Skip to main content
SpringerLink
Log in

An experimental work on using conductive powder-filled polymer composite cast material as tool electrode in EDM

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper introduces the composite tool electrodes made of electrical conductive powder-filled polyester resin matrix material, providing promise for the electrical discharge machining (EDM) process. The dendrite-shaped copper powder, graphite powder, and their mixture were used as conductive fillers. Six different types of composite electrodes, namely, plain copper-polyester, pressed copper-polyester, furnaced copper-polyester, plain copper-graphite-polyester, pressed copper-graphite-polyester, and furnaced copper-graphite-polyester were prepared. It is found experimentally that increasing v f improved workpiece material removal rate, tool wear rate, relative wear, and electrical conductivity of electrodes. The pressed copper-polyester electrodes were found to be promising in the ED finishing of workpieces at low machining current settings. The practical applicability of the proposed composite electrodes in the industry was also illustrated.

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

Similar content being viewed by others

References

  1. Kechagias J, Iakovakis V, Katsanos M, Maropoulos S (2008) EDM electrode manufacture using rapid tooling: a review. J Mat Sci 43:2522–35

    Article  Google Scholar 

  2. Berger MA, McCullough RL (1985) Characterization and analysis of the electrical properties of metal-filled polymer. Composite Sci Tech 22:81–106

    Article  Google Scholar 

  3. Kroker R, Schneider M, Hamann K (1972) Polymer reaction on powder surfaces. Prog Org Coatings 1:23–44

    Article  Google Scholar 

  4. Kim HK, Shi FG (2001) Electrical reliability of electrically conductive adhesive joints: dependence on curing condition and current density. Microelectron J 32:315–21

    Article  Google Scholar 

  5. Nguyen TP, Ettaik H, Lefrant S (1990) Studies of the polyparaphenylene/aluminum interface. Synth Met 38:69–76

    Article  Google Scholar 

  6. Vilcakova J, Saha P, Quadrat O (2002) Electrical conductivity of carbon fibers-polyester resin composites in the percolation threshold region. Eur Polym J 38:2343–2347

    Article  Google Scholar 

  7. Jimenez MM, Elizalde MP, Gonzales M (2000) Electrochemical behavior of nickel-polyester composite electrodes. Electrochim Acta 45:4187–93

    Article  Google Scholar 

  8. Shimada Y, Daoqiang L, Wong CP (2000) Electrical characterizations and considerations of electrically conductive adhesives (ECAs). Int Symp Adv Packag Mater 16:214–32

    Google Scholar 

  9. Puertolas JA, Oriol L, Calleja RD (1994) Dielectric and mechanical behaviour of a copper (II) metallomesogenic homopolymer. J Non-Cryst Solids 172(4):950–954

    Article  Google Scholar 

  10. Mamunya YP, Davydenko VV, Pissis P, Lebedev EV (2002) Electrical and thermal conductivity of polymers filled with metal powders. Eur Polym J 38:1887–97

    Article  Google Scholar 

  11. Roldughin VI, Vysotskii VV (2000) Percolation properties of metal-filled polymer films, structure and mechanisms of conductivity. Prog Org Coatings 39:81–100

    Article  Google Scholar 

  12. Carmona F (1989) Conducting filled polymers. Physica A 157:461–9

    Article  Google Scholar 

  13. Wycisk W, Pozniak R, Pasternak A (2002) Conductive polymer materials with low filler content. J Electrost 56:55–66

    Article  Google Scholar 

  14. Bhattacharyya KS (1979) Electrical resistivity of PVC-Cu composites. Polymer 20:1166–7

    Article  Google Scholar 

  15. Kalyon DM, Birinci E, Yazıcı R, Karuv B, Walsh S (2002) Electrical properties of composites as affected by the degree of mixedness of the conductive filler in the polymer matrix. Polymer Eng and Sci 42(7):42–7

    Article  Google Scholar 

  16. El-Tantawy F, Kamada K, Ohnabe H (2002) Electrical properties and stability of epoxy reinforced carbon black composites. Mater Lett 57:242–51

    Article  Google Scholar 

  17. Eubank PT, Bradley WL, Stucker BE, Bozkurt B, Norasetthekul S (1998) A new electrode material resistant to spark/arc erosion. NSF Des. and Manuf. Grantees Conf. Monterrey Mexico. 713–714

  18. Arthur A, Dickens PM, Cobb RC (1996) Using rapid prototyping to produce electrical discharge machining electrodes. Rapid Prototyping J 2(1):4–12

    Article  Google Scholar 

  19. Curodeau A, Richard M, Frohn L (2004) Mold Surface finishing with new EDM process in air with thermoplastic composite electrodes. J Mat Proc Tech 149:278–83

    Article  Google Scholar 

  20. Khan DA, Hameedullah M (2011) Effect of tool polarity on the machining characteristics in electric discharge machining of silver steel and statistical modelling of the process. Int J Eng Sci Tech 3(6):5001–10

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Defense Industries Research and Development Institute (TUBİTAK-SAGE), The Scientific and Technological Research Council of Turkey, Ankara, Turkey

    Kemal Yaman

  2. Mechatronics Engineering Department, Faculty of Engineering, Çankaya University, Ankara, Turkey

    Can Çoğun

Authors
  1. Kemal Yaman
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Can Çoğun
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Can Çoğun.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yaman, K., Çoğun, C. An experimental work on using conductive powder-filled polymer composite cast material as tool electrode in EDM. Int J Adv Manuf Technol 73, 535–543 (2014). https://doi.org/10.1007/s00170-014-5839-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-5839-y

Keywords

Search

Navigation