Study of using three dimensional printer for EDM electrode fabrication

In this study, Cu-Al2O3 powder was prepared using ball mill and used separately for powder metallurgy (PM) and Three Dimensional Printer (3DP) application to fabricate electrode for electrical discharge machining (EDM). The materials in powder form were analyzed under scanning electron microscop...

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Main Author:	Hassan, Noor Haslyena
Format:	Thesis
Language:	English English
Published:	2011
Subjects:	TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice
Online Access:	http://eprints.uthm.edu.my/2761/1/24p%20NOOR%20HASLYENA%20HASSAN.pdf http://eprints.uthm.edu.my/2761/2/NOOR%20HASLYENA%20HASSAN%20WATERMARK.pdf
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spelling	my-uthm-ep.27612021-11-01T06:55:09Z Study of using three dimensional printer for EDM electrode fabrication 2011-09 Hassan, Noor Haslyena TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice In this study, Cu-Al2O3 powder was prepared using ball mill and used separately for powder metallurgy (PM) and Three Dimensional Printer (3DP) application to fabricate electrode for electrical discharge machining (EDM). The materials in powder form were analyzed under scanning electron microscope (SEM) and particle size analyzer (PSA) to ensure that they fulfill the requirement for each fabrication method. For PM process, five compositions of Cu-%wt Al2O3 powder were prepared ranging from 0% to 20% Al2O3 contents at 5% increment. The powder were compacted and sintered in argon protected atmosphere to determine the suitable compaction pressure and sintering temperature to fabricate PM electrode. Microscopic analysis revealed that 48MPa and 921°C is the best compaction pressure and sintering temperature respectively for EDM electrode fabrication. EDM electrode samples were fabricated using both recommended parameters, and were tested to erode JIS SKD11 (mould steel) workpiece for 5 minutes, with solid Cu electrode as the benchmark. Electrodes’ performances were assessed by calculating the tool wear rate (TWR), material removal rate (MRR) and by measuring the average surface roughness (Ra) of the eroded cavity. From the experiment conducted, the PM electrodes are not as good as solid Cu electrode in terms of MRR, but the addition of Al2O3 at around 10%wt could reduce the TWR and Ra. The composition of Cu-10%wt Al2O3 powder electrode that has the optimum machining results was then prepared for 3DP application. Green parts were fabricated using 3DP, sintered and infiltrated prior to being tested at EDM machine. Although sintering was a success, samples were still porous due to the failure in infiltration process. The performance of EDM electrodes fabricated using 3DP were evaluated the same way as the ones fabricated via PM process. Experiments using 3DP electrodes showed that the electrodes depleted and became the alloying element on the workpiece. Further studies are needed on the sintering and infiltration method in order to improve the quality of the electrode fabricated using 3DP. 2011-09 Thesis http://eprints.uthm.edu.my/2761/ http://eprints.uthm.edu.my/2761/1/24p%20NOOR%20HASLYENA%20HASSAN.pdf text en public http://eprints.uthm.edu.my/2761/2/NOOR%20HASLYENA%20HASSAN%20WATERMARK.pdf text en validuser mphil masters Universiti Tun Hussein Malaysia Fakulti Kejuruteraan Mekanikal dan Pembuatan
institution	Universiti Tun Hussein Onn Malaysia
collection	UTHM Institutional Repository
language	English English
topic	TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice
spellingShingle	TJ Mechanical engineering and machinery TJ1125-1345 Machine shops and machine shop practice Hassan, Noor Haslyena Study of using three dimensional printer for EDM electrode fabrication
description	In this study, Cu-Al2O3 powder was prepared using ball mill and used separately for powder metallurgy (PM) and Three Dimensional Printer (3DP) application to fabricate electrode for electrical discharge machining (EDM). The materials in powder form were analyzed under scanning electron microscope (SEM) and particle size analyzer (PSA) to ensure that they fulfill the requirement for each fabrication method. For PM process, five compositions of Cu-%wt Al2O3 powder were prepared ranging from 0% to 20% Al2O3 contents at 5% increment. The powder were compacted and sintered in argon protected atmosphere to determine the suitable compaction pressure and sintering temperature to fabricate PM electrode. Microscopic analysis revealed that 48MPa and 921°C is the best compaction pressure and sintering temperature respectively for EDM electrode fabrication. EDM electrode samples were fabricated using both recommended parameters, and were tested to erode JIS SKD11 (mould steel) workpiece for 5 minutes, with solid Cu electrode as the benchmark. Electrodes’ performances were assessed by calculating the tool wear rate (TWR), material removal rate (MRR) and by measuring the average surface roughness (Ra) of the eroded cavity. From the experiment conducted, the PM electrodes are not as good as solid Cu electrode in terms of MRR, but the addition of Al2O3 at around 10%wt could reduce the TWR and Ra. The composition of Cu-10%wt Al2O3 powder electrode that has the optimum machining results was then prepared for 3DP application. Green parts were fabricated using 3DP, sintered and infiltrated prior to being tested at EDM machine. Although sintering was a success, samples were still porous due to the failure in infiltration process. The performance of EDM electrodes fabricated using 3DP were evaluated the same way as the ones fabricated via PM process. Experiments using 3DP electrodes showed that the electrodes depleted and became the alloying element on the workpiece. Further studies are needed on the sintering and infiltration method in order to improve the quality of the electrode fabricated using 3DP.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Hassan, Noor Haslyena
author_facet	Hassan, Noor Haslyena
author_sort	Hassan, Noor Haslyena
title	Study of using three dimensional printer for EDM electrode fabrication
title_short	Study of using three dimensional printer for EDM electrode fabrication
title_full	Study of using three dimensional printer for EDM electrode fabrication
title_fullStr	Study of using three dimensional printer for EDM electrode fabrication
title_full_unstemmed	Study of using three dimensional printer for EDM electrode fabrication
title_sort	study of using three dimensional printer for edm electrode fabrication
granting_institution	Universiti Tun Hussein Malaysia
granting_department	Fakulti Kejuruteraan Mekanikal dan Pembuatan
publishDate	2011
url	http://eprints.uthm.edu.my/2761/1/24p%20NOOR%20HASLYENA%20HASSAN.pdf http://eprints.uthm.edu.my/2761/2/NOOR%20HASLYENA%20HASSAN%20WATERMARK.pdf
_version_	1747830983678230528

Study of using three dimensional printer for EDM electrode fabrication

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