MATERIAL DEPOSITION FOR PATTERN GENERATION USING W–Cu SINTERED TOOL IN REVERSE EDM

Abstract

This experimental study explores the possibility of pattern generation in the reverse electric discharge machining (EDM) process using powder metallurgical (PM) sintered tool electrodes. The experimentation is conducted to generate a complex-shaped pattern by transferring tool materials using PM sintered tools on the surface of Aluminium 6061. The selected controlling process parameters are compact load (CL), pulse on-time ([Formula: see text]), and peak current ([Formula: see text]) where surface roughness (Ra) and edge deviation (ED) are chosen as output parameters. A minimum Ra of 2.6[Formula: see text][Formula: see text]m and minimum ED of 14.79[Formula: see text][Formula: see text]m are obtained at CL of 20 tons, [Formula: see text] of 2[Formula: see text]A and [Formula: see text] of 100[Formula: see text][Formula: see text]s. The surface characteristics of the deposited pattern are analyzed by FESEM, EDS, and XRD studies which confirm the migration of tool constituents on the pattern surface. The thickness of the deposit is found to be 86.25[Formula: see text][Formula: see text]m. The migration of tool particles increases the surface hardness more than four times of base material.