Study of the performance of Cu-Gr composite tool during EDM of AISI 1020 mild steel

Uddin, Md Piyar; Majumder, Arindam; Barma, John Deb; Kumar, P Veerathevar Arul

doi:10.1016/j.matpr.2022.04.542

Cited by 4 publications

(3 citation statements)

References 13 publications

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“…It is carried out between the tool electrode and the work material using precisely controlled, cyclically repeating electrical discharges in the presence of a dielectric [14,15]. Since the whole machining process is carried out in a force-free manner, it finds its suitable application also in the machining of hard metals [16,17]. This advanced technology produces machining tools characterized by high hardness, strength, and wear resistance from the material.…”

Section: Carbide Machining Using Electrical Discharge Machining Techn...mentioning

confidence: 99%

Surface Quality of Carbide Metal After Electrical Discharge Machining

Straka

Kuchta

2023

IJEMS

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Recently, the requirements for machining shape-complex products made of hard-to-machine materials, including carbide, have been increasing significantly. However, their machining is rather problematic. Additionally, a high-quality standard of the machined surface is generally required, not only in terms of roughness but also in terms of the geometric accuracy of the machined surface. All this while maintaining a high level of economy in the machining process. However, meeting these demanding requirements in real technical practice is not always an easy task. Moreover, in combination with modern machining processes, only a limited number of production technologies can meet this requirement. Therefore, due to the high demands placed on today's modern production and the required high standard of the machined surface, progressive EDM technology is increasingly finding its application. And it is through this progressive technology that it is possible to achieve relatively good success in carbide machining. The aim of this paper was therefore to describe in detail the results of an experimental investigation aimed at identifying the quality of the machined surface achieved in terms of the roughness parameters of the machined surface in the electrical discharge machining of selected types of carbides using a wire tool electrode.

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Section: Carbide Machining Using Electrical Discharge Machining Techn...mentioning

confidence: 99%

Surface Quality of Carbide Metal After Electrical Discharge Machining

Straka

Kuchta

2023

IJEMS

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“…Using Cu-SiC electrodes also caused a continuous, uniform hardening layer on the machined surface. Cu-Gr composite materials have been investigated as EDM tools for cutting AISI 1020 mild steel by Uddin et al [15] According to the study, adding more graphite to the Cu-Gr composite tool significantly reduced the tool wear rate (TWR) by up to 83% while keeping the metal removal rate (MRR) at 73%. TiC/Cu powder metallurgy (P/M) electrode was used in an experiment by Chundru et al [16] to modify the surface of Ti6Al4V alloy.…”

Section: Introductionmentioning

confidence: 99%

Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining

Abdulwahhab,

Ibrahim

2023

ETJ

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The TWR for the pure copper electrode was 0.514 gm/min, while the composite electrode (Cu-1%Cr-0.5%WC-1%Ag) had the lowest TWR at 0.215gm/min.• The pure copper electrode had a higher MRR of 54.5588 mm 3 /min, while the composite electrode (Cu-1%Cr-0.5%WC-1%Ag) had the best MRR at 56.8689 mm 3 /min. • The composite electrode (Cu-1%Cr-0.5%WC-1%Ag) had an improved SR of 3.747 μm versus 3.967 μm for the pure copper electrode. • Current, followed by pulse on/off time, significantly impacted the electrodes' TWR, MRR, and SR.Electrical Discharge Machining (EDM) is a non-traditional technique widely used in various industries to remove material using electrical discharges. Finding a suitable electrode material that can resist high temperatures and efficiently remove material from the workpiece is a major difficulty in electrical discharge machining (EDM). Due to their exceptional electrical and thermal properties, composite electrodes of various metals have become extremely popular. In this study, a composite electrode (Cu-1%Cr-0.5%WC-1%Ag) manufactured using the stir casting technique will be utilized to evaluate the electrical discharge machining (EDM) process. The study compares the performance between conventional pure copper electrodes and composite electrode utilization of stainless steel 304L as the workpiece material. The results indicate composite electrodes can increase machining effectiveness and reduce electrode wear. Utilizing a current of 10 A, with a pulse on time of 50µs followed by a pulse off time of 50 µs, reduced the tool wear rate to 0.215 gm/min for the composite electrode. By comparison, it was observed that the copper electrodes displayed a tool wear rate of 0.514 gm/min under the same conditions. While the pure copper electrode had the lowest material removal rate (MRR) at 54.5588 mm 3 /min, the composite electrode had the greatest MRR at 56.8689 mm 3 /min. The surface Roughness (SR) of the composite electrode was 3.747μm; this value was lower than that of the pure copper electrode, 3.967μm. As a result, composite electrodes present a potentially viable substitute for traditional EDM electrodes.

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“…Due to the aforementioned disadvantages and limitations versus pure copper as a material for electrodes for the EDM process, intensive research projects are being conducted to find appropriate materials to increase the efficiency of the process. The materials used for the electrodes include copper and its alloys 10 – 12 , 20 , graphite 13 , 14 , copper graphite 15 , tellurium copper 6 , tungsten 16 , 20 , tungsten carbide 16 , silver 17 , silver tungsten 18 and aluminum 19 , 20 .…”

Section: Introductionmentioning

confidence: 99%

Effect of microstructure refinement of pure copper on improving the performance of electrodes in electro discharge machining (EDM)

Skiba,

Kulczyk,

Przybysz-Gloc

et al. 2023

Sci Rep

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The paper presents an analysis of the impact of plastic deformation using hydrostatic extrusion (HE) on the structural, mechanical and functional properties of pure copper for use as electrodes in the process of electro discharge machining (EDM). As part of the research, copper was subjected to the HE process with the maximum cumulative true strain equal to ɛcum = 3.89 obtained in 5 stages. The result was, a refinement of the microstructure with the grains elongated in the direction of extrusion, with a cross-sectional size of d2 = 228 nm. As the obtained material can be potentially used in the process of electro discharge machining, the copper specimens after the HE process were subjected to a comprehensive analysis to determine the mechanical, physical and functional properties of the material. A significant increase in strength (UTS) and yield strength (YS) of the HE-processed copper was obtained, reaching respectively UTS = 464 MPa and YS = 456 MPa at the maximum strain of ɛ = 3.89. Despite the clear strain-induced strengthening of the material, a very high electrical conductivity of not less than 97% was obtained. The electrodes made of copper after HE process have reduced erosion wear while maintaining a comparable or better quality of the machined surface. The best results were obtained for finish machining, where the electrical discharge wear was lower by 60% compared to the electrode made of non-processed copper. In addition, an improvement in the surface quality after the EDM process by 25% was observed when using the HE-processed electrodes.

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Study of the performance of Cu-Gr composite tool during EDM of AISI 1020 mild steel

Cited by 4 publications

References 13 publications

Surface Quality of Carbide Metal After Electrical Discharge Machining

Surface Quality of Carbide Metal After Electrical Discharge Machining

Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining

Effect of microstructure refinement of pure copper on improving the performance of electrodes in electro discharge machining (EDM)

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