Effects of electrolytic copper and copper alloy electrodes on machining performance in electrical discharge machining (EDM)

Şimşek, Ülke; Çoğun, Can; Esen, Ziya

doi:10.1080/10910344.2022.2044855

Cited by 11 publications

(3 citation statements)

References 28 publications

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“…The bubble flow model is mainly to solve the Navier-Stokes equation of fluid momentum, the average continuity equation of mixture and the gas phase transport equation. The velocity, pressure and volume fraction of liquid are obtained [9].…”

Section: Figure 2 Schematic Of Plane Arc Groove Machiningmentioning

confidence: 99%

Multiphysics Coupled Simulation of Electrolytic Machining of Toothed Grooves of Contrate Gear

Chen

Liu

2022

MSF

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In the field of aviation, the contrate gear is an important component, the material of the contrate gear is the basis for ensuring the reliability and high performance of the aircraft engine, the commonly used material for contrate gear is 20Cr2Ni4A. In order to fully understand the electrolytic machining of the toothed groove of the contrate gear, a multiphysics coupling model of the electric field, the gas-liquid two-phase flow field and the temperature field was established to study the distribution of bubble rate, temperature, conductivity and current density in the processing gap. Simulation results show that the temperature and bubble rate gradually increase along the process direction in the processing gap, the conductivity and current density of the electrolyte gradually decrease.

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Section: Figure 2 Schematic Of Plane Arc Groove Machiningmentioning

confidence: 99%

Multiphysics Coupled Simulation of Electrolytic Machining of Toothed Grooves of Contrate Gear

Chen

Liu

2022

MSF

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“…EDM performance was guaranteed with a copper electrode for better material removal, a moderate degree of surface polishing, and a negligible wear rate [8][9][10]. In order to maximise MRR and minimise EWR during the spark eroding process, ceramic composites have been machined using spark EDM with a solid Cu electrode [11]. Copper's ability to undergo a chemical reaction at higher temperatures is stymied when zirconium is present in the mix.…”

Section: Introductionmentioning

confidence: 99%

Si₃N₄–TiN conductive ceramic composites: topography on EDMed surfaces and precise drilled holes

Selvarajan

Venkataramanan²

2023

Materials Science and Technology

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In this study, it is challenging to drill a 5 mm hole in a Si3N4–TiN conductive ceramic composite, specifically when attempting to identify an association between EDM machining inputs such as current, pulse on-time, pulse off-time, dielectric pressure and spark gap and performance parameters like as Material Removal Rate, Electrode Wear Rate, Average Surface Roughness, and geometrical tolerances such as Cylindricity, Circularity and perpendicularity. The study examines the surface deformations of a composite comprising EDAX report, machined electrode and molybdenum wire following WEDM machining. Current of 5A, Pulse on-time of 9µs, Pulse off-time of 7µs, spark gap of 0.15 mm, dielectric pressure of 21.0 kg/cm2, material removal rate of 0.004214 g/min, electrode wear rate of 0.000245 g/min and surface roughness of 0.349 µm were found to be optimal. The experimental findings show that good surface finish may be attained on a copper electrode-machined surface, along with improved machining accuracy, closer geometrical tolerances and lesser anomalies.

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“…Therefore, EDM is run with tool electrodes made of varieties of materials such as copper, brass, graphite, molybdenum, and tungsten. The performance of a tool electrode is assessed in terms of its ability to produce improved (a) material subtraction rate, (b) dimensional accuracy, (c) degree of surface finish, (d) tool wear, and (e) white layer thickness, to name a few [ 15 , 16 ]. In the past, macro-EDM of biomaterials was performed using different materials of tool electrodes namely copper, brass, graphite, silicon, and tungsten [ 10 , 17 ].…”

Section: Introductionmentioning

confidence: 99%

Surface modification of biodegradable Mg alloy by adapting µEDM capabilities with cryogenically-treated tool electrodes

Davis

Singh

Debnath

et al. 2023

Int J Adv Manuf Technol

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Biomaterials are engineered to develop an interaction with living cells for therapeutic and diagnostic purposes. The last decade reported a tremendously rising shift in the requirement for miniaturized biomedical implants exhibiting high precision and comprising various biomaterials such as non-biodegradable titanium (Ti) alloys and biodegradable magnesium (Mg) alloys. The excellent mechanical properties and lightweight characteristics of Mg AZ91D alloy make it an emerging material for biomedical applications. In this regard, micro-electric discharge machining ( µ EDM) is an excellent method that can be used to make micro-components with high dimensional accuracy. In the present research, attempts were made to improve the µ EDM capabilities by using cryogenically-treated copper (CTCTE) and brass tool electrodes (CTBTE) amid machining of biodegradable Mg AZ91D alloy, followed by their comparison with a pair of untreated copper (UCTE) and brass tool electrodes (UBTE) in terms of minimum machining-time and dimensional-irregularity. To investigate the possible modification on the surfaces achieved with minimum machining-time and dimensional-irregularity, the morphology, chemistry, micro-hardness, corrosion resistance, topography, and wettability of these surfaces were further examined. The surface produced by CTCTE exhibited the minimum surface micro-cracks and craters, acceptable recast layer thickness (2.6 µm), 17.45% improved micro-hardness, satisfactory corrosion resistance, adequate surface roughness ( R a : 1.08 µm), and suitable hydrophobic behavior (contact angle: 119°), confirming improved biodegradation rate. Additionally, a comparative analysis among the tool electrodes revealed that cryogenically-treated tool electrodes outperformed the untreated ones. CTCTE-induced modification on the Mg AZ91D alloy surface suggests its suitability in biodegradable medical implant applications.

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Effects of electrolytic copper and copper alloy electrodes on machining performance in electrical discharge machining (EDM)

Cited by 11 publications

References 28 publications

Multiphysics Coupled Simulation of Electrolytic Machining of Toothed Grooves of Contrate Gear

Multiphysics Coupled Simulation of Electrolytic Machining of Toothed Grooves of Contrate Gear

Si₃N₄–TiN conductive ceramic composites: topography on EDMed surfaces and precise drilled holes

Surface modification of biodegradable Mg alloy by adapting µEDM capabilities with cryogenically-treated tool electrodes

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Effects of electrolytic copper and copper alloy electrodes on machining performance in electrical discharge machining (EDM)

Cited by 11 publications

References 28 publications

Multiphysics Coupled Simulation of Electrolytic Machining of Toothed Grooves of Contrate Gear

Multiphysics Coupled Simulation of Electrolytic Machining of Toothed Grooves of Contrate Gear

Si3N4–TiN conductive ceramic composites: topography on EDMed surfaces and precise drilled holes

Surface modification of biodegradable Mg alloy by adapting µEDM capabilities with cryogenically-treated tool electrodes

Contact Info

Product

Resources

About

Si₃N₄–TiN conductive ceramic composites: topography on EDMed surfaces and precise drilled holes