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Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM

An electrode is a vital transmission tool of electrical charges that erodes a workpiece surface in die-sinking electrical discharge machining (EDM). However, the demanding requirements of the geometrical complexity and accuracy of an electrode significantly affected its manufacturing cost and time....

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Main Authors: Kit, Fong Mun, Ng Yang Zu, Nicolas, Abdul Haq, Reazul Haq, Manshoor, Bukhari, Abdul Ghafir, Mohammad Fahmi, Marwah, Omar Mohd Faizan, Hoffmann, Jörg
Format: Article
Language:English
Published: semarak ilmu 2024
Subjects:
T Technology (General)
Online Access:http://eprints.uthm.edu.my/11771/1/J17284_446e9b2bdbf45dd4169d3eaeaa4a83e3.pdf
http://eprints.uthm.edu.my/11771/
https://doi.org/10.37934/araset.34.3.129142
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spelling my.uthm.eprints.117712025-02-18T00:57:46Z http://eprints.uthm.edu.my/11771/ Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM Kit, Fong Mun Ng Yang Zu, Nicolas Abdul Haq, Reazul Haq Manshoor, Bukhari Abdul Ghafir, Mohammad Fahmi Marwah, Omar Mohd Faizan Hoffmann, Jörg T Technology (General) An electrode is a vital transmission tool of electrical charges that erodes a workpiece surface in die-sinking electrical discharge machining (EDM). However, the demanding requirements of the geometrical complexity and accuracy of an electrode significantly affected its manufacturing cost and time. Therefore, rapid tooling (RT) was attempted to improve electrode manufacturing. This research aims to verify the application of the FDM electrode in die-sinking EDM. Furthermore, the metallization and the machining performance of the FDM electrode were also studied. Fused Deposition Modelling (FDM) was utilized to fabricate a cylindrical electrode core made of Polyethylene Terephthalate Glycol (PETG). In primary metallization, the electrode core was immersed in copper paint. Next, the coated PETG substrate was electroplated in secondary metallization at a current density of 0.023 A cm-2 for 168 hours (7 days). The electrolyte consists of 80 g/ℓ copper (II) sulphate pentahydrate and 20 ml/ℓ sulphuric acid. The machining performance of FDM electrode such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) was benchmarked with a copper electrode. Copper coating with an average thickness of 334 µm was successfully electroplated on the surface of the FDM electrode. Additionally, the FDM electrode was able to machine the mild steel workpiece with 1 mm infit at a peak current of 16 A and pulse-on time of 50 µs without suffering premature electrode failures such as edge failure, delamination, distortion and rupturing. Lastly, the machining performance of the FDM electrode was comparable to the copper electrode in terms of MRR, EWR and SR. The potential of the FDM electrode in EDM machining is proven successful and can be investigated further to enhance the performance of this electrode. semarak ilmu 2024 Article PeerReviewed text en http://eprints.uthm.edu.my/11771/1/J17284_446e9b2bdbf45dd4169d3eaeaa4a83e3.pdf Kit, Fong Mun and Ng Yang Zu, Nicolas and Abdul Haq, Reazul Haq and Manshoor, Bukhari and Abdul Ghafir, Mohammad Fahmi and Marwah, Omar Mohd Faizan and Hoffmann, Jörg (2024) Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM. Journal of Advanced Research in Applied Sciences and Engineering Technology, 35 (1). pp. 129-142. ISSN 2462-1943 https://doi.org/10.37934/araset.34.3.129142
institution Universiti Tun Hussein Onn Malaysia
building UTHM Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Tun Hussein Onn Malaysia
content_source UTHM Institutional Repository
url_provider http://eprints.uthm.edu.my/
language English
topic T Technology (General)
spellingShingle T Technology (General)
Kit, Fong Mun
Ng Yang Zu, Nicolas
Abdul Haq, Reazul Haq
Manshoor, Bukhari
Abdul Ghafir, Mohammad Fahmi
Marwah, Omar Mohd Faizan
Hoffmann, Jörg
Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM
description An electrode is a vital transmission tool of electrical charges that erodes a workpiece surface in die-sinking electrical discharge machining (EDM). However, the demanding requirements of the geometrical complexity and accuracy of an electrode significantly affected its manufacturing cost and time. Therefore, rapid tooling (RT) was attempted to improve electrode manufacturing. This research aims to verify the application of the FDM electrode in die-sinking EDM. Furthermore, the metallization and the machining performance of the FDM electrode were also studied. Fused Deposition Modelling (FDM) was utilized to fabricate a cylindrical electrode core made of Polyethylene Terephthalate Glycol (PETG). In primary metallization, the electrode core was immersed in copper paint. Next, the coated PETG substrate was electroplated in secondary metallization at a current density of 0.023 A cm-2 for 168 hours (7 days). The electrolyte consists of 80 g/ℓ copper (II) sulphate pentahydrate and 20 ml/ℓ sulphuric acid. The machining performance of FDM electrode such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) was benchmarked with a copper electrode. Copper coating with an average thickness of 334 µm was successfully electroplated on the surface of the FDM electrode. Additionally, the FDM electrode was able to machine the mild steel workpiece with 1 mm infit at a peak current of 16 A and pulse-on time of 50 µs without suffering premature electrode failures such as edge failure, delamination, distortion and rupturing. Lastly, the machining performance of the FDM electrode was comparable to the copper electrode in terms of MRR, EWR and SR. The potential of the FDM electrode in EDM machining is proven successful and can be investigated further to enhance the performance of this electrode.
format Article
author Kit, Fong Mun
Ng Yang Zu, Nicolas
Abdul Haq, Reazul Haq
Manshoor, Bukhari
Abdul Ghafir, Mohammad Fahmi
Marwah, Omar Mohd Faizan
Hoffmann, Jörg
author_facet Kit, Fong Mun
Ng Yang Zu, Nicolas
Abdul Haq, Reazul Haq
Manshoor, Bukhari
Abdul Ghafir, Mohammad Fahmi
Marwah, Omar Mohd Faizan
Hoffmann, Jörg
author_sort Kit, Fong Mun
title Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM
title_short Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM
title_full Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM
title_fullStr Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM
title_full_unstemmed Performance Evaluation of Electrode Fabricated by using FDM in DieSinking EDM
title_sort performance evaluation of electrode fabricated by using fdm in diesinking edm
publisher semarak ilmu
publishDate 2024
url http://eprints.uthm.edu.my/11771/1/J17284_446e9b2bdbf45dd4169d3eaeaa4a83e3.pdf
http://eprints.uthm.edu.my/11771/
https://doi.org/10.37934/araset.34.3.129142
_version_ 1825163107259908096
score 13.244413

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