Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining

An electrode is a vital transmission tool of electrical charges that erodes a workpiece surface in die-sinking electrical discharge machining (EDM). However, the demanding requirements of the geometrical complexity and accuracy of an electrode significantly affected its manufacturing cost and time....

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Main Author:	Ng, Nicolas Yang Zu
Format:	Thesis
Language:	English English English
Published:	2022
Subjects:	T Technology (General)
Online Access:	http://eprints.uthm.edu.my/10959/1/24p%20NICOLAS%20NG%20YANG%20ZU.pdf http://eprints.uthm.edu.my/10959/2/NICOLAS%20NG%20YANG%20ZU%20COPYRIGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/10959/3/NICOLAS%20NG%20YANG%20ZU%20WATERMARK.pdf
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spelling	my-uthm-ep.109592024-05-13T11:52:58Z Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining 2022-12 Ng, Nicolas Yang Zu T Technology (General) An electrode is a vital transmission tool of electrical charges that erodes a workpiece surface in die-sinking electrical discharge machining (EDM). However, the demanding requirements of the geometrical complexity and accuracy of an electrode significantly affected its manufacturing cost and time. Therefore, rapid tooling (RT) was attempted to improve electrode manufacturing. This research aims to verify the application of the FDM electrode in die-sinking EDM. Furthermore, the metallization and the machining performance of the FDM electrode were also studied. Fused Deposition Modelling (FDM) was utilized to fabricate a cylindrical electrode core made of Polyethylene Terephthalate Glycol (PETG). In primary metallization, the electrode core was immersed in copper paint. Next, the coated PETG substrate was electroplated in secondary metallization at a current density of 0.023 A cm-2 for 168 hours (7 days). The electrolyte consists of 80 g/ℓ copper sulphate and 20 ml/ℓ sulphuric acid. The machining performance of FDM electrode such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) was benchmarked with a copper electrode. Copper coating with an average thickness of 334 μm was successfully electroplated on the surface of the FDM electrode. Additionally, the FDM electrode can machine the mild steel workpiece with 1 mm infit at a peak current of 16 A and pulse-on time of 50 μs without suffering premature electrode failures such as edge failure, delamination, distortion and rupturing. Lastly, the machining performance of the FDM electrode was comparable to the copper electrode in terms of MRR, EWR and SR 2022-12 Thesis http://eprints.uthm.edu.my/10959/ http://eprints.uthm.edu.my/10959/1/24p%20NICOLAS%20NG%20YANG%20ZU.pdf text en public http://eprints.uthm.edu.my/10959/2/NICOLAS%20NG%20YANG%20ZU%20COPYRIGHT%20DECLARATION.pdf text en staffonly http://eprints.uthm.edu.my/10959/3/NICOLAS%20NG%20YANG%20ZU%20WATERMARK.pdf text en validuser mphil masters Universiti Tun Hussein Onn Malaysia Fakulti Kejuruteraan Mekanikal dan Pembuatan
institution	Universiti Tun Hussein Onn Malaysia
collection	UTHM Institutional Repository
language	English English English
topic	T Technology (General)
spellingShingle	T Technology (General) Ng, Nicolas Yang Zu Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining
description	An electrode is a vital transmission tool of electrical charges that erodes a workpiece surface in die-sinking electrical discharge machining (EDM). However, the demanding requirements of the geometrical complexity and accuracy of an electrode significantly affected its manufacturing cost and time. Therefore, rapid tooling (RT) was attempted to improve electrode manufacturing. This research aims to verify the application of the FDM electrode in die-sinking EDM. Furthermore, the metallization and the machining performance of the FDM electrode were also studied. Fused Deposition Modelling (FDM) was utilized to fabricate a cylindrical electrode core made of Polyethylene Terephthalate Glycol (PETG). In primary metallization, the electrode core was immersed in copper paint. Next, the coated PETG substrate was electroplated in secondary metallization at a current density of 0.023 A cm-2 for 168 hours (7 days). The electrolyte consists of 80 g/ℓ copper sulphate and 20 ml/ℓ sulphuric acid. The machining performance of FDM electrode such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) was benchmarked with a copper electrode. Copper coating with an average thickness of 334 μm was successfully electroplated on the surface of the FDM electrode. Additionally, the FDM electrode can machine the mild steel workpiece with 1 mm infit at a peak current of 16 A and pulse-on time of 50 μs without suffering premature electrode failures such as edge failure, delamination, distortion and rupturing. Lastly, the machining performance of the FDM electrode was comparable to the copper electrode in terms of MRR, EWR and SR
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Ng, Nicolas Yang Zu
author_facet	Ng, Nicolas Yang Zu
author_sort	Ng, Nicolas Yang Zu
title	Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining
title_short	Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining
title_full	Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining
title_fullStr	Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining
title_full_unstemmed	Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining
title_sort	performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining
granting_institution	Universiti Tun Hussein Onn Malaysia
granting_department	Fakulti Kejuruteraan Mekanikal dan Pembuatan
publishDate	2022
url	http://eprints.uthm.edu.my/10959/1/24p%20NICOLAS%20NG%20YANG%20ZU.pdf http://eprints.uthm.edu.my/10959/2/NICOLAS%20NG%20YANG%20ZU%20COPYRIGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/10959/3/NICOLAS%20NG%20YANG%20ZU%20WATERMARK.pdf
_version_	1804890125873709056

Performance evaluation of electrode fabricated by fused deposition modelling in die-sinking electrical discharge machining

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