Skip to main content
SpringerLink
Log in

Powder mixed-electrical discharge machining (EDM) with the electrode is made by fused deposition modeling (FDM) at Ti-6Al-4V machining procedure

  • Original Paper
  • Published:
Multiscale and Multidisciplinary Modeling, Experiments and Design Aims and scope Submit manuscript

Abstract

Rapid prototyping (RP) is a collection of techniques, and it is used in many industries to make a robust model of a mechanical sample instantly. RP is usually implemented by employing 3D printing or additive manufacturing (AM) technology with three-dimensional modeling. In the context of RP, rapid tooling (RT) is the result of applying the RP with non-conventional tooling. RT causes many discharge channels between the electrode in electro-discharge machining (EDM). In our study, acrylonitrile butadiene styrene is coated with a thin layer of copper and is used as an electrode tool in powder mixed electro-discharge machining (PM-EDM). We have employed the fused deposition modeling (FDM) method of rapid prototyping to improve the conductivity of the electrode tools for the PM-EDM. Cost, machining-time, and the quality of the surface are the significant outputs of the PM-EDM process for the fabrication of tools in sensitive industries. In our present research, a new kind of electrode is compared with a solid electrode with powder and without powder. Material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR) have been measured for both scenarios. In this method, peak current, pulse-on time, and concentration of aluminium powder are the input parameters. We have also added a surfactant on kerosene for separating and distributing the powders. Our study demonstrates that the RP electrodes have the potential for utilizing the PM-EDM tools with complex shapes. The conventional processes do not make these complex shapes. Indeed, comparing the results of the output parameters in our proposed method with the PM-EDM existing methods indicates an improvement for MRR, TWR, and SR, by 33%, 31%, and 77%, respectively. Hence, the average surface quality, which is created by the PM-EDM, has been substantially improved. Thus, our proposed method is cost-effective, and it can be used to create various complex topologies, potentially in the medical and aerospace industries.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  • Abbas NM, Solomon DG, Bahari MF (2007) A review on current research trends in electrical discharge machining (EDM). Int J Mach Tools Manuf 47:1214–1228

    Article  Google Scholar 

  • Chow H-M, Yan B-H, Huang F-Y, Hung J-C (2000) Study of added powder in kerosene for the micro-slit machining of titanium alloy using electro-discharge machining. J Mater Process Technol 101:95–103

    Article  Google Scholar 

  • Ekmekci N, Ekmekci B (2016) Electrical discharge machining of Ti6Al4V in hydroxyapatite powder mixed dielectric liquid. Mater Manuf Process 31:1663–1670

    Article  Google Scholar 

  • Gibson I, Rosen DW, Stucker B (2010) Additive manufacturing technologies: rapid prototyping to direct digital manufacturing. Springer, New York. https://doi.org/10.1007/978-1-4419-1120-9

    Book  Google Scholar 

  • Hashmi S, Batalha GF, Van Tyne CJ, Yilbas BS (2014) Comprehensive materials processing. Elsevier, New York

    Google Scholar 

  • Hosni NAJ, Lajis MA (2018) The influence of span-20 surfactant and micro-/nano-chromium (Cr) powder mixed electrical discharge machining (PM-EDM) on the surface characteristics of AISI D2 hardened steel. IOP Conf Ser Mater Sci Eng 342:012095

    Article  Google Scholar 

  • Khan MS, Dash JP (2018) Enhancing surface finish of fused deposition modelling parts. In: 3D printing and additive manufacturing technologies. Springer, Singapore, pp 45–57. https://doi.org/10.1007/978-981-13-0305-0_5

  • Kolli M, Kumar A (2017) Surfactant and graphite powder-assisted electrical discharge machining of titanium alloy. Proc Inst Mech Eng Part B J Eng Manuf 231:641–657

    Article  Google Scholar 

  • Kumar A, Maheshwari S, Sharma C, Beri N (2010) Research developments in additives mixed electrical discharge machining (AEDM): a state of art review. Mater Manuf Process 25:1166–1180

    Article  Google Scholar 

  • Kumar LJ, Pandey PM, Wimpenny DI (2019a) 3D printing and additive manufacturing technologies. Springer, Berlin

    Book  Google Scholar 

  • Kumar N, Jain PK, Tandon P, Pandey PM (2019) Toolpath generation for additive manufacturing using CNC milling machine. In: 3D printing and additive manufacturing technologies. Springer, Singapore, pp 73–82. https://doi.org/10.1007/978-981-13-0305-0_7

  • Lakshmi KS, Arumaikkannu G (2017) Influence of process parameters on tensile strength of additive manufactured polymer parts using taguchi method. In: Advances in 3D printing and additive manufacturing technologies. Springer, Singapore, pp 1–7. https://doi.org/10.1007/978-981-10-0812-2_1

  • Mahdavinejad RA, Ilani MA (2019) IJSRMME19339|Superior advance research in the electro-discharge machining of Ti alloys: review

  • Saxena P, Metkar RM (2018) Development of electrical discharge machining (EDM) electrode using fused deposition modeling (FDM). In: 3D printing and additive manufacturing technologies. Springer, Singapore, pp 257–268. https://doi.org/10.1007/978-981-13-0305-0_22

  • Srivastava M, Rathee S, Maheshwari S, Kundra TK (2019) Design and processing of functionally graded material: review and current status of research. In: 3D printing and additive manufacturing technologies. Springer, Singapore, pp 243–255. https://doi.org/10.1007/978-981-13-0305-0_21

  • Verma R, Kaushal G (2019) State of the art of powder bed fusion additive manufacturing: a review. In: 3D printing and additive manufacturing technologies. Springer, Singapore, pp 269–279. https://doi.org/10.1007/978-981-13-0305-0_23

  • Zhang B et al (2018) The biomimetic design and 3D printing of customized mechanical properties porous Ti6Al4V scaffold for load-bearing bone reconstruction. Mater Des. https://doi.org/10.1016/j.matdes.2018.04.065

    Article  Google Scholar 

Download references

Acknowledgements

I would like to express my deepest gratitude to Professor Sergey Kravchenko for his continuous encouragement and support. Affiliated Research Professor Mohammad Khoshnevisan, Physics Department, Northeastern University, USA.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran

    Mohsen Asghari Ilani

  2. College of Science, Physics Department, Northeastern University, Boston, MA, 02115, USA

    Mohammad Khoshnevisan

Authors
  1. Mohsen Asghari Ilani
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mohammad Khoshnevisan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mohammad Khoshnevisan.

Ethics declarations

Conflict of interest

On behalf of all authors, the corresponding author states that there is no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ilani, M.A., Khoshnevisan, M. Powder mixed-electrical discharge machining (EDM) with the electrode is made by fused deposition modeling (FDM) at Ti-6Al-4V machining procedure. Multiscale and Multidiscip. Model. Exp. and Des. 3, 173–186 (2020). https://doi.org/10.1007/s41939-020-00070-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s41939-020-00070-6

Keywords

Search

Navigation