Abstract
Electrochemical discharge machining (ECDM) is an emerging method for developing micro-channels in conductive or non-conductive materials. In order to machine the materials, it uses a combination of chemical and thermal energy. The tool electrode’s arrangement is crucial for channeling these energies from the tool electrode to the work material. As a consequence, tool electrode optimization and analysis are crucial for efficiently utilizing energies during ECDM and ensuring machining accuracy. The main motive of this study is to experimentally investigate the influence of different electrode materials, namely titanium alloy (TC4), stainless steel (SS304), brass, and copper–tungsten (CuW) alloys (W70Cu30, W80Cu20, W90Cu10), on electrodes’ electrical properties, and to select an appropriate electrode in the ECDM process. The material removal rate (MRR), electrode wear ratio (EWR), overcut (OC), and surface defects are the measurements considered. The electrical conductivity and thermal conductivity of electrodes have been identified as analytical issues for optimal machining efficiency. Moreover, electrical conductivity has been shown to influence the MRR, whereas thermal conductivity has a greater impact on the EWR, as characterized by TC4, SS304, brass, and W80Cu20 electrodes. After that, comparison experiments with three CuW electrodes (W70Cu30, W80Cu20, and W90Cu10) are carried out, with the W70Cu30 electrode appearing to be the best in terms of the ECDM process. After reviewing the research outcomes, it was determined that the W70Cu30 electrode fits best in the ECDM process, with a 70 μg/s MRR, 8.1% EWR, and 0.05 mm OC. Therefore, the W70Cu30 electrode is discovered to have the best operational efficiency and productivity with performance measures in ECDM out of the six electrodes.
Highlights
The manufacturing industry faces a challenge in creating holes or cuts in rigid materials with high geometrical precision
The electrode content, electrode shape, and machining parameters all have a significant impact on electrical discharge machining (EDM) and electrochemical discharge machining (ECDM) efficiency
Regarding the combined process of EDM ablation and ECM in an aerosol dielectric, the material removal rate (MRR) was 3.7 times higher than that of EDM or ECM, the tools wear rate (TWR) was reduced by 53.3%, and the value of the corner arc radius decreased by 44.3% [15]
Summary
The manufacturing industry faces a challenge in creating holes or cuts in rigid materials with high geometrical precision. The process of electrochemical discharge machining (ECDM) is a combination of electrochemical and electro-discharge machining, with applications in aerospace, electronics, and miniaturized medical equipment, especially for drilling holes with complex shapes and geometries. Due to the uncertain nature of the ECDM mechanism, electrode material selection is made on an empirical basis based on experimental results. It is critical to select an effective tool electrode to improve performances, such as the material removal rate (MRR), electrode wear ratio (EWR), overcut (OC), and surface defects on difficult-to-machine alloys. The electrode content, electrode shape, and machining parameters all have a significant impact on electrical discharge machining (EDM) and ECDM efficiency. It can be inferred that there is a requirement for a comparative investigation about the effects of the tool material.
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