Characteristics of Ternary Metal (Cu-Ni-TiN) Electrodes Used in an Electrical Discharge Machining Process
Abstract
:1. Introduction
2. Experimental Procedure
2.1. Material Data
2.2. Material Setup
2.3. Characterization Techniques
3. Results and Discussion
3.1. Structural Analysis Results
3.2. Hardness Property Results
3.3. Electric Resistivity Results
3.4. Density/Porosity Results
3.5. Material Removal Rate Results
3.6. Electrode Wear Ratio Results
3.7. Surface Roughness Results
4. Conclusions
- The appropriate calcination temperature for yielding the highest hardness (115.43 HV) was determined to be 1100 °C.
- The 80% Cu–3% Ni–17% TiN electrode obtained at a pressure of 18 MPa had the highest hardness of 124.38 HV and the lowest electric resistivity of 0.39188 Ω·cm.
- The 85% Cu–3% Ni–12% TiN electrode manufactured at a pressure of 20 MPa showed the highest density of 8.5472 g/cm3 and the lowest porosity of 6.2922%. The main elements were continuously dispersed throughout the electrode, and the element concentration reflected the ratio after sintering.
- The porosities and densities of the electrodes differed because each metal had a different melting temperature. Therefore, there was an imbalance in the mass transfer during diffusion, which depended on the temperature and duration of sintering, leading to different levels of homogeneous substance.
- The lowest material removal rate of 0.0038 g/min was obtained for the 80% Cu–3% Ni–17% TiN electrode manufactured at 22 MPa, and the lowest electrode wear ratio of 9.46% was detected in the 90% Cu–3% Ni–7% TiN electrode compressed at 18 MPa.
- The average surface roughness of the tungsten carbide surface obtained by machining with the Cu–Ni–TiN electrode was the lowest (1.183 μm) because the melting temperatures of TiNi and TiCu yielded similar results, leading to the smallest wear ratio and a good surface quality.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
- Hugh, B. Alloy Phase Diagrams; ASM Handbook; ASM International Materials Park: Novelty, OH, USA, 1992; Volume 3. [Google Scholar]
- Janmanee, P.; Kumjing, S. A study of tungsten carbide surfaces during the electrical discharge machining using artificial neural network model. Int. J. Appl. Eng. Res. 2017, 12, 3214–3227. [Google Scholar]
- Janmanee, P. Performance of Cu-Cr-Zr electrodes in electrical discharge machining of tungsten carbide composite material base using Taguchi method. Int. J. Mach. Mach. Mater. 2016, 18, 412–425. [Google Scholar] [CrossRef]
- Jamkamon, K.; Janmanee, P. Improving machining performance for deep hole drilling in the electrical discharge machining process using a step cylindrical electrode. Appl. Sci. 2021, 11, 2084. [Google Scholar] [CrossRef]
- Gupta, A.; Kumar, H.; Nagdeve, L.; Arora, P.K. EDM parametric study of composite materials: A review. Evergreen 2020, 7, 519–529. [Google Scholar] [CrossRef]
- Gostimirovic, M.; Kovac, P.; Sekulic, M.; Skoric, B. Influence of discharge energy on machining characteristics in EDM. J. Mech. Sci. Technol. 2012, 26, 173–179. [Google Scholar] [CrossRef]
- Panchal, D.L.; Biradar, S.K.; Gosavi, V.Y. Analysis of EDM Process Parameters by Using Coated Electrodes. Int. J. Eng. Trends Technol. 2016, 41, 181–185. [Google Scholar] [CrossRef]
- Zaw, H.; Fuh, J.; Nee, A.; Lu, L. Formation of a new EDM electrode material using sintering techniques. J. Mater. Process. Technol. 1999, 89–90, 182–186. [Google Scholar] [CrossRef]
- Mohri, N.; Saito, N.; Tsunekawa, Y. Metal Surface Modification by Electrical Discharge Machining with Composite Electrode. Ann. CIRP 1993, 42, 219–222. [Google Scholar] [CrossRef]
- Pramanik, A.; Basak, A. Sustainability in wire electrical discharge machining of titanium alloy: Understanding wire rupture. J. Clean. Prod. 2018, 198, 472–479. [Google Scholar] [CrossRef]
- Ramulu, M.; Spaulding, M. Drilling of hybrid titanium composite laminate (HTCL) with electrical discharge machining. Materials 2016, 9, 746. [Google Scholar] [CrossRef] [PubMed] [Green Version]
- Machno, M. Impact of process parameters on the quality of deep holes drilled in Inconel 718 using EDD. Materials 2019, 12, 2298. [Google Scholar] [CrossRef] [Green Version]
- Pramanik, A.; Islam, M.N.; Boswell, B.; Yu, D.; Guy, L. Accuracy and finish during wire electric discharge machining of metal matrix composites for different reinforcement size and machining conditions. Proc. Inst. Mech. Eng. B J. Eng. Manuf. 2018, 232, 1068–1070. [Google Scholar] [CrossRef] [Green Version]
- Pramanik, A.S.; Chattopadhyaya, B.A. A novel approach towards sustainable electrical discharge machining of metal matrix composites (MMCs). Int. J. Adv. Manuf. Technol. 2020, 198, 1477–1486. [Google Scholar]
- Beri, N.; Maheshwari, S.; Sharma, C.; Kumar, A. Technological Advancement in Electrical Discharge Machining with Powder Metallurgy Processed Electrodes: A Review. Mater. Manuf. Process. 2010, 25, 1186–1197. [Google Scholar] [CrossRef]
- Pramanik, A. Developments in the non-traditional machining of particle reinforced metal matrix composites. Int. J. Mach. Tools Manuf. 2014, 86, 44–61. [Google Scholar] [CrossRef] [Green Version]
- Pramanik, A. Problems and solutions in machining of titanium alloys. Int. J. Adv. Manuf. Technol. 2014, 70, 919–928. [Google Scholar] [CrossRef]
- Pilligrin, J.C.; Asokan, P.; Jerald, J.; Kanagaraj, G. Effects of electrode materials on performance measures of electrical discharge micro-machining. Mater. Manuf. Process. 2017, 33, 606–615. [Google Scholar] [CrossRef]
- Taylan, A.; Blaine, L.; Yen, Y.C.; Taylan, A. Manufacturing of Dies and Molds. CIRP Ann. 2001, 50, 404–422. [Google Scholar]
- Amitava, M.; Amit, R.D.; Chattopadhyaya, S.; Paramanik, A.; Sergej, H.; Grzegorz, K. Improvement of surface integrity of Nimonic C 263 superalloy produced by WEDM through various post-processing techniques. Int. J. Adv. Manuf. Technol. 2017, 93, 433–443. [Google Scholar]
- Pramanik, A.; Basak, A.K.; Islam, M.N.; Littlefair, G. Electrical discharge machining of 6061aluminium alloy. Trans. Nonferrous Met. Soc. China 2015, 25, 2866–2874. [Google Scholar] [CrossRef]
- Pramanik, A.; Basak, A. Degradation of wire electrode during electrical discharge machining of metal matrix composites. Wear. 2016, 346, 124–131. [Google Scholar] [CrossRef] [Green Version]
- Bartkowiak, T.; Mendak, M.; Mrozek, K.; Wieczorowski, M. Analysis of Surface Microgeometry Created by Electric Discharge Machining. Materials 2020, 13, 3830. [Google Scholar] [CrossRef]
- Korlos, A.; Tzetzis, D.; Mansour, G.; Sagris, D.; David, C. The delamination effect of drilling and electro-discharge machining on the tensile strength of woven composites as studied by X-ray computed tomography. Int. J. Mach. Mach. Mater. 2016, 18, 426–448. [Google Scholar] [CrossRef]
- Agureev, L.; Kostikov, V.; Eremeeva, Z.; Savushkina, S.; Ivanov, B.; Khmelenin, D.; Belov, G.; Solyaev, Y. Influence of Alumina Nanofibers Sintered by the Spark Plasma Method on Nickel Mechanical Properties. Metals 2021, 11, 548. [Google Scholar] [CrossRef]
- Tsai, H.; Yan, B.; Huang, F. EDM performance of Cr/Cu-based composite electrodes. Int. J. Mach. Tools Manuf. 2003, 43, 245–252. [Google Scholar] [CrossRef]
- Fonda, P.; Wang, Z.; Yamazaki, K.; Akutsu, Y. A fundamental study on Ti–6Al–4V’s thermal and electrical properties and their relation to EDM productivity. J. Mater. Process. Technol. 2008, 202, 583–589. [Google Scholar] [CrossRef]
- Chaiyasak, P.; Kalnaowakul, P.; Rodchanarowan, A. The investigation of magnetic property and corrosion resistance of the assisted Sol-Gel synthesis of Ti/Ni/Co nanocomposites. Surf. Coat. Technol. 2020, 393, 125800. [Google Scholar] [CrossRef]
- Dong, S.; Wang, Z.Y.; Liu, H. An experimental investigation of enhancement surface quality of micro-holes for Cr-Cu alloys using micro-EDM with a multidiameter electrode and different dielectrics. Procedia CIRP 2016, 42, 257–262. [Google Scholar] [CrossRef]
- Padhi, S.K.; Mahapatra, S.S.; Das, H.C. Performance of a copper electroplated plastic electrical discharge machining electrode compared to a copper electrode. Int. J. Pure Appl. Math. 2017, 114, 459–469. [Google Scholar]
- Ho, K.H.; Newman, S.T. State of the art electrical discharge machining (EDM). Int. J. Mach. Tools Manuf. 2003, 43, 1287–1300. [Google Scholar] [CrossRef]
- Davim, J.P. Nontraditional Machining Processes; Springer: London, UK, 2013. [Google Scholar]
- Kolar, D.; Pejovnik, S. Sintering Theory and Practice; Elsevier: Amsterdam, The Netherlands, 1982. [Google Scholar]
- Li, L.; Wong, Y.; Fuh, J.; Lu, L. Effect of TiC in copper—Tungsten electrodes on EDM performance. J. Mater. Process. Technol. 2001, 113, 563–567. [Google Scholar] [CrossRef]
- Vernickaite, E.; Tsyntsaru, N.; Cesiulis, H. Electrochemical co-deposition of tungsten with cobalt and copper: Peculiarities of binary and ternary alloys coatings formation. Surf. Coat. Technol. 2016, 307, 1341–1349. [Google Scholar] [CrossRef]
- Srivastava, V.; Pandey, P.M. Study of ultrasonic assisted cryogenically cooled EDM process using sintered (Cu–TiC) tooltip. J. Manuf. Process. 2013, 15, 158–166. [Google Scholar] [CrossRef]
- Li, L.; Feng, L.; Bai, X.; Li, Z.Y. Surface characteristics of Ti–6Al–4V alloy by EDM with Cu–SiC composite electrode. Appl. Surf. Sci. 2016, 288, 546–550. [Google Scholar] [CrossRef]
- Chen, Y.-F.; Chow, H.-M.; Lin, Y.-C.; Lin, C.-T. Surface modification using semi-sintered electrodes on electrical discharge machining. Int. J. Adv. Manuf. Technol. 2008, 36, 490–500. [Google Scholar] [CrossRef]
- Jeswani, M.L. Effects of the addition of graphite powder to kerosene used as the dielectric fluid in electrical discharge machining. Wear 1981, 70, 133–139. [Google Scholar] [CrossRef]
- Kiyak, M.; Çakır, O. Examination of machining parameters on surface roughness in EDM of tool steel. J. Mater. Process. Technol. 2007, 191, 141–144. [Google Scholar] [CrossRef]
- Kansal, H.K.; Singh, S.; Kumar, P. Parametric optimization of powder mixed electrical discharge machining by response surface methodology. J. Mater. Process. Technol. 2005, 169, 427–436. [Google Scholar] [CrossRef]
- Lee, H.-T.; Tai, T. Relationship between EDM parameters and surface crack formation. J. Mater. Process. Technol. 2003, 142, 676–683. [Google Scholar] [CrossRef]
- Bozkurt, B.; Gadalla, A.M.; Eubank, P.T. Simulation of erosion in a single discharge EDM process. Mater. Manuf. Process. 1996, 11, 555–563. [Google Scholar] [CrossRef]
Powder Properties | Cu | Ni | TiN |
---|---|---|---|
Purity (%) | 99.00 | 99.90 | 99.90 |
Density (g/cm3) | 8.96 | 8.88 | 5.22 |
Melting Point (°C) | 1083 | 1455 | 2930 |
Electric Resistivity (Ω·cm) | 1.70 × 10−6 | 6.40 × 10−6 | 6.0 × 10−3 |
Thermal Conductivity (W/m·K) | 383 | 65.5 | 19.2 |
Electrode Code | Composite Electrode Ratio (%) | ||
---|---|---|---|
Cu | Ni | TiN | |
A | 100 | - | - |
B | 80 | 3 | 17 |
C | 85 | 3 | 12 |
D | 88 | 3 | 9 |
E | 90 | 3 | 7 |
F | 93 | 3 | 4 |
Elements (wt.%) | Cu | Ni | Co | Ti |
80.17 | 3.02 | 0.81 | 16.00 |
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. |
© 2021 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
Share and Cite
Saodaen, R.; Janmanee, P.; Rodchanarowan, A. Characteristics of Ternary Metal (Cu-Ni-TiN) Electrodes Used in an Electrical Discharge Machining Process. Metals 2021, 11, 694. https://doi.org/10.3390/met11050694
Saodaen R, Janmanee P, Rodchanarowan A. Characteristics of Ternary Metal (Cu-Ni-TiN) Electrodes Used in an Electrical Discharge Machining Process. Metals. 2021; 11(5):694. https://doi.org/10.3390/met11050694
Chicago/Turabian StyleSaodaen, Rattikorn, Pichai Janmanee, and Aphichart Rodchanarowan. 2021. "Characteristics of Ternary Metal (Cu-Ni-TiN) Electrodes Used in an Electrical Discharge Machining Process" Metals 11, no. 5: 694. https://doi.org/10.3390/met11050694