Performance of copper electrode in electical discharge machining (EDM) of AISI H13 harden steel

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17 Citations (Scopus)

Abstract

Electrical discharge machining (EDM) is a popular non-conventional machining method for manufacturing geometrically complex or hard materials parts that are extremely difficult to machine by conventional machining. EDM applies the concept of metal removal by using electric spark erosion. This study is carried out to investigate the performance of copper electrode when EDMing AISI H13 tool steel. The parameters considered are the peak current, pulse ON-time, and pulse OFF-time. The effect of peak current settings (1, 2 and 4 A), pulse-ON time (3, 6 and 12,us) and pulse-OFF time (1, 2 and 4 μs) were investigated on the machining performance of the surface roughness (Ra), electrode wear rate (EWR) and material removal rate (MRR). Results showed that the optimum condition for surface roughness was obtained at low peak current, low pulse-ON and pulse-OFF time. Whereas, high URR was obtained when setting at high peak current, medium pulse-ON time, and low pulse-OFF time. Therefore the peak current was the major factor affecting the MRR and surface finish both for finishing and roughing operations. The 'no wear' situation for EWR was obtained at high peak current, high pulse-ON time, and low pulse-OFF time.

Original languageEnglish
Pages (from-to)25-29
Number of pages5
JournalInternational Journal of Mechanical and Materials Engineering
Volume3
Issue number1
Publication statusPublished - 2008

Fingerprint

Electric discharge machining
Steel
Copper
Machining
Wear of materials
Electrodes
Surface roughness
Tool steel
Electric sparks
Erosion
Metals

Keywords

  • Copper electrode material
  • EDM
  • Electrode wear rate
  • Material removal rate
  • Surface roughness

ASJC Scopus subject areas

  • Mechanical Engineering
  • Mechanics of Materials
  • Materials Science(all)

Cite this

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title = "Performance of copper electrode in electical discharge machining (EDM) of AISI H13 harden steel",
abstract = "Electrical discharge machining (EDM) is a popular non-conventional machining method for manufacturing geometrically complex or hard materials parts that are extremely difficult to machine by conventional machining. EDM applies the concept of metal removal by using electric spark erosion. This study is carried out to investigate the performance of copper electrode when EDMing AISI H13 tool steel. The parameters considered are the peak current, pulse ON-time, and pulse OFF-time. The effect of peak current settings (1, 2 and 4 A), pulse-ON time (3, 6 and 12,us) and pulse-OFF time (1, 2 and 4 μs) were investigated on the machining performance of the surface roughness (Ra), electrode wear rate (EWR) and material removal rate (MRR). Results showed that the optimum condition for surface roughness was obtained at low peak current, low pulse-ON and pulse-OFF time. Whereas, high URR was obtained when setting at high peak current, medium pulse-ON time, and low pulse-OFF time. Therefore the peak current was the major factor affecting the MRR and surface finish both for finishing and roughing operations. The 'no wear' situation for EWR was obtained at high peak current, high pulse-ON time, and low pulse-OFF time.",
keywords = "Copper electrode material, EDM, Electrode wear rate, Material removal rate, Surface roughness",
author = "{A Ghani}, Jaharah and Liang, {C. G.} and Wahid, {S. Z.} and {Ab Rahman}, {Mohd Nizam} and {Che Haron}, {Che Hassan}",
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T1 - Performance of copper electrode in electical discharge machining (EDM) of AISI H13 harden steel

AU - A Ghani, Jaharah

AU - Liang, C. G.

AU - Wahid, S. Z.

AU - Ab Rahman, Mohd Nizam

AU - Che Haron, Che Hassan

PY - 2008

Y1 - 2008

N2 - Electrical discharge machining (EDM) is a popular non-conventional machining method for manufacturing geometrically complex or hard materials parts that are extremely difficult to machine by conventional machining. EDM applies the concept of metal removal by using electric spark erosion. This study is carried out to investigate the performance of copper electrode when EDMing AISI H13 tool steel. The parameters considered are the peak current, pulse ON-time, and pulse OFF-time. The effect of peak current settings (1, 2 and 4 A), pulse-ON time (3, 6 and 12,us) and pulse-OFF time (1, 2 and 4 μs) were investigated on the machining performance of the surface roughness (Ra), electrode wear rate (EWR) and material removal rate (MRR). Results showed that the optimum condition for surface roughness was obtained at low peak current, low pulse-ON and pulse-OFF time. Whereas, high URR was obtained when setting at high peak current, medium pulse-ON time, and low pulse-OFF time. Therefore the peak current was the major factor affecting the MRR and surface finish both for finishing and roughing operations. The 'no wear' situation for EWR was obtained at high peak current, high pulse-ON time, and low pulse-OFF time.

AB - Electrical discharge machining (EDM) is a popular non-conventional machining method for manufacturing geometrically complex or hard materials parts that are extremely difficult to machine by conventional machining. EDM applies the concept of metal removal by using electric spark erosion. This study is carried out to investigate the performance of copper electrode when EDMing AISI H13 tool steel. The parameters considered are the peak current, pulse ON-time, and pulse OFF-time. The effect of peak current settings (1, 2 and 4 A), pulse-ON time (3, 6 and 12,us) and pulse-OFF time (1, 2 and 4 μs) were investigated on the machining performance of the surface roughness (Ra), electrode wear rate (EWR) and material removal rate (MRR). Results showed that the optimum condition for surface roughness was obtained at low peak current, low pulse-ON and pulse-OFF time. Whereas, high URR was obtained when setting at high peak current, medium pulse-ON time, and low pulse-OFF time. Therefore the peak current was the major factor affecting the MRR and surface finish both for finishing and roughing operations. The 'no wear' situation for EWR was obtained at high peak current, high pulse-ON time, and low pulse-OFF time.

KW - Copper electrode material

KW - EDM

KW - Electrode wear rate

KW - Material removal rate

KW - Surface roughness

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