Electro discharge machining performance of cryogenic heat treated copper electrode

Savaş Apak; Mustafa Ay

doi:10.1515/mt-2024-0055

Article

Electro discharge machining performance of cryogenic heat treated copper electrode

Savaş Apak
Savaş Apak graduated from Fırat University, Faculty of Technical Education, Department of Mechanical Education, Machining Production Teaching Program in 2008. In 2010, he started to work as a Mold and Machine Technology Field Teacher. In 2017, he completed his master’s degree at Fırat University Institute of Science and Technology, Department of Mechatronics Engineering, Mechanical Systems Program. He is still working as a teacher.
and Mustafa Ay
Mustafa Ay, born in 1972, received his PhD degree in Machine Science from the University of Firat, Elazig, Turkey, in 2013. He is an Assistant Professor in the Manufacturing Division of the Mechatronics Department, Technology Faculty, Firat University, Elazig, Turkey. His current research areas include advanced manufacturing methods, CAD/CAM, three-dimensional modeling, design and robotics.

Published/Copyright: August 7, 2024

Published by

Become an author with De Gruyter Brill

Submit Manuscript Author Information

From the journal Materials Testing Volume 66 Issue 9

Abstract

In this study, the EDM machining performance of a cryogenic heat treated copper electrode was investigated. Within the scope of the study, electrodes selected from copper material were subjected to cryogenic heat treatment with a cycle between [room temperature/ − 184 °C/room temperature]. In the experimental design, the electrode material was changed at two levels: copper electrode (Cu) and cryogenic copper electrode (CCu). Controllable machine parameters, peak current (Ip), active pulse duration (Ton), pulse gap duration (Toff) and gap voltage (Vg) were changed at three levels. The effects of these parameters on outputs such as recast layer thickness (RLT), material removal rate (MRR), electrode wear rate (EWR) and taper angle (TA), which are taken into consideration in determining the processing quality after EDM machining experiments, were taken into account. A total of 18 experiments were carried out on Ti–6Al–4V (Titanium alloy) workpiece with copper electrode. Lower YKTK with combinations of EDM process parameters such as cryogenic copper electrode (CCu), 4 A peak current (Ip), 110 µs active pulse duration (Ton), 72 µs pulse gap time (Toff) and 6 V gap voltage (Vg), It was observed that EWR and TA and higher MRR were obtained.

Keywords: cryogenic heat treatment; EDM; Ti–6Al–4V

Corresponding author: Mustafa Ay, Department of Mechatronics Engineering, 37510 Firat Universitesi , Elazig, 23119, Türkiye, E-mail: mustafaay@firat.edu.tr

About the authors

Savaş Apak

Savaş Apak graduated from Fırat University, Faculty of Technical Education, Department of Mechanical Education, Machining Production Teaching Program in 2008. In 2010, he started to work as a Mold and Machine Technology Field Teacher. In 2017, he completed his master’s degree at Fırat University Institute of Science and Technology, Department of Mechatronics Engineering, Mechanical Systems Program. He is still working as a teacher.

Mustafa Ay

Mustafa Ay, born in 1972, received his PhD degree in Machine Science from the University of Firat, Elazig, Turkey, in 2013. He is an Assistant Professor in the Manufacturing Division of the Mechatronics Department, Technology Faculty, Firat University, Elazig, Turkey. His current research areas include advanced manufacturing methods, CAD/CAM, three-dimensional modeling, design and robotics.

Acknowledgments

This research was supported by the FÜBAP TEKF 17 11 project. We thank because of the financial support and guiding reports.

Research ethics: We declare that this article describes the original work and has not been published elsewhere or is not currently under consideration for publication elsewhere. Not applicable.
Author contributions: Apak S, experimental design and experiments, obtaining data, analyzing data interpretation of the results and writing the paper. Ay M, determining the study topic, having the idea, controlling, interpreting the results and writing the article. The author(s) have (has) accepted responsibility for the entire content of this manuscript and approved its submission.
Competing interests: The author states no conflict of interest.
Research funding: This research was supported by the FÜBAP TEKF 17 11 project.
Data availability: Not applicable.

References

[1] M. Ay and F. Yücelişli, “Investigation of the effect of process parameters on cutting quality in fiber laser cutting of Ti-6Al-4V alloy,” Firat University, Eng. Bil. J., vol. 30, no. 2, pp. 215–223, 2018.Search in Google Scholar

[2] S. Apak, “Optimization of process parameters for the improvement of dimensional tolerances in the machining of Ti6al4v superalloy with an electro-erosion machine” Master thesis, Fırat University, Elazığ, Turkey, 2019.Search in Google Scholar

[3] E. Nas, “Analysis of the electrical discharge machining (EDM) performance on Ramor 550 armor steel,” Mater. Test., vol. 62, no. 5, pp. 481–491, 2020, https://doi.org/10.3139/120.111510.Search in Google Scholar

[4] D. Bhaduri, A. S. Kuar, S. Sarkar, S. K. Biswa, and S. Mitra, “Electro discharge machining of titanium nitride-aluminium oxide composite for optimum process criteria yield,” Mater. Manuf. Processes, vol. 24, no. 12, pp. 1312–1320, 2009, https://doi.org/10.1080/10426910902996987.Search in Google Scholar

[5] V. Yılmaz, “Deep micro-hole drilling of Hardox 500 by electro-discharge machining,” Mater. Test., vol. 58, no. 1, pp. 69–74, 2016, https://doi.org/10.3139/120.110821.Search in Google Scholar

[6] M. Prabu, S. Magibalan, C. Senthilkumar, R. Palanivelu, P. Senthilkumar, and R. Boopathi, “Modeling of machining parameters for MRR and TWR in EDM characteristics on Al/10 wt.-% TiB2 composites,” Mater. Test., vol. 61, no. 6, pp. 559–566, 2019, https://doi.org/10.3139/120.111355.Search in Google Scholar

[7] R. Boopathi, S. Sundaram, C. Senthilkumar, and M. Prabu, “Effect of machining characteristics of nano-TiC mixed dielectric fluids on Inconel 718 in the EDM process,” Mater. Test., vol. 59, no. 4, pp. 402–408, 2017, https://doi.org/10.3139/120.111002.Search in Google Scholar

[8] H. I. Medellin, D. F. DeLange, J. Morales, and A. Flores, “Experimental study on electro discharge machining in water of D2 tool steel using two different electrode materials,” Proc. Inst. Mech. Eng., Part B: J. Eng. Manuf, vol. 223, no. 11, pp. 1423–1430, 2009, https://doi.org/10.1243/09544054JEM1573.Search in Google Scholar

[9] B. H. Yan, H. C. Tsai, and F. Y. Huang, “The effect in EDM of a dielectric of aurea solution in water on modifying the surface of titanium,” Int. J. Mach. Tools Manuf., vol. 45, pp. 194–200, 2005, https://doi.org/10.1016/j.ijmachtools.2004.07.006.Search in Google Scholar

[10] M. Sofu, E. Hamamcı, and M. Kayacan, “Effect of cutting parameters on surface roughness and wire consumption during wire electro-discharge machining,” Mater. Test., vol. 59, no. 3, pp. 278–283, 2017, https://doi.org/10.3139/120.110998.Search in Google Scholar

[11] T. Teker and I. Dalmis, “Yilmaz Effect of heat treatment on the wear behavior of GX200Cr13Ni6WMoMn,” Mater. Test., vol. 61, no. 5, pp. 441–447, 2019, https://doi.org/10.3139/120.111339.R.Search in Google Scholar

[12] N. Vasudevan, G. Bhaskar, T. Rao, and M. Mohandass, “Mechanical properties of cryogenically treated AA5083 friction stir welds,” Mater. Test., vol. 61, no. 12, pp. 1129–1134, 2019, https://doi.org/10.3139/120.111430.Search in Google Scholar

[13] F. Kara and A. Takmaz, “Optimization of cryogenic treatment effects on the surface roughness of cutting tools,” Mater. Test., vol. 61, no. 11, pp. 1101–1104, 2019, https://doi.org/10.3139/120.111427.Search in Google Scholar

[14] A. Y. L. Yong and K. H. W. Seah, “Rahman Performance evaluation of cryogenically treated tungsten carbide tools in turning,” Int. J. Mach. Tools Manuf., vol. 46, no. 15, pp. 2051–2056, 2006, https://doi.org/10.1016/j.ijmachtools.2006.01.002.M.Search in Google Scholar

[15] S. Lomte, R. Deshmukh, T. Sonar, M. Ivanov, and V. Balasubramanian, “Effect of deep cryogenic processing cycles on surface roughness, dimensional stability and microstructure of high carbon high chromium tool steel for cutting tool and dies applications,” Mater. Test., vol. 65, no. 4, pp. 629–640, 2023, https://doi.org/10.1515/mt-2022-0435.Search in Google Scholar

[16] L. Singh and J. Singh, “Effect of cryogenic treatment on the microstructure and wear behavior of a T-42 tool steel,” Mater. Test., vol. 57, no. 4, pp. 306–310, 2015, https://doi.org/10.3139/120.110720.Search in Google Scholar

[17] A. Kumar, S. Maheshwari, C. Sharma, and N. Beri, “Machining efficiency evaluation of cryogenically treated copper electrode in additive mixed EDM,” Mater. Manuf. Processes, vol. 27, no. 10, pp. 1051–1058, 2012, https://doi.org/10.1080/10426914.2011.654151.Search in Google Scholar

[18] S. S. Gill and J. Singh, “Effect of deep cryogenic treatment on machinability of titanium alloy (Ti-6246) in electric discharge drilling,” Mater. Manuf. Process, vol. 25, no. 6, pp. 378–385, 2010, https://doi.org/10.1080/10426910903179914.Search in Google Scholar

[19] A. Sing and N. K. Grover, “Wear properties of cryogenic treated electrodes on machining of en-31,” Mater. Today Proc., vol. 2, no. 4–5, pp. 1406–1413, 2015, https://doi.org/10.1016/j.matpr.2015.07.060.Search in Google Scholar

[20] J. M. Jafferson and P. Hariharan, “Machining performance of cryogenically treated electrodes in micro electric discharge machining: a comparative study,” Mater. Manuf. Process, vol. 28, no. 4, pp. 397–402, 2013, https://doi.org/10.1080/10426914.2013.763955.Search in Google Scholar

[21] S. Datta, B. B. Biswal, and S. S. Mahapatra, “Electrical discharge machining of Inconel 825 using cryogenically treated copper electrode: emphasis on surface integrity and metallurgical characteristics,” J. Manuf. Processes, vol. 26, pp. 188–202, 2017, https://doi.org/10.1016/j.jmapro.2017.02.020.Search in Google Scholar

[22] H. Singh and A. Singh, “Wear behavior of AISI D3 die steel using cryogenic treated copper and brass electrode in electric discharge machining,” Int. J. Modern Eng. Res., vol. 2, no. 6, pp. 4462–4464, 2012.Search in Google Scholar

[23] A. Çetin, G. Çakır, K. Aslantaş, N. Uçak, and A. Çiçek, “Performance of cryogenically treated Cu and CuCrZr electrodes in an EDM process,” Kovove Materialy, vol. 55, pp. 431–440, 2017, https://doi.org/10.4149/km_2017_6_431.Search in Google Scholar

[24] N. S. Kalsi, R. Sehgal, and V. S. Sharma, “Cryogenic treatment of tool materials: a review,” Mater. Manuf. Processes, vol. 25, no. 10, pp. 1077–1100, 2010, https://doi.org/10.1080/10426911003720862.Search in Google Scholar

[25] S. Alagarsamy and M. Ravichandran, “Variation of electrode materials and parameters in the EDM of an AA7075-TiO2 composite,” Mater. Test., vol. 63, no. 2, pp. 182–189, 2021, https://doi.org/10.1515/mt-2020-0025.Search in Google Scholar

[26] S. H. Lee and X. P. Li, “Study of the effect of machining parameters on the machining characteristics in the electrical discharge machining of tungsten carbide,” J. Mater. Process. Technol., vol. 115, pp. 344–358, 2001, https://doi.org/10.1016/S0924-0136(01)00992-X.Search in Google Scholar

[27] W. S. Lau, M. Wang, and W. B. Lee, “Electrical discharge machining of carbon fibre composite materials,” Int. J. Mach. Tools Manuf., vol. 30, pp. 297–308, 1990, https://doi.org/10.1016/0890-6955(90)90138-9.Search in Google Scholar

[28] H. M. Chow, B. H. Yan, F. Y. Huang, and J. C. Hung, “Study of added powder in kerosene for the micro-slit machining of Titanium alloy using electro-discharge machining,” J. Mater. Process Technol., vol. 101, pp. 95–103, 2000, https://doi.org/10.1016/S0924-0136(99)00458-6.Search in Google Scholar

Published Online: 2024-08-07

Published in Print: 2024-09-25

You are currently not able to access this content.

Articles in the same Issue

https://doi.org/10.1515/mt-2024-0055

Keywords for this article

cryogenic heat treatment; EDM; Ti–6Al–4V