Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining
Electrical Discharge Machining (EDM) is a non-traditional technique widely used in various industries to remove material using electrical discharges. Finding a suitable electrode material that can resist high temperatures and efficiently remove material from the workpiece is a major difficulty in el...
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| Format: | Article |
| Language: | English |
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Unviversity of Technology- Iraq
2023-12-01
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| Series: | Engineering and Technology Journal |
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| Online Access: | https://etj.uotechnology.edu.iq/article_181031_e10a1854bde63c99e3a4cc91b63d4896.pdf |
| _version_ | 1797337724749873152 |
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| author | Ahmed Abdulwahhab Abbas Ibrahim |
| author_facet | Ahmed Abdulwahhab Abbas Ibrahim |
| author_sort | Ahmed Abdulwahhab |
| collection | DOAJ |
| description | Electrical Discharge Machining (EDM) is a non-traditional technique widely used in various industries to remove material using electrical discharges. Finding a suitable electrode material that can resist high temperatures and efficiently remove material from the workpiece is a major difficulty in electrical discharge machining (EDM). Due to their exceptional electrical and thermal properties, composite electrodes of various metals have become extremely popular. In this study, a composite electrode (Cu-1%Cr-0.5%WC-1%Ag) manufactured using the stir casting technique will be utilized to evaluate the electrical discharge machining (EDM) process. The study compares the performance between conventional pure copper electrodes and composite electrode utilization of stainless steel 304L as the workpiece material. The results indicate composite electrodes can increase machining effectiveness and reduce electrode wear. Utilizing a current of 10 A, with a pulse on time of 50µs followed by a pulse off time of 50 µs, reduced the tool wear rate to 0.215 gm/min for the composite electrode. By comparison, it was observed that the copper electrodes displayed a tool wear rate of 0.514 gm/min under the same conditions. While the pure copper electrode had the lowest material removal rate (MRR) at 54.5588 mm3/min, the composite electrode had the greatest MRR at 56.8689 mm3/min. The surface Roughness (SR) of the composite electrode was 3.747μm; this value was lower than that of the pure copper electrode, 3.967μm. As a result, composite electrodes present a potentially viable substitute for traditional EDM electrodes. |
| first_indexed | 2024-03-08T09:17:47Z |
| format | Article |
| id | doaj.art-19a1addacf5f40ee9c0117c247e6d991 |
| institution | Directory Open Access Journal |
| issn | 1681-6900 2412-0758 |
| language | English |
| last_indexed | 2024-03-08T09:17:47Z |
| publishDate | 2023-12-01 |
| publisher | Unviversity of Technology- Iraq |
| record_format | Article |
| series | Engineering and Technology Journal |
| spelling | doaj.art-19a1addacf5f40ee9c0117c247e6d9912024-01-31T14:11:22ZengUnviversity of Technology- IraqEngineering and Technology Journal1681-69002412-07582023-12-0141121528153810.30684/etj.2023.142962.1550181031Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge MachiningAhmed Abdulwahhab0Abbas Ibrahim1Production Engineering and Metallurgy Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.Production Engineering and Metallurgy Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.Electrical Discharge Machining (EDM) is a non-traditional technique widely used in various industries to remove material using electrical discharges. Finding a suitable electrode material that can resist high temperatures and efficiently remove material from the workpiece is a major difficulty in electrical discharge machining (EDM). Due to their exceptional electrical and thermal properties, composite electrodes of various metals have become extremely popular. In this study, a composite electrode (Cu-1%Cr-0.5%WC-1%Ag) manufactured using the stir casting technique will be utilized to evaluate the electrical discharge machining (EDM) process. The study compares the performance between conventional pure copper electrodes and composite electrode utilization of stainless steel 304L as the workpiece material. The results indicate composite electrodes can increase machining effectiveness and reduce electrode wear. Utilizing a current of 10 A, with a pulse on time of 50µs followed by a pulse off time of 50 µs, reduced the tool wear rate to 0.215 gm/min for the composite electrode. By comparison, it was observed that the copper electrodes displayed a tool wear rate of 0.514 gm/min under the same conditions. While the pure copper electrode had the lowest material removal rate (MRR) at 54.5588 mm3/min, the composite electrode had the greatest MRR at 56.8689 mm3/min. The surface Roughness (SR) of the composite electrode was 3.747μm; this value was lower than that of the pure copper electrode, 3.967μm. As a result, composite electrodes present a potentially viable substitute for traditional EDM electrodes.https://etj.uotechnology.edu.iq/article_181031_e10a1854bde63c99e3a4cc91b63d4896.pdfelectrical discharge machiningtool wear ratecomposite electrodematerial removal ratesurface roughnessstir casting process |
| spellingShingle | Ahmed Abdulwahhab Abbas Ibrahim Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining Engineering and Technology Journal electrical discharge machining tool wear rate composite electrode material removal rate surface roughness stir casting process |
| title | Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining |
| title_full | Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining |
| title_fullStr | Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining |
| title_full_unstemmed | Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining |
| title_short | Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining |
| title_sort | improvement of performance evaluation using hybrid composite electrode cu cr wc ag in electric discharge machining |
| topic | electrical discharge machining tool wear rate composite electrode material removal rate surface roughness stir casting process |
| url | https://etj.uotechnology.edu.iq/article_181031_e10a1854bde63c99e3a4cc91b63d4896.pdf |
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