Performance of Copper Electrode for Machining En-19 and Nickel Plated En-19 Alloy Steel by EDM

Abstract

Electric discharge machining (EDM) is non-conventional machining processes that involves a transient spark discharges through the fluid due to the potential difference between the electrode and the work piece. The aim of this project is to determine the proper machining conditions for machining EN-19 and Nickel Plated EN-19 work pieces using electrical discharge machining (EDM). Basically, improper choice of parameter in EDM machine may result a few problems like the machine may cause of poor machining performance and it will decrease the accuracy of the products and incurs a lot of cost. The aim of this project is to determine the optimal machining parameters for machining work pieces using electrical discharge machining (EDM). Intensity of current, pulse on time and pulse of time were used as process parameters. This paper explores the characteristic of electric discharge machine (EDM) that is tool wear rate (TWR) and material removal rate (MRR) by using different workpiece materials namely En-19 and Nickel Plated En-19 alloy steel and copper as a tool material in order to increase the understanding of EDM processes. To achieve this project objective, an experimentation was done where the approach used was response surface methodology in which a well-designed experimental scheme named box behnken design was used to reduce the total number of experiments into 15 for each workpiece material. A second order empirical model is developed to predict the MRR and TWR. Finally ANOVA analysis is done to validate the model developed.

Ti6Al4V Alaşımının Elektro Erozyon ile İşlemesinde Elektrolitik Cu ve CuBe Takım Elektrotlarının Performansının Karşılaştırılması

“…High TWR and RW are undesirable since they indicate rapid tool electrode shape degeneration. Two main problems of the EDM process are the high cost of the electrode production process and the high electrode wear [6,7]. In recent years, researchers have mainly focused on low production costs and better EDM performance outputs.…”