Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

Padhi, S. K.; Mahapatra, Siba Sankar; Padhi, Rosalin; Das, Harish Chandra

doi:10.1007/s40436-018-0238-5

Cited by 35 publications

(16 citation statements)

References 22 publications

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“…[11][12][13] However, the anisotropic characteristic of composites presents a challenge in failure analysis and prediction in mechanical tests, generating considerable data dispersion in the results. [13,14] Considering that in most structural applications failure is due to cyclic loading, [15] in mechanical tests the reliability level of the measurement and analysis of variance are fundamental for determining the fatigue delamination parameters.…”

Section: Introductionmentioning

confidence: 99%

Mode I and mode II delamination of carbon/glass/epoxy hybrid composite: A statistics‐based analysis

et al. 2021

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The delamination of a carbon/glass/epoxy hybrid composite was studied experimentally to analyze the effect of reinforcement heterogeneity on data dispersion. A statistical approach was applied to evaluate the effect of the carbon/glass/epoxy hybrid composite on the individual modes (I and II) of delamination. The analysis of variance evidenced the contribution of reinforcement type in strain energy release ratio (SERR). Curve fitting for the quasi-static test was performed with the Weibull distribution model to predict the energy release versus crack length with different reliability levels. The 60% reliability curve presented the best fit with the average of the experimental data. For all reliability levels, the hybrid composite showed an increase in SERR.

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Section: Introductionmentioning

confidence: 99%

Mode I and mode II delamination of carbon/glass/epoxy hybrid composite: A statistics‐based analysis

et al. 2021

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“…The maximum time of electroplating elapsed for the electrode is about 210 hours to obtain a thickness of 1 mm at the rate of 110 μm/24 hours. A scanning electron microscope (SEM) was used in determining the thickness as they give direct evidence [19]. At τ = 75%…”

Section: Methodsmentioning

confidence: 99%

“…At τ = 80% 7 International Journal of Polymer Science 0.035 MPa. EDM operations of 10 minutes each were conducted for both electrodes, and results are tabulated in Tables 2-4 for varying DC from 2 to 4 A and altering T on and τ (refer to equation ( 1)) for both electrodes [19].…”

Section: Methodsmentioning

confidence: 99%

“…As a result of the comparison, it has been seen that the electroplated electrode has a greater density and is more robust than metal spray coating [18]. Electroplating by electroforming reproduces the mandrel's form precisely without shrinking and distortion, resulting in similar metal forming processes (casting, stamping, or drawing) [19]. Investigations on the usage of quick EDM electrodes produced from most suitable two different methods of RT processes used in the finishing of lasersintered tools (Cu coating of stereolithography models and direct metal laser-sintered (bronze) models) were performed.…”

Section: Introductionmentioning

confidence: 99%

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Effect of a Rapid Tooling Technique in a 3D Printed Part for Developing an EDM Electrode

Alamro

Yunus

Alfattani

et al. 2021

International Journal of Polymer Science

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The role of rapid tooling (RT) in additive manufacturing (AM) seems essential in improving and spreading out the vista of manufacturing proficiency. In this article, attempts were made to discover the feasibility and the accomplishments of the RT electrode in the field of electro-discharge machining (EDM). Fused deposition modeling (FDM) is one of the AM processes adopted to fabricate the EDM electrode prototype by coating with copper. The copper is deposited on FDM-built ABS plastic component for about 1 mm through thick electroplating. The copper-coated FDM (CCF) and solid copper (SC) electrodes are used to conduct experiments on a die-sinking EDM machine using tool alloy steel as a workpiece. The CCF polymer electrode can be efficiently used in EDM operations as the build time of any complex shape was substantially reduced. However, the material removal rate (MRR) is far less than that of the SC electrode. It is recommended that the CCF electrode is used for semifinishing and finishing operations in which MRR happens to be less. However, CCF can get spoiled as high temperatures are generated on the machining tool, and the plastic core hardly sustains such high temperatures.

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“…Machining is a major constituent of manufacturing system and sustainability in machining is related to environmental friendliness (cutting fluids), minimum cost and energy consumption, higher production and quality, better waste management and safety of worker [5]. The productivity, cost and quality of electric discharge machined parts are measured through performance measures: material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) respectively [6]. Machining performance measures are directly associated with process parameters including pulse on time (Pon), current, pulse off time (Poff), voltage, flushing pressure, polarity, servo speed, frequency, gap and jump distance as shown in Figure 1a.…”

Section: Introductionmentioning

confidence: 99%

Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

et al. 2019

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Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

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Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

Cited by 35 publications

References 22 publications

Mode I and mode II delamination of carbon/glass/epoxy hybrid composite: A statistics‐based analysis

Mode I and mode II delamination of carbon/glass/epoxy hybrid composite: A statistics‐based analysis

Effect of a Rapid Tooling Technique in a 3D Printed Part for Developing an EDM Electrode

Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

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