Toward the Targeted Material Removal with Optimized Surface Finish During EDM for the Repair Applications in Dies and Molds

The importance of dies and molds in the manufacturing industry cannot be mitigated, but their frequent and ongoing use frequently necessitates repair as their surface wear is associated with repetitive applications. Among the distinct machining options available in this regard, Electric discharge ma...

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Bibliographic Details
Published in:Arabian journal for science and engineering (2011) 2023-03, Vol.48 (3), p.2653-2669
Main Authors: Ishfaq, Kashif, Rehman, Mudassar, Wang, Yanen
Format: Article
Language:English
Subjects:
Copper
EDM electrodes
Electric discharge machining
Electrode materials
Electrodes
Engineering
Experimentation
Humanities and Social Sciences
Minimal surfaces
Molds
multidisciplinary
Orthogonal arrays
Rapid prototyping
Research Article-Mechanical Engineering
Science
Surface finish
Surface roughness
Tungsten carbide
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Summary:The importance of dies and molds in the manufacturing industry cannot be mitigated, but their frequent and ongoing use frequently necessitates repair as their surface wear is associated with repetitive applications. Among the distinct machining options available in this regard, Electric discharge machining (EDM) is a promising candidate. However, the inherent stochastic nature of the process makes specific control challenging because there occurs a significant difference between designed and actual MRR which severely hinders the targeted material removal. Thus, the application of EDM in getting controlled MRR with minimum surface roughness (SR) for repair purposes is not yet significantly explored. Also, the selection of the most suitable electrode material from three different material categories (metal, non-metal, ceramic) in controlled machining has still not been explicitly discussed before. The experimentation was performed by following Taguchi L18 orthogonal array with six EDM variables along with relative MRR and SR as output responses. The findings revealed that the relative MRR (103%) was close to the desired MRR (100%), with a minimal surface roughness-SR (2.48 µm). The machining performance of three electrodes concerning the controlled machining with minimum surface roughness followed as Tungsten carbide (WC) 
ISSN:2193-567X
1319-8025
2191-4281
DOI:10.1007/s13369-022-07006-x