The Effects of Cutting Parameters on the Kerf and Surface Roughness on the Electrode in Electro Erosion Process

Abstract

In this study, electrode wear caused by machining from cold work tool steel with heat treated 60-62 HRC hardness was investigated by using electro erosion method and Cupro MAX CuCrZr electrode. The workpiece and electrode material are eroded by melting and evaporation as a result of the electrical arc (sparking) that occurs between the electrode and the workpiece in the dielectric environment. These erosions can be interpreted by changes in electrode form measurements and surface roughness. In this context, erosion process was performed using three different current values (6.25, 12.5, 25 A), three different pulse on times (3, 6, 9 µs) and pulse off times (4, 6, 8 µs), respectively, and the electrode wear rate of these processing parameters, the effects on kerf angle and surface roughness were analyzed by macro and analytical measurements. As a result of the analysis, with increasing current, machining time decreased due to increased sparking between workpiece and electrode, but the average surface roughness, kerf angle and wear rate of the electrode increased. It has been determined that as the pulse on time increases, the electrode wear rate decreases. The reduction in electrode wear resulted from the increase in the strength of the electrode due to the protective layer formed by the adhesion of the dielectric fluid and carbon particles released from the workpiece to the electrode surface.