Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode
In the present study, cylindrical ABS P400 polymer parts (diameter 6.5 mm) to be used as die-sinking EDM (electric discharge machining) novel electrodes were fabricated using a fused deposition modeling (FDM) process. To meet the conductivity requirement in EDM, ABS parts were metallized using an in...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-11-01
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| Series: | Polymers |
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| Online Access: | https://www.mdpi.com/2073-4360/13/23/4109 |
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| author | Azhar Equbal Asif Equbal Zahid A. Khan Irfan Anjum Badruddin Mohamed Bashir Ali Bashir Hussein Alrobei |
| author_facet | Azhar Equbal Asif Equbal Zahid A. Khan Irfan Anjum Badruddin Mohamed Bashir Ali Bashir Hussein Alrobei |
| author_sort | Azhar Equbal |
| collection | DOAJ |
| description | In the present study, cylindrical ABS P400 polymer parts (diameter 6.5 mm) to be used as die-sinking EDM (electric discharge machining) novel electrodes were fabricated using a fused deposition modeling (FDM) process. To meet the conductivity requirement in EDM, ABS parts were metallized using an innovative method that comprised putting aluminum–charcoal (Al–C) on them followed by their copper electroplating. Real-time EDM of the mild steel workpiece was performed using novel electrodes, and machining performance of the electrodes, measured in terms of dimensional accuracy, i.e., change in diameter (Δ<i>D</i>) and change in depth (Δ<i>H</i>) of the cavity, under varying levels of three EDM factors, i.e., current (<i>I</i>), pulse on time (<i>T<sub>on</sub></i>), and pulse off time (<i>T</i><i><sub>off</sub></i>), was investigated. Machining results were analyzed using analysis of variance (ANOVA), perturbation graphs, and 3D surface plots. The optimal setting of the EDM parameters for minimizing Δ<i>D</i> and Δ<i>H</i> was determined using the desirability function approach. The suitability of the novel electrodes for EDM was ascertained by comparing their machining results with those of solid copper (SC) electrodes and electrodes fabricated by FDM and metallized using the electro-deposition method (FDM-EM), already reported in the literature, under similar machining conditions. From the results, it was found that Δ<i>D</i> and Δ<i>H</i> were less when EDM was performed using novel electrodes. |
| first_indexed | 2024-03-10T04:47:01Z |
| format | Article |
| id | doaj.art-086b9395f7354e02b50cefd331795118 |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-10T04:47:01Z |
| publishDate | 2021-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-086b9395f7354e02b50cefd3317951182023-11-23T02:53:04ZengMDPI AGPolymers2073-43602021-11-011323410910.3390/polym13234109Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM ElectrodeAzhar Equbal0Asif Equbal1Zahid A. Khan2Irfan Anjum Badruddin3Mohamed Bashir Ali Bashir4Hussein Alrobei5Department of Mechanical Engineering, Faculty of Engineering and Technology, Jamia Millia Islamia, New Delhi 110025, IndiaDepartment of Mechanical Engineering, Cambridge Institute of Technology, Ranchi 835213, IndiaDepartment of Mechanical Engineering, Faculty of Engineering and Technology, Jamia Millia Islamia, New Delhi 110025, IndiaMechanical Engineering Department, College of Engineering, King Khalid University, Abha 61413, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering, Jouf University, Sakaka 42421, Saudi ArabiaDepartment of Mechanical Engineering, College of Engineering, Prince Sattam bin Abdullaziz University, Al-Kharj 16273, Saudi ArabiaIn the present study, cylindrical ABS P400 polymer parts (diameter 6.5 mm) to be used as die-sinking EDM (electric discharge machining) novel electrodes were fabricated using a fused deposition modeling (FDM) process. To meet the conductivity requirement in EDM, ABS parts were metallized using an innovative method that comprised putting aluminum–charcoal (Al–C) on them followed by their copper electroplating. Real-time EDM of the mild steel workpiece was performed using novel electrodes, and machining performance of the electrodes, measured in terms of dimensional accuracy, i.e., change in diameter (Δ<i>D</i>) and change in depth (Δ<i>H</i>) of the cavity, under varying levels of three EDM factors, i.e., current (<i>I</i>), pulse on time (<i>T<sub>on</sub></i>), and pulse off time (<i>T</i><i><sub>off</sub></i>), was investigated. Machining results were analyzed using analysis of variance (ANOVA), perturbation graphs, and 3D surface plots. The optimal setting of the EDM parameters for minimizing Δ<i>D</i> and Δ<i>H</i> was determined using the desirability function approach. The suitability of the novel electrodes for EDM was ascertained by comparing their machining results with those of solid copper (SC) electrodes and electrodes fabricated by FDM and metallized using the electro-deposition method (FDM-EM), already reported in the literature, under similar machining conditions. From the results, it was found that Δ<i>D</i> and Δ<i>H</i> were less when EDM was performed using novel electrodes.https://www.mdpi.com/2073-4360/13/23/4109ABS P400 Polymerfused deposition modelingEDMelectrodesmetallizationdimensional accuracy |
| spellingShingle | Azhar Equbal Asif Equbal Zahid A. Khan Irfan Anjum Badruddin Mohamed Bashir Ali Bashir Hussein Alrobei Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode Polymers ABS P400 Polymer fused deposition modeling EDM electrodes metallization dimensional accuracy |
| title | Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode |
| title_full | Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode |
| title_fullStr | Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode |
| title_full_unstemmed | Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode |
| title_short | Investigating the Dimensional Accuracy of the Cavity Produced by ABS P400 Polymer-Based Novel EDM Electrode |
| title_sort | investigating the dimensional accuracy of the cavity produced by abs p400 polymer based novel edm electrode |
| topic | ABS P400 Polymer fused deposition modeling EDM electrodes metallization dimensional accuracy |
| url | https://www.mdpi.com/2073-4360/13/23/4109 |
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