WEAR CHARACTERISTICS OF COPPER AND ALUMINUM ELECTRODES DURING EDM OF STAINLESS STEEL AND CARBIDE

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1 Proceedings of the Internatial Cference Mechanical Engineering (ICME) 8-3 December, Dhaka, Bangladesh ICME-AM-9 WEAR CHARACTERISTICS OF COPPER AND ALUMINUM ELECTRODES DURING EDM OF STAINLESS STEEL AND CARBIDE Ahsan Ali Khan and Safry Ezan Saifuddin Department of Manufacturing and Materials Engineering, Internatial Islamic University Malaysia, 3 Kuala Lumpur, Malaysia. ABSTRACT The present work gives a comparative analysis of the performance of copper and electrodes for machining and. It was found that MRR (material removal rate) increases with increase in current and voltage, but MRR is higher during machining of than that of. During machining, electrode wear and corner wear were higher than those during machining. Wear of copper electrodes was less than that of electrodes. Volumetric wear ratio i.e., the ratio of the material removed from the work to the same removed from the electrode decreases with increase of current or voltage. That means, comparatively more material is removed from the electrode than that removed from the work. Investigatis work surface finish show that electrodes produce smoother surface than copper electrodes during machining of both and. The surface was found to be smoother than. Keywords: EDM, Electrode wear, Corner wear, Volumetric wear ratio, Material removal rate.. INTRODUCTION Electrical discharge machining (EDM) is e of the main methods of die producti with high accuracy and precisi with no physical ctact between the tool and the workpiece. Therefore, no mechanical stress is developed the work surface. The important output parameters of the process are material removal rate (MMR), tool wear, tool wear ratio and surface roughness [, ]. EDM process is widely used for machining high strength, tungsten and hardened [3]. These materials are extremely hard and cannot be machined by cvential techniques. Electrodes for EDM are usually made of graphite, brass, copper and copper-tungsten alloys []. Amg the other electrode materials tungsten, tungsten, alloys and zinc alloys are worth mentiing. MRR is the primary factor that should be csidered for EDM. Many works have been de MRR as a functi of current, voltage, pulse durati, etc. [,6]. In all those works it was found that MRR tends to increase with the increase in current, voltage and durati of the pulse. But no comparative analysis of different electrodes was de. In fact EDM process is based thermal energy that is generated by an electric arc between the electrode and the work that melts and vaporizes the work material. Due to this high temperature developed during the electric spark, a porti of material is also eroded from the electrode which is termed as electrode wear. Due to this wear, electrode looses its length and the depth of cavity formed becomes smaller than the desired e. However, attempts have been made to compensate the shortening of the electrodes by ctinuous mitoring. [7-]. Volumetric wear ratio, which is the ratio of the material removed from the work to the same removed from the electrode, is also an important factor. It is desirable that MRR should be high keeping the electrode wear as small as possible. Again, if the cross-secti of the electrode is a complicated e, sharp corners are eroded intensively and the electrode looses its normal shape. As a result, the shape of the cavity formed looses its precisi. Finally, high quality dies and cavities require good surface finish. In the present work, and have been taken as the work materials for investigatis due to their extensive use in die making. They have been machined using copper and electrodes at different values of current and voltage. The output parameters that have been investigated in the present study are MRR, electrode wear, corner wear, volumetric wear ratio and work surface finish.. EXPERIMENTAL DETAILS. Electrode and Work Materials Copper and electrodes were used in the present study. The physical properties of the electrode material are: electrical resistivity-.3 x -6 ohm-cm, electrical cductivity compared to silver- 63%, thermal cductivity- 7 W/m-K, melting point- 6 o C, heat capacity-.893 J/g- o C and coefficient of thermal expansi- 3. µm/m- o C. The main properties of the ICME AM-9

2 copper electrode material are: electrical resistivity-.7x -6 ohm-cm, electrical cductivity compared to silver 9%, thermal cductivity- 39 W/m-K, melting point- 83 o, heat capacity-.38 J/g- o C and coefficient of thermal expansi- 7 µm/m- o C. Work materials used in the present work were and. The principal mechanical and chemical properties of the plates of grade GC-US6 used in the study are: 8% WC, % Co, grain size of the cstituents.8 micrs, hardness of 9.8 HRA and density of 3.8 g/cc. The main properties of the of grade SUS 3 used are: 8% to % Cr, 8% to.% Ni, tensile strength of 7 ksi, yield strength of 3 ksi and hardness of 87 HB.. Experimental Technique Copper and electrodes used were of the cross-secti of mm x mm and a length of 7 mm. The experiments were carried out a CNC die sinking machine of model ATC-VSH. The experimental set-up is shown in Fig.. Iized water was used as the dielectric measured using an optical microscope Mitutoyo Hisomet II. Roughness of the horiztal machined surface was measured by the surface roughness measuring equipment Mitutoto SURFTEST SV-. 3. RESULTS AND DISCUSSION 3. Material Removal Rate The material removal rate (MMR) shows an increasing trend with increase in current as illustrated in Fig. 3. A higher current produces strger sparks with higher thermal energy causing increase in MRR. Similar results were fd during machining of composite materials, silic and 9WC-6Co s and tool s [-]. Influence of current MMR is more prominent during machining of compared to s. This is because of lower specific thermal energy of. s need more thermal energy than to be melted and vaporized. Copper electrodes show better performance in terms of MRR which is due to its better thermal stability than electrodes. Relatiship of MRR with current (V = ) Fig. Set-up for the experiments MRR (g/min) copper stainles copper Fig 3. Relatiship of MRR with current Relatiship of MRR with voltage (A = 3.) Fig. Wear of an electrode material during machining. Machining tests were carried out at current ranging from. A to 7. A and voltage of V to V. Rectangular holes of cross-secti mm x mm with a depth of mm were made and plates using copper and electrodes. The lengths and weights of the electrodes were measured before and after machining. The difference between the weights of the electrodes before and after machining gives the electrode wear and the difference of weights of the work specimens before and after machining gives the weight of the material removed from the work. Volumetric wear ratio was calculated as the ratio of the volume of material removed from the work to the same removed from the electrode material. Corner wears of the electrodes, as shown in fig., were MRR (g/min) Fig. Relatiship of MRR with voltage copper copper Influence of voltage MRR is shown in Fig.. The reas of increasing of MRR with the increase of voltage is similar to the reas for current. In this case also copper electrodes showed better performance than electrodes and MRR was found to be higher during machining of than machining of ICME AM-9

3 . It can be ccluded that melting point of the work material is a key factor for MRR. 3. Electrode Wear A higher current or voltage produces strger spark with more thermal energy causing more electrode wear as shown in Fig. and Fig. 6. Thermal cductivity of copper is about. times higher than that of. As a result, heat is more easily dissipated into the body of the electrode causing less electrode wear compared to the electrodes. It can be ccluded that thermal cductivity is an important factor that reduces electrode wear. Electrode wear (g)... Influence of current electrode wear (V = ) 6 8 copper copper Fig. Influence of current electrode wear electrode wear (g) Influence of voltage electrode wear (A = 3.) copper aliminum copper Fig 6. Influence of voltage electrode wear Figures and 6 also show that during machining of, electrode wear is higher than during machining of. The heat energy required to remove unit volume of is much higher than that required for. As a result, it needs a lger time for machining of s causing more electrode wear. 3.3 Corner Wear Relatiship of corner wear with current and voltage during machining of and with copper and electrodes is illustrated in Fig. 7 and Fig. 8. Corner wear increases almost linearly with increase of current or voltage which is due to the availability of more thermal energy at a higher current or voltage. Again, better thermal cductivity of copper results less corner wear than. Higher requirement of thermal energy during machining of s causes more corner wear of electrodes than during machining of. Corner wear (mm) Corner wear (mm) Influence of current corner wear (V = ) Current (A) 6 8 copper copper Fig 7. Influence of current corner wear Influence of voltage corner wear (A = 3.) Fig 8. Influence of voltage corner wear copper copper 3. Volumetric Wear Ratio Volumetric wear ratio was calculated as the ratio of the volume of material removed from the work material to the same removed from the electrode material. Figure 9 and illustrate the relatiship of volumetric wear ratio with current and voltage. It was found that volumetric wear ratio decreases with increase in current and voltage. It can be supported by the fact that at a higher current and voltage comparatively more material is removed from the electrode than from the work. During machining of volumetric wear ratio was found to be higher than that during machining of. This is due to the fact that the specific heat energy and melting point of is higher than those of which causes less MRR for. Moreover, volumetric wear ratio was found to be higher while using copper electrodes. This is because of higher melting point and thermal cductivity of copper than. During machining of volumetric wear ratio was found to be higher than that during machining of. This is due to the fact that the specific heat energy and melting point of is higher than those of which causes less MRR for. Moreover, volumetric wear ratio was found to be higher while using copper electrodes. This is because of higher melting point and thermal cductivity of copper than. ICME 3 AM-9

4 Volumetric wear ratio Relatiship of volumetric wear ratio with current (V = ) copper copper Surface roughness (um) Effect of current surface reoughness (V = 3.) Copper Copper Fig 9. Relatiship of volumetric wear ratio with current Fig. Effect of current surface finish Volumetric wear ratio Relatiship of volumetric wear ratio with voltage (A = 3.) copper copper Fig. Relatiship of volumetric wear ratio with voltage 3. Surface Finish A higher current or voltage produces a strg spark with higher energy. As a result a crater of larger dimensi is made the work material resulting a poorer surface finish as illustrated in Fig. and Fig.. Puetas [6] also found similar results 9WC-6Co. However, it was stated that with the increase of current, surface roughness value reaches to a maximum value, then it decreases. With increase in voltage, surface finish increases steadily (Fig. ). But an increase in current causes a sharp increase in surface roughness during machining of (Fig. ). This is due to the formati of craters of larger size at a higher current. On the ctrary, during machining of s surface roughness increases slowly with increase in current due to the higher thermal stability of s and formati of smaller craters produced during each spark. Fig. and Fig. also show that electrodes produce better surface finish than copper electrodes during machining of both and. As it has already been discussed, during machining with copper electrodes, MRR is higher than that of. As a result, more number of particles removed from the work is accumulated within the gap between the electrode and the work. This accumulati of particles causes additial uncoordinated sparks that results a poor machined surface. Surface Roughness (um) Effect of voltage surface roughness (A = 3.) 6 Copper Copper Fig. Effect of voltage surface finish. CONCLUSIONS From the above analysis and discussis the following cclusis can be made: i. MRR increases with the increase of current and voltage. MRR of is higher than that of due to less specific energy of than. ii. Copper electrodes give higher MRR than electrodes during machining of and s. iii. electrodes undergo more wear than copper electrodes due to their lower melting point and specific thermal energy than copper electrodes. Corner wear of was also found to be higher than that of copper electrodes due to the same reas. Both copper and electrodes undergo more wear during machining of than during machining of due to more machining time required to remove the same volume of material from. iv. Volumetric wear ratio shows a decreasing trend with increase of current and voltage. It indicates that at a higher current or voltage comparatively more material is removed from the electrodes compared to the work materials. Volumetric wear ratio is higher during machining of than machining of s. It was found that during machining of with electrodes, volumetric wear ratio is very low ICME AM-9

5 which indicates an intensive wear of electrode material compared to the work material. v. Surface finish becomes poorer with increase of current and voltage. A higher current or voltage gives a strger spark, making a crater of higher depth the work surface. As a result, the surface becomes rougher. Influence of current surface finish is strger than. Copper electrodes remove comparatively more work material than electrodes that accumulate within the gap between the work and the electrode. As a result, additial uncoordinated sparks occur making the work surface rougher.. REFERENCES. Marafa J. and C. Wykes C,, A new method of optimizing material removal rate using EDM with copper-tungsten electrodes, Internatial Journal of machine Tools & Manufacture, vol. : Wang P. J. and K.M. Tsai K. M.,, Semi-empirical model of surface finish electrical discharge machining, Internatial Journal of Machine tools and Manufacture, vol. : Wang P. J. and Tsai K. M.,, Semi-empirical model work removal and tool wear in electrical discharge machining, Journal of Materials Processing Technology, vol. : -7.. Kalpakjian S. and Schmid S.R.,, Manufacturing Engineering and Technology, th editi, Prentice Hall, New Jersey,. Koing W. and F.J. Siebers F. J., 993, Manufacturing Science and Engineering, ASME. 6. Ramasawmy H. and Blunt L.,, 3D surface characterizati of electropolished EDMed surface and quantitative assessment of process variables using Taguchi Methodology, Internatial Journal of Machine Tools & manufacture, vol. : Bleys P., Kruth J. P. and Lauwers B.,, Sensing and compensati of tool wear in milling EDM, Journal of Materials Processing Technology, vol. 9: Kruth J. P. and Bleys P.,, Machining curvilinear surfaces by NC electro-discharge machining, Proc. Int. Cf. MMSS, Krakow, (), pp Bleys P., 3, Electrical discharge milling: technology and tool wear compensati, Ph.D Thesis, K.U. Leuven, Department of Mechanical Engineering, Leuven,.. Dauw D., 986, On the deviati and applicati of a real-time wear sensor in EDM, Ann. CIRP vol. 3 (): -6.. Narender P., Raghukandan K., Rathinasabapathi M. and B.C. Pai B. C.,, Electric discharge machining of Al-% SiC p as-cast metal matrix composites, Journal of Materials Processing Technology, vol. 6:-67.. Luis C. J., Puertas I. and Villa G.,, Material removal rate and electrode wear study the EDM of silic, Journal of Materials Processing Technology, vol. 6: Puertas I., Luis C. J.and Alvarez L.,, Analysis of the influence of EDM parameters surface quality, MRR and EW of WC-Co, Journal of Materials Processing Technology, vol. :6-3.. Che Har C. H., Md. Deros B., Ginting A. and Fauziah M.,, Investigati the influence of machining parameters when machining tool using EDM, Journal of materials Processing Technology, vol. 6: ICME AM-9