No abstract

The research is aimed at expanding the technological capabilities of electrical processing methods through the use of programming systems for the technical characteristics of electrode tools (EI) directly in a digital model with their subsequent production by additive methods. The article discusses the issues of obtaining parts of complex shape. This is realized by the method of preliminary 3D printing of the electrode-tool with subsequent metallization of the working surfaces, which excludes finishing with the use of expensive equipment. However, the process of designing such a tool is associated with the complexity of its implementation for the conditions of a single or pilot production. The approach proposed by the authors to the design and manufacture of a complex-shaped combined EI makes it possible to significantly reduce its cost, especially at the stage of debugging the technological process in the conditions of launching the product into production.

Purpose of research is to develop a methodology that allows designing EDM electrodes applying advanced computer-aided design (CAD) systems by forming the tool’s working surface with geometry which is inverse equidistant to the geometry of a given workpiece taking into account the EDM gap, working translation or translation-rotational motion of EDM electrodes, the value of the layer of conductive coating based on the technological parameters of the processing procedure. It is also necessary to propose, implement and formulate technological guidelines for manufacturing EDM electrodes from dielectric materials by additive techniques with the subsequent formation of a conductive layer on them; the value of the layer should ensure the flow of working electrical processes in the EDM gap and the necessary tool life. This will make it possible to expand the scope of application of combination EDM electrodes as applied to combined processing techniques which are characterized by a wide variety of working surface shapes, which correspond to the geometry of the workpiece, which is not limited by the degree of curvature, has by far lower cost and high processability when creating a special tool for pilot and single manufacturing.Methods. When carrying out the work, theory of the classical laws of mechanical engineering technology, electrical processing techniques, the known laws of rapid prototyping and additive technologies were used.Results. The theoretical foundations and the technology for manufacturing combination EDM electrodes by rapid prototyping have been developed and a methodology for calculating and designing the working part of EDM electrodes has been proposed taking into account the geometric parameters of the machined surface and a variable EDM gap value.Conclusion. The mechanism of EDM electrode design by means of digital prototyping in modern CAD systems is justified taking into account the features of the workpiece geometry, EDM gap and metallization material.