Dry die-sinking EDM with mouldable graphite–polymer electrode investigation of process parameters and pulse identification methods

• Published in: International journal of advanced manufacturing technology Vol. 65; no. 5-8; pp. 1125 - 1139
• Main Authors: Frohn-Villeneuve, L., Curodeau, A.
• Format: Journal Article
• Language: English
• Published: London Springer-Verlag 01.03.2013; Springer Nature B.V
• Subjects: CAE) and Design; Circuits; Computer-Aided Engineering (CAD; Die sinking; Dies; EDM electrodes; Electrodes; Engineering; Feasibility studies; Identification methods; Industrial and Production Engineering; Material removal rate (machining); Mechanical Engineering; Media Management; Open circuit voltage; Original Article; Parameter identification; Polishing; Polymer matrix composites; Polymers; Process parameters; Surface finish; Tool steels; Wear rate; Dry EDM; High frequency position control; Pulse identification; Polymer composite electrode; Die-sinking EDM; Surface finishing; Powder-mixed EDM
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-012-4244-7

In this paper, a new dry die-sinking EDM polishing method using a mouldable polymer composite electrode as tool is presented. This EDM method involves two new concepts, namely: dry die sinking and the polymer composite tool. An experimental investigation was performed on the dry die-sinking EDM process to assess the feasibility of finishing down to 0.2–0.3 μm Sa, and polishing from 0.2 to 0.3 μm Sa down to the finest achievable surface finish. To simplify sample preparation, the methodology involved a reversal of the polishing process. Hence, the surface finish of a 13-mm diameter P20 tool steel disk was taken from a lapped 0.01-μm Sa surface finish up to a rougher steady-state surface finish value, assuming comparable results with conventional rough-to-fine polishing procedures. Several process parameters were evaluated such as: pulse current level I EP , open-circuit voltage V OC , pulse time on T ON , pulse time off T OFF , number of polishing cycles N C and three pulse identification methods, for their effect on sample surface finish micrometre Sa, material removal rate MRR [cubic millimetre per hour] and electrode relative wear rate ERWR.