A Comparative Study on Performance of 3D-Printed EDM Electrode with Conventional EDM Electrode

  • L. Mahipal ReddyEmail author
  • L. Siva Rama Krishna
  • S. Sharath Kumar
  • P. Ravinder Reddy
Conference paper
Part of the Lecture Notes in Mechanical Engineering book series (LNME)


Electro Discharge Machining (EDM) is an unconventional machining process used to make hard metal tools and complex shapes, which are difficult to machine by the conventional machining process. Additive manufacturing is the process of creating a 3D object from a CAD Model by adding one layer over another layer. In this work, it is proposed to fabricate an EDM electrode using Direct Metal Laser Sintering (DMLS) 3D printing process and compare its performance with conventional EDM electrodes in terms of Material Removal Rate (MRR), Tool Wear Rate (TWR), and surface finish. The material used for printing the EDM electrode is aluminum AlSi10 Mg and it is proposed to print it on the Direct Metal Laser Sintering 3D Printing machine. The workpiece material used for the EDM process is steel alloy 681-08 of grade D3. The experiment is conducted on EDM with the DMLS electrode and conventional electrode by varying the peak Current (I), Pulse on time (Ton), and Pulse off time (Toff). A comparison of MRR, TWR, and surface roughness is made varying the above-mentioned parameters.




  1. 1.
    Mahipal Reddy L, Siva Rama Krishna L, Sharath Kumar S, Ravinder Reddy, P (2018) Estimation of electrical conductivity of ABS and PLA based EDM electrode fabricated by using FDM 3D printing process. IJMERT 5(Special Issue):332–338Google Scholar
  2. 2.
    Equbal A, Sood AP (2014) Metallization on FDM parts using chemical deposition technique. Coatings 4:574–586CrossRefGoogle Scholar
  3. 3.
    Fefar Savan D, Karajagikar JS (2014) Study and analysis of metallized electrode fabricated with FDM rapid prototyping technique for electro discharge machining. In: IITGuwahati—conference AIMTDRC-2014, vol 15(3), pp 171–176Google Scholar
  4. 4.
    Amorim FL et al (2014) Selective laser sintering of Mo-CuNi composite to be used as EDM electrode. Rapid Prototyp J 59–68 (Emerald publications)Google Scholar
  5. 5.
    Amorim FL et al (2013) Performance of sinking EDM electrodes made by selective laser sintering technique. Int J Adv Manuf Technol 65:1423–1428CrossRefGoogle Scholar
  6. 6.
    Meena VK, Nagahanumaiah (2006) Optimization of EDM machining parameters using DMLS electrodes. Rapid Prototyp J 12(4):222–228CrossRefGoogle Scholar
  7. 7.
    Stucker BE, Bradley WL (1995) The production of electrical discharge machining electrodes using SLS: preliminary results. Research gate Article, pp 278–286Google Scholar
  8. 8.
    Kechagias J et al (2008) EDM electrode manufacture using rapid tooling: a review. J Mater Sci 43:2522–2535 (Springer)CrossRefGoogle Scholar
  9. 9.
    Patel N (2015) Review on importance of electrodes in electrical discharge machining process. Int J Res Aeronaut Mech Eng 3:36–41Google Scholar
  10. 10.
    Equbal A, Dixit NK, Sood AK (2013) Rapid prototyping application in manufacturing of EDM electrode. Int J Sci Eng Res 4(8):1–4Google Scholar
  11. 11.
    Mohanty SD, Mohanty RC (2017) Study on performance of EDM electrodes produced through rapid tooling route. J Adv Manuf Syst 16(4):357–374CrossRefGoogle Scholar
  12. 12.
    Mathalai Sundaram C, Sivasubramanian R, Chandrasekaran K (2016) Experimental investigations of new powder metallurgy electrode in electrical discharge machining of OHNS using Taguchi method. Int J Adv Engg Technol VII(I):559–564Google Scholar
  13. 13.
    Allen SM, Sachs EM (2000) Three-dimensional printing of metal parts for tooling and other applications. Met Mater 6(6):589–594CrossRefGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2020

Authors and Affiliations

  • L. Mahipal Reddy
    • 1
    Email author
  • L. Siva Rama Krishna
    • 1
  • S. Sharath Kumar
    • 1
  • P. Ravinder Reddy
    • 2
  1. 1.Department of Mechanical Engineering, UCE (A)Osmania UniversityHyderabadIndia
  2. 2.Chaitanya Bharathi Institute of TechnologyHyderabadIndia

Personalised recommendations