Thermal debinding mass transfer mechanism and dynamics of copper green parts fabricated by an innovative 3D printing method

Yan, Xiaokang; Wang, Chao; Xiong, Wei; Hou, Tongwei; Liu, Hao; Tang, Danna

doi:10.1039/c7ra13149f

Cited by 25 publications

(14 citation statements)

References 25 publications

(28 reference statements)

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“…21 The amalgamation of polymer extrusion process and sintering was also explored for the formation of pure copper. 22,23 However, the fabricated parts resulted in the involvement of oxidation and chlorides as impurities, high shrinkage and porosity. The ultrasonic vibration assistance was also investigated for improving the density of the pure copper parts fabricated by using 3D printing and sintering.…”

Section: Introductionmentioning

confidence: 99%

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Singh

Pandey

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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The present investigation addresses the machining outcome of electric discharge machining using a rapid manufactured complex shape copper electrode. Developed rapid manufacturing technique using an amalgamation of polymer 3D printing and pressureless sintering of loose powder as rapid tooling has been used to fabricate copper electrode from the computer-aided design model of the desired shape. The fabricated electrode was used for the electric discharge machining of the D-2 steel workpiece. Central composite design was employed to study the electric discharge machining parameters (pulse duration, duty cycle and peak current) effect on the electric discharge machining characteristics such as material removal rate, electrode wear rate and cavity dimensional deviation as overcut from electrode computer-aided design model. Analysis of variance was executed to attain significant parameters along with interactions. Peak current was found to be the utmost dominating parameter for three responses. The high percentage of carbon was observed on the electrode surface after electric discharge machining at the high level of pulse duration and resulted in low electrode wear rate. The high percentage of dimensional deviation was noticed at the maximum duty cycle and maximum peak current by the substantial interactions. Genetic algorithm-based multi-objective optimization was employed for the electric discharge machining parameters optimization to maximize material removal rate, minimize electrode wear rate and dimensional deviation. The multi-feature complex copper electrode was fabricated and used for electric discharge machining as the case study to check the efficacy of the optimized process. It was witnessed that the process was competent to fabricate complex shape cavity as per the desired computer-aided design model shape with efficient material removal rate and electrode wear rate.

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Section: Introductionmentioning

confidence: 99%

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Singh

Pandey

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…32 The combination of polymer extrusion process and sintering was also identified for the formation of pure copper parts. 33 However, the involvement of oxidation and chlorides as impurities, high shrinkage and porosity was reported for the fabricated parts. The investigations were made using the assistance of ultrasonic vibration for decreasing the porosity and improving the density of the pure copper parts made by utilizing 3D printing and ultrasonic-assisted sintering.…”

Section: Introductionmentioning

confidence: 99%

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

Singh

Pandey

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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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.

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“…Metal paste injection 3D printing technology (MPI) is a new type of metal 3D printing technology. 1,2 It uses the material deposition principle for forming 3D shapes layer-by-layer, similar to Fused Deposition Modeling (FDM). 3,4 Compared with selective laser melting (SLM), electron beam melting (EBM) and laser micro sintering (LMS) technology, [5][6][7] MPI has the outstanding advantages of low cost and a wide application range of materials, and also avoids micro-crack defects in laser melting technology, 8 showing a broad development prospect in the eld of micro-miniature metal parts manufacturing.…”

Section: Introductionmentioning

confidence: 99%

“…13,14 In order to explore basic scientic issues to develop the optimal debinding process, the mass transfer mechanism and dynamics had been investigated quantitatively in previous publication. 15 In this work, the metal paste were separately prepared by using copper powders and cupronickel powders. The copper paste and cupronickel paste were alternately injected layer by layer through the double nozzles to get polymetallic material green parts, aer which the debinding temperature, debinding time and heating rate were discussed from the perspective of kinetic analysis.…”

Section: Introductionmentioning

confidence: 99%

Design of a debinding process for polymetallic material green parts fabricated via metal paste injection 3D printing with dual nozzles

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Thermal debinding mass transfer mechanism and dynamics of copper green parts fabricated by an innovative 3D printing method

Abstract: Thermal debinding mass transfer mechanism and dynamics of copper green parts fabricated by an innovative 3D printing method are discussed.

Cited by 25 publications

References 25 publications

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

Electric discharge machining using rapid manufactured complex shape copper electrode: Parametric analysis and process optimization for material removal rate, electrode wear rate and cavity dimensions

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

Design of a debinding process for polymetallic material green parts fabricated via metal paste injection 3D printing with dual nozzles

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