The use of copper-coated aluminum electrodes in the electrical discharge machining of 38X2H2MA steel is assessed. Such electrodes prove effective. The use of coated electrodes improves the economics of electrical discharge machining by permitting the use of cheaper materials in the electrode core.

Copper-coated electrodes for electrical discharge machining of 38X2H2MA steel

https://iopscience.iop.org/article/10.1088/1757-899X/510/1/012001/pdf

Experimental investigation of wear resistance of copper coated electrode-tool during electrical discharge machining

Electric discharge machining (EDM) is one of the viable techniques for machining of D2 steel, in which the material removal occurs by spark erosion. The poor selection of EDM parameters affect the machining quality and productivity. Considering this, the present work investigates the effect of current, charging and discharging time on the material removal rate (MRR) and the surface roughness (Ra) while machining of D2 steel using graphite electrode. The results were analysed using statistical methods to identify the effect of control parameters and to optimise the settings. The study shows that MRR and Ra was significantly influenced by current. At optimum settings, the MRR and the Ra obtained was 38.16 mg/min and 3.39 μm respectively. Morphological analysis of the machined surface show that the size of the globules formed decreased with increase in current

/pdf/optimisation-of-current-and-pulse-duration-in-electric-591gtetnys.pdf

Optimisation of Current and Pulse Duration in Electric Discharge Drilling of D2 Steel Using Graphite Electrode

A vortex tube is a device, which uses pressurised inlet gas to split into hot and cold separate streams. This phenomenon is referred to as energy separation. The literature behind the energy separa...

Review of vortex tube: a sustainable and energy separation device for multi-purpose applications

In the present scenario, great effort is expended to improve the machining process by adopting multi-criteria decision making in electrical discharge machining (EDM). In this research article, an attempt was made to optimize the process parameters of EDM with Nickel Coated Aluminium Electrode for machining Titanium Alloy using Preference Selection Index (PSI). The experimental work were performed using Taguchi based L16 orthogonal to solve multi-objective optimization problem. The current (I), voltage (U) and pulse on time (Ton) were used as input response variables for investigation process while material removal rate (MRR) and tool wear rate (TWR) were selected as performance measures. The experimental results show that set of optimized parameters of the multi-objective optimization problem in EDM with nickel coated aluminium electrode could improve the machining with better surface measures with less deviation from the prediction. The combination between PSI and Taguchi method reduced and saved significantly the experimental time and cost and increased accuracy for optimization process.

/pdf/multi-criteria-decision-making-in-electrical-discharge-24b0y4xo.pdf

Multi-criteria decision making in electrical discharge machining with nickel coated aluminium electrode for titanium alloy using preferential selection index

The influence of wire-cut electrical discharge machining on the surface quality of 65Г steel is investigated. With increase in the machining parameters, the depth of the white layer increases, and the chemical composition of the surface changes. (The copper and zinc content increases.) A mathematical model is developed for determining the depth of the modified surface layer and the geometry of the microrelief.

Influence of Wire-Cut Electrical Discharge Machining on Surface Quality

The possibility of using vortex tubes to inject cooled ionized air into the cutting zone in high-speed machining is considered. Numerical calculation of the vortex effect is employed to predict the cooling of the cutting zone. The results are compared with experimental data.

Prediction of the cooling of cutting zones by means of vortex tubes in high-speed machining

The properties of composites based on expanded graphite and a steel base with structured macroscopic relief are studied: specifically, the wear resistance, frictional coefficient, and reduced wear. The structured macroscopic relief is produced by deformational cutting.

Wear Resistance of Composites Based on Expanded Graphite and a Steel Base with Structured Macroscopic Relief

Wire electric-discharge machining (EDM) is investigated. A complete factorial experiment is conducted. Regression methods are used in analysis of the experimental results and the derivation of an empirical formula. The empirical model obtained permits assessment of how the roughness of the machined surface depends on the cutting conditions, the height of the workpiece, and its properties.

Roughness of the machined surface in wire EDM

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