Abstract
The article is devoted to increasing the efficiency of electrical discharge machining of special-purpose items with composite electrode tools. The subject of research is the parameter of the roughness of the processed surface and the work of the electro-discharge machining (EDM) of 40Crsteel in various modes of electrical discharge machining. The aim of the work is to increase the efficiency of the process of copy-piercing electrical discharge machining of parts introduced into the composition of a special-purpose product and the use of electrode tools with the introduction of 20% graphite. Experimental studies were carried out using the method of a full factorial experiment with a subsequent regression analysis. The experiments were carried out using a copy-piercing Smart CNC EDM machine, a tool electrode, and a profile composite electrode. Empirical dependencies were established, reflecting the relationship between the processing modes, productivity, and surface roughness parameter after processing. A theoretical model for calculating the roughness parameter was developed, which makes it possible to predict the quality of the processed surface with a reliability of 10–15%. To ensure the required ratios of the quality of the processed surface at the maximum performance indicators, technological recommendations were obtained, as a result of which a 35% reduction in machine time was achieved when processing the “screw” part with the required indicators of surface quality.
Highlights
When creating products operating under conditions of increased loads, alloy steels with increased physical and mechanical properties are used
A theoretical model was developed that makes it possible to evaluate the effect of modes on the roughness parameter the electro-discharge machining (EDM)
EDM modes on the roughness of the treated surface of parts using a 40Cr alloy steel with from a graphite content of
Summary
When creating products operating under conditions of increased loads, alloy steels with increased physical and mechanical properties are used. The most promising such material is a composite material of a pseudo-alloy system of copper–colloidal graphite (CCG) with a graphite content of 20%; ETs from this material are not widely used in the EDM of special parts This is due to the fact that the operational properties of ETs from a given composite material in the case of EDM for chromium-containing steels have been little studied; there are no recommendations on the appointment of processing modes [11,12,13]. The aim of this work is to increase the efficiency of the process of copy-piercing electrical discharge machining of parts included in the composition of a special-purpose product by using electrode tools made of a composite material such as a pseudo-alloy system of CCG with a graphite content of 20%
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