Electrode wear and material removal rate during EDM of aluminum and mild steel using copper and brass electrodes
In the present study an analysis has been done to evaluate the electrode wear along the cross-section of an electrode compared to the same along its length during EDM of aluminum and mild steel using copper and brass electrodes. In an overall performance comparison of copper and brass electrode...
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| Format: | Article |
| Language: | English |
| Published: |
Springer London
2008
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| Online Access: | http://irep.iium.edu.my/7833/ http://irep.iium.edu.my/7833/ http://irep.iium.edu.my/7833/ http://irep.iium.edu.my/7833/1/2008_Ahsan.pdf |
| Summary: | In the present study an analysis has been done to
evaluate the electrode wear along the cross-section of an
electrode compared to the same along its length during
EDM of aluminum and mild steel using copper and brass
electrodes. In an overall performance comparison of copper
and brass electrodes, we found that electrode wear increases
with an increase in both current and voltage, but wear along
the cross-section of the electrode is more compared to the
same along its length. This is due to easier heat transfer
along the length compared to the same along the crosssection
of the electrode. It was also found that the wear
ratio increases with an increase in current. That means,
though a higher current causes more removal of work
material and the electrode, comparatively more material is
removed from the electrode. The highest wear ratio was
found during machining of steel using a brass electrode.
The low thermal conductivity of brass electrodes causes
less heat loss, and its low melting point results in fast
melting of the electrode material. At the same time, low
thermal conductivity of steel results in poor heat absorption,
and its high melting temperature causes poor removal of
work material. These factors result in the highest wear ratio
during machining of steel using a brass electrode. The
highest material removal rate was observed during machining
of aluminum using brass electrodes. Comparatively low
thermal conductivity of brass as an electrode material does
not allow the absorption of much heat energy, and most of
the heat is utilized in the removal of material from
aluminum workpiece at a low melting point. But during
machining of steel using copper electrodes, a comparatively
smaller quantity of heat is absorbed by the work material
due to its low thermal conductivity. As a result material
removal rate becomes very low. |
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