Experimental study of tool degradation in EDM processes: electrode material loss at the border and central zones
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The analysis and optimization of tool life is an essential key to enhance the performance of EDM processes as a manufacturing technology for naval, aerospace, automotive, and other different industrial sectors. For this reason, the study of electrode degradation as a consequence of the thermal effects originated on the tool surface is of great interest to improve these material removal processes. In the present work, the degradation of electrode geometry is analyzed as a function of some process parameters such as the current intensity selected for this material removal technology and the overall depth covered by the electrode during the machining of workpiece material. This study is focused on the analysis of the mechanisms that provoke the formation of a tool groove on the frontal surface of the electrode and the average worn depth evidenced on the electrode central zone. The topology of the worn surface of the cutting tool during die-sinking EDM is analyzed, and the current intensity and penetration depth were probed to present a great influence on the tool wear. According to the results of this work, the groove depth can be adopted to describe the tool groove from the selected cutting conditions and the material profile ratio can serve to characterize the surface texture on the central zone of the electrode active surface.
KeywordsElectro-discharge machining (EDM) Experimental analysis Surface morphology Tool wear
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