Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode

Abstract

In the present study, cylindrical ABS P400 polymer parts (diameter 6.5 mm) to be used as die-sinking EDM (electric discharge machining) novel electrodes were fabricated using a fused deposition modeling (FDM) process. To meet the conductivity requirement in EDM, ABS parts were metallized using an innovative method that comprised putting aluminum–charcoal (Al–C) on them followed by their copper electroplating. Real-time EDM of the mild steel workpiece was performed using novel electrodes, and machining performance of the electrodes, measured in terms of dimensional accuracy, i.e., change in diameter (ΔD) and change in depth (ΔH) of the cavity, under varying levels of three EDM factors, i.e., current (I), pulse on time (Ton), and pulse off time (Toff), was investigated. Machining results were analyzed using analysis of variance (ANOVA), perturbation graphs, and 3D surface plots. The optimal setting of the EDM parameters for minimizing ΔD and ΔH was determined using the desirability function approach. The suitability of the novel electrodes for EDM was ascertained by comparing their machining results with those of solid copper (SC) electrodes and electrodes fabricated by FDM and metallized using the electro-deposition method (FDM-EM), already reported in the literature, under similar machining conditions. From the results, it was found that ΔD and ΔH were less when EDM was performed using novel electrodes.

Evaluating machining performance of acrylonitrile-butadiene-styrene (ABS) based electrical discharge machining (EDM) electrodes fabricated by fused deposition modelling (FDM) followed by a novel metallization method

“…Production of EDM electrode EDM electrodes were produced as per the procedure available in the literature. 20 However, for the benefit of the readers and practitioners, the process is explained briefly as follows: ABS cylindrical electrodes were produced at optimal combination of the FDM process parameters. Compressive strength of the electrodes was measured to ensure that they possessed sufficient strength to withstand high compressive stresses produced at their inner core during machining.…”

“…To produce ABS based electrodes using FDM followed by their metallization to make them suitable for EDM application in accordance with the process reported in the literature. 20 (ii) To evaluate machining performance of the new electrodes, in terms of MRR, TWR and SR, under the influence of three EDM parameters, each at three levels, using response surface methodology (RSM) based face centred central composite design (FCCCD).…”

“…To produce ABS based electrodes using FDM followed by their metallization to make them suitable for EDM application in accordance with the process reported in the literature. 20…”

Machining of Triangular Holes in D2 Steel by the Use of Non-Conventional Electrodes in Die-Sinking Electric Discharge Machining

“…Bhatt et al [ 24 ] combined PMEDM with the assistance of magnetic field and achieved improved MRR and surface roughness. Another approach to improve the EDM performance is reported in [ 25 ] wherein novel electrodes are used to machine blind circular holes in mild steel. Polymer-based ABS electrodes are electroplated with copper to ensure the conductivity of polymeric electrodes.…”

Selected Properties of the Surface Layer of C45 Steel Samples after Slide Burnishing

“…Centrifugal shot peening [26], by applying the microhammering head, can be used formodifications effects after electro-discharge machining (EDM) [27]. Electrodes, used in EDM, may be produced via Fused Deposition Modeling (FDM) [28] using ABS P400 polymer material [29] or sintered material [30].…”