Electroforming of a Stereolithography Master Pattern for use as an Electro-Discharge Machine Electrode

Rennie, Allan; Bocking, C.; Bennett, Graham R.

doi:10.1007/978-1-4471-0777-4_47

Cited by 3 publications

(2 citation statements)

References 1 publication

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“…The activation was accomplished by applying 50 A° palladium oxide coating on them to provide good adhesion between the copper coating and SLA epoxy. In literature, silver‐loaded paint was frequently used for the activation process (Arthur et al , 1996, Arthur and Dickens, 1996a, b; Bocking, 2000; Rennie et al , 2000). However, when the copper‐coating thickness was increased above 1 mm, the coating started delaminating from the surface.…”

Section: Experimental Workmentioning

confidence: 99%

“…Then copper is removed from the prototype, and supported from the back with some filler. Finally, the supported copper shell can be used as an electrode (Yarlagadda et al , 2001; Bocking, 2000, Bocking et al , 2000; Rennie et al , 2000, 2001, Rennie and Bocking, 2002). Both of these techniques require conductive stereolithography (SLA) electrodes for copper coating by using the electrolysis process.…”

Section: Introductionmentioning

confidence: 99%

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Performance of copper‐coated stereolithographic electrodes with internal cooling channels in electric discharge machining (EDM)

Anil

Çoğun²

2008

Rapid Prototyping Journal

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PurposeThe purpose of this paper is to produce electric discharge machining (EDM) electrodes by using stereolithography (SLA) rapid prototyping technique and investigate the machining performance of these electrodes. In the experimental part of the study, the performance of solid copper and copper‐coated SLA (cc/SLA) electrodes are observed and compared.Design/methodology/approachThe performance outputs such as material removal rate, machining depth, workpiece surface roughness and electrode front surface wear are used as metrics of comparison. The temperature measurements taken from the face of both solid copper and cc/SLA electrodes indicated that the heat build up during machining significantly accelerated the failure of cc/SLA electrodes.FindingsThe paper finds that circulating the cooling liquid inside the internal cooling channels formed with SLA technique, elongated the life of cc/SLA electrodes by dissipating the heat from the coating.Originality/valueThe Fluent Computational Fluid Dynamics (CFD) Software is used to numerically analyze various aspects of cooling of cc/SLA electrodes. The key findings of the study are presented in this paper.

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Section: Experimental Workmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Performance of copper‐coated stereolithographic electrodes with internal cooling channels in electric discharge machining (EDM)

Anil

Çoğun²

2008

Rapid Prototyping Journal

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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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Electroforming of rapid prototyping mandrels for electro-discharge machining electrodes

Rennie¹,

Bocking²,

Bennett³

2001

Journal of Materials Processing Technology

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Electroforming of a Stereolithography Master Pattern for use as an Electro-Discharge Machine Electrode

Cited by 3 publications

References 1 publication

Performance of copper‐coated stereolithographic electrodes with internal cooling channels in electric discharge machining (EDM)

Performance of copper‐coated stereolithographic electrodes with internal cooling channels in electric discharge machining (EDM)

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

Electroforming of rapid prototyping mandrels for electro-discharge machining electrodes

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