publications

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“…Further development of rapid tooling processes resulted in several possible variations of the additive manufacturing of EDM electrodes that could be produced from non-conductive materials (i.e. stereolithography forwarded by metallisation), conductive materials (selective laser sintering (SLS) process) or cast made materials [19][20][21].…”

Section: Additive Manufacturing For Edm Electrode Productionmentioning

confidence: 99%

Application of a Cold Spray Based 3D Printing Process in the Production of EDM Electrodes

Klarić

Botak

Hill

et al. 2020

Teh. glas. (Online)

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Cold spray process principles allow the production of near-net-shape metal parts with a fast layer deposition by using 3D printing techniques via supersonic 3D deposition (SP3D). This innovative additive manufacturing process allows an easy and quick production of copper and aluminium parts with future possibilities to expand materials and alloys. The speed and materials enable the application of this cold spray based 3D printing process for the production of tools. In this paper, Electrical Discharge Machining (EDM) electrodes were fabricated by using SP3D to investigate its application in tool production. Requirements for the materials of electrodes and some existing solutions for the production of EDM electrodes with additive manufacturing methods are described first. The fabrication and experimental results are then presented for 3D printed copper EDM electrodes that were tested by using St 37-2 (DIN 17100) steel as the workpiece.

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Section: Additive Manufacturing For Edm Electrode Productionmentioning

confidence: 99%

Application of a Cold Spray Based 3D Printing Process in the Production of EDM Electrodes

Klarić

Botak

Hill

et al. 2020

Teh. glas. (Online)

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“…Vinod and Srinivasa [7] have also confirmed the favourable effects of nickel on improving part density and reducing porosity. A study by Amorim et al [8] produced EDM electrodes via DMLS, using a metal-matrix of molybdenum and a copper-nickel alloy. The results showed that the electrodes with added molybdenum had superior durability against electric spark erosion.…”

Section: Additive Manufacturing With Coppermentioning

confidence: 99%

A Computational Study on Additively Manufactured Welding Electrodes

Kirkman

Pillay²,

Padayachee

2019

rdj

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Advances in additive manufacturing technology present new design opportunities for metal parts that would otherwise be infeasible with subtractive manufacturing technologies. Clifford Machines & Technology (Pty) Ltd is an international producer of large mesh welding machines. The research was conducted with the aim of investigating the advantages that can be provided through the redesign of the mesh welding electrodes, for production using additive manufacturing. Simulation studies were applied in order to evaluate the performance of the redesigned electrodes and the results were compared to the existing electrodes. The results show that the electrodes designed for additive manufacturing achieved mass reductions of up to 58.2%. The electrodes were also able to support increases of current density by up to 98%, while operating at a lower temperature than the original electrodes. The study has identified the high initial cost of production and increased power consumption to be the disadvantages of additively manufactured electrodes.

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“…To obtain the electric conductivity, the model has been impregnated by a dispersion of carbon nano fibers (CNF) in epoxy resin. Amorim et al [18] used electrodes made with SLS utilizing pure copper, bronze-nickel alloy, copper-bronze-nickel alloy and steel alloy powders for finishing, semi-finishing and roughing operations. The bronze-nickel powder electrode showed the best EDM performance followed by those made by the mixture of copper and bronze nickel powder.…”

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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Performance of sinking EDM electrodes made by selective laser sintering technique

Cited by 34 publications

References 9 publications

Application of a Cold Spray Based 3D Printing Process in the Production of EDM Electrodes

Application of a Cold Spray Based 3D Printing Process in the Production of EDM Electrodes

A Computational Study on Additively Manufactured Welding Electrodes

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

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