We apologize for a recent technical issue with our email system, which temporarily affected account activations. Accounts have now been activated. Authors may proceed with paper submissions. PhDFocusTM
CFP last date
20 December 2024
Reseach Article

Fabrication and Application of Composite Electrodes in Electrical Discharge Machining-A Review

Published on July 2018 by Arminder Singh Walia, Vineet Srivastava, Vivek Jain
International Conference on Advances in Emerging Technology
Foundation of Computer Science USA
ICAET2017 - Number 4
July 2018
Authors: Arminder Singh Walia, Vineet Srivastava, Vivek Jain
bd8f0c52-7e12-429b-b47a-646ef1de82d4

Arminder Singh Walia, Vineet Srivastava, Vivek Jain . Fabrication and Application of Composite Electrodes in Electrical Discharge Machining-A Review. International Conference on Advances in Emerging Technology. ICAET2017, 4 (July 2018), 1-5.

@article{
author = { Arminder Singh Walia, Vineet Srivastava, Vivek Jain },
title = { Fabrication and Application of Composite Electrodes in Electrical Discharge Machining-A Review },
journal = { International Conference on Advances in Emerging Technology },
issue_date = { July 2018 },
volume = { ICAET2017 },
number = { 4 },
month = { July },
year = { 2018 },
issn = 0975-8887,
pages = { 1-5 },
numpages = 5,
url = { /proceedings/icaet2017/number4/29659-7088/ },
publisher = {Foundation of Computer Science (FCS), NY, USA},
address = {New York, USA}
}
%0 Proceeding Article
%1 International Conference on Advances in Emerging Technology
%A Arminder Singh Walia
%A Vineet Srivastava
%A Vivek Jain
%T Fabrication and Application of Composite Electrodes in Electrical Discharge Machining-A Review
%J International Conference on Advances in Emerging Technology
%@ 0975-8887
%V ICAET2017
%N 4
%P 1-5
%D 2018
%I International Journal of Computer Applications
Abstract

Electrical discharge machining (EDM) is a non conventional machining process extensively used in the machining of hard to machine materials and in die manufacturing industry. The major cost component in EDM is the cost of the electrode. The conventionally used electrode material like Copper and Graphite has very low wear resistance and wear out fast. There is continual process of finding electrode materials which have optimum value of electrical conductivity, thermal conductivity and wear resistance. Different composites of various combinations of material have been used in search of alternative tool material. This paper presents a review of different materials used for the manufacturing of composite electrodes for EDM and their fabrication techniques. It has been observed that among the different electrode fabrication techniques available, powder metallurgy has shown very good results.

References
  1. Geric, K. 2010. Ceramics tool materials with Alumina matrix. Machine Design. 367-372.
  2. Mishra, P. K. 1997. Nonconventional Machining. Narosa Publishing House, London.
  3. Pandey, P. C. and Shan, H. S. 2008. Moderm Machining Process, Tata McGraw-Hill Company Limited.
  4. Kunieda, M. , Lauwers, B. , Rajurkar, K. P. , and Schumacher B. M. 2005. Advancing EDM through Fundamental Insight into the Process. CIRP Annals - Manufacturing Technology. 54(2), 64-87.
  5. Khanra, A. K. , Sarkar, B. R. , Bhattacharya, B. , Pathak L. C. , and Godkhindi, M. M. 2007. Performance of ZrB2–Cu composite as an EDM electrode. Journal of Materials Processing Technology. 183, 122-126.
  6. Li, L. , Wong, Y. S. , Fuh, J. Y. H. , and Lu, L. 2001. EDM performance of TiC/Copper-based sintered electrodes. Materials and Design. 22, 669-678.
  7. Srivastava, V. , and Pandey, P. M. 2013. Study of ultrasonic assisted cryogenically cooled EDM process using sintered (Cu–TiC) tool tip. Journal of Manufacturing Processes. 15, 158-166.
  8. Arthur, A. , Dickens, P. M. , and Cobb, R. C. 1996. Using rapid prototyping to produce electrical discharge machining electrodes. Rapid Prototyping Journal. 2(1), 4-12.
  9. Zaw, H. M. , Fuh, J. Y. H. , Nee, A. Y. C. , and Lu, L. 1999. Formation of a new EDM electrode material using sintering techniques. Journal of Materials Processing Technology. 89-90, 182-186.
  10. Kechagias, J. , Iakovakis, V. , Katsanos, M. , and Maropoulos, S. 2008. EDM electrode manufacture using rapid tooling: a review. J Mater Sci. 43, 2522-2535.
  11. Correia, J. B. , Davies H. A. , and Sellars, C. M. 1997. Strengthening in rapidly solidified age hardened Cu–Cr and Cu–Cr–Zr alloys. Acta Mater. 45, 177-190.
  12. Alpas, A. T. , Hu, H. , and Zhang J. 1993. Plastic deformation and damage accumulation below the worn surfaces. Wear. 164, 188-195.
  13. Shukla, A. K. , Murty, S. V. S. N. , Kumar, R. S. , and Mondal, K. 2013. Effect of powder milling on mechanical properties of hot-pressed and hot-rolled Cu–Cr–Nb alloy. J Alloy Compd. 580, 427-434.
  14. Buytoz, S. , Dagdelen, F. , Islak, S. , Kok, M. , Kir, D. , and Ercan, E. 2014. Effect of TiC content on microstructure and thermal properties of Cu-TiC composites prepared by powder metallurgy. J Thermal Anal Carolim. 117, 1277-1283.
  15. Norasetthekul, S. , Eubank, P. T. , Bradley, W. L. , Bozkurt, B. , and Stucker, B. 1999. Use of zirconium diboride-copper as an electrode in plasma applications. Journal of Materials Science. 34, 1261 – 1270.
  16. Tay, F. E. H. and Haider, E. A. 2001. The Potential of Plating Techniques in the Development of Rapid EDM Tooling. International Journal of Advanced Manufacturing Technology. 18, 892– 896.
  17. Meena, V. K. and Nagahanumaiah. 2006. Optimization of EDM machining parameters using DMLS electrode. Rapid Prototyping Journal. 12 (4), 222 – 228.
  18. Hascal?k, A. and Caydas, U. 2007. Electrical discharge machining of titanium alloy (Ti–6Al–4V). Applied Surface Science. 253, 9007–9016.
  19. Mishra, S. K. and Pathak, L. C. 2008. Effect of carbon and titanium carbide on sintering behaviour of zirconium diboride. Journal of Alloys and Compounds. 465, 547–555.
  20. Kumar, V. , Beri, N. , Kumar, A. , and Singh, P. 2010. Some studies on electric discharge machining of hastelloy using powder metallurgy electrode. International Journal of Advanced Engineering Technology. 1(2), 16-27.
  21. Janmanee, P. and Muttamara, A. 2010. Performance of Difference Electrode Materials in Electrical Discharge Machining of Tungsten Carbide. Energy Research Journal. 1(2), 87-90.
  22. Beri, N. , Maheshwari, S. , Sharma, C. , and Kumar, A. 2014. Surface Quality modification Using powder metallurgy processed CuW electrode during electric discharge machining of Inconel 718. Procedia Materials Science. 5, 2629-2634.
  23. Li, L. , Li, Z. Y. , Wei, X. T. , and Cheng, X. 2015. Machining Characteristics of Inconel 718 by Sinking-EDM and Wire-EDM. Materials and Manufacturing Processes. 30, 968-973.
  24. Kestursatya, M. , Kim, J. K. , and Rohatgi, P. K. 2003. Wear performance of copper-graphite composite and a leaded copper alloy. Mater Science and Engineering: A. 1(2), 150-158.
  25. Kaczmar, J. W. , Pietrzak, K. , and Wlosinski, W. 2000. The production and application of metal matrix composite materials. Journal of Materials Processing Technology. 106, 58-67.
  26. Upadhyaya, A. and Upadhyaya, G. S. 1995. Sintering of copper–alumina composites through blending and mechanical alloying powder metallurgy routes. Materials & Design. 16, 41-45.
  27. Rajkumar, K. and Aravindan, S. 2011. Tribological performance of microwave sintered copper–TiC–graphite hybrid composites. Tribology International. 44, 347-358.
  28. Mohri, N. , Saito, N. , and Tsunekawa, Y. 1993. Metal Surface Modification by Electrical Discharge Machining with Composite Electrode. Annals of the CIRP. 42(1), 219-222.
  29. Samuel, M. P. and Philip, P. K. 1996. Properties of compacted, pre-sintered and fully sintered electrodes produced by powder metallurgy for Electric Discharge Machining. Indian Journal of Engineering and Material Sciences. 3, 229-233.
  30. Yarlagadda, P. K. D. V. , Christodoulou, P. , and Subramanian, V. S. 1999. Feasibility studies on the production of electro-discharge machining electrodes with rapid prototyping and electroforming process. Journal of Materials Processing Technology. 89–90, 231–237.
  31. Durr, H. , Pilz, R. and Eleser, N. S. 1999. Rapid tooling of EDM electrodes by means of selective laser sintering. Computers in Industry. 39, 35–45.
  32. Yang, B. and Leu, M. C. 1999. Integration of Rapid Prototyping and Electroforming for Tooling Application. Annals of the ClRP. 48(1), 119–122.
  33. Rennie, A. E. W. , Bocking, C. E. , and Bennett, G. R. 2001. Electroforming of rapid prototyping mandrels for electro-discharge machining electrodes. Journal of Materials Processing Technology. 110, 186-196.
  34. Li, L. , Wong, Y. S. , Fuh, J. Y. H. , and Lu, L. 2001. Effect of TiC in copper tungsten electrodes on EDM performance. Journal of Materials Processing Technology. 113, 563-567.
  35. Tsai, H. C. , Yan, B. H. , and Huang, F. Y. 2003. EDM performance of Cr/Cu-based composite electrodes. International Journal of Machine Tools & Manufacture. 43, 245–252.
  36. Zhao, J. , Li, Y. , Zhang, J. , Yu, C. , and Zhang, Y. 2003. Analysis of the wear characteristics of an EDM electrode made by selective laser sintering. Journal of Materials Processing Technology. 138, 475–478.
  37. Blom, R. , Yarlagadda, P. K. D. V. , and Iyer, M. 2004. Evaluation Of Rapid Tooling For Electric Discharge Machining Using Electroforming And Spray Metal Deposition Techniques. Proceedings 1st Global Congress on Manufacturing and Management, Vellore, India. 490-495.
  38. Dimla, D. E. , Hopkinson, N. , and Rothe, H. 2004. Investigation of complex rapid EDM electrodes for rapid tooling applications. International Journal of Advance Manufacturing Technology. 23, 249-255.
  39. Gillot, F. , Mognola, P. , and Furet, B. 2005. Dimensional accuracy studies of copper shells used for electro-discharge machining electrodes made with rapid prototyping and the electroforming process. Journal of Materials Processing Technology. 159, 33–39
  40. Ferreira, J. C. , Mateus, A. S. , and Alves, N. F. 2007. Rapid tooling aided by reverse engineering to manufacture EDM electrodes. International Journal of Advanced Manufacturing Technology. 34, 1133– 1143.
  41. Hsu, C. Y. , Chen, D. Y. , Lai, M. Y. , and Tzou, G. J. 2008. EDM electrode manufacturing using RP combining electroless plating with electroforming. International Journal of Advanced Manufacturing Technology. 38, 915–924.
  42. Monzon, M. , Benitez, A. N. , Marrero, M. D. , Hernandez, N. , Hernandez, P. , and Aisa, J. 2008. Validation of electrical discharge machining electrodes made with rapid tooling technologies. Journal of Materials Processing Technology. 196, 109-114.
  43. Balasubramanian, P. and Senthilvelan, T. 2014. Optimization of Machining Parameters in EDM process using Castand Sintered Copper Electrodes. Procedia Materials Science. 6, 1292-1302.
  44. Pal, V. K. and Choudhury, S. K. 2016. Fabrication of texturing tool to produce array of square holes for EDM by abrasive water jet machining. Int J Adv Manuf Technol. 85, 2061-2071.
  45. Gill, A. S. and Kumar, S. 2016. Surface Roughness and Microhardness Evaluation for EDM with Cu–Mn Powder Metallurgy Tool. Materials and Manufacturing Processes. 31, 514-521.
Index Terms

Computer Science
Information Sciences

Keywords

Electrical Discharge Machining Material Removal Rate Powder Metallurgy Rapid Prototyping Tool Wear Rate