Performance Evaluation of Electrical Discharge Machining using Ultrafine-Grained Cu Electrodes Processed by Equal Channe
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Performance Evaluation of Electrical Discharge Machining using Ultrafine-Grained Cu Electrodes Processed by Equal Channel Angular Pressing and Deep Cryogenic Treatment Kun Xia Wei, Zhu Qi Chu, Li Chen Yang, Wei Wei
, Qing Bo Du, Igor V. Alexandrov, and Jing Hu
Submitted: 7 April 2020 / Revised: 1 November 2020 / Accepted: 8 November 2020 The role of the electrode in electric discharge machining (EDM) performance is crucial because it has an impact on the geometrical accuracy, machining efficiency and surface finish of the machined components. In the present work, a new technical approach combining equal channel angular pressing (ECAP) and deep cryogenic treatment (DCT) was put forward to manufacture copper electrodes for enhancing the machining characteristics of electric discharge machining (EDM). Effects of the ECAP, the ECAP + DCT on the EDM performances including the electrode wear rate (EWR), the workpiece corner sharpness (WCS), the surface roughness (Ra) and the surface characteristics of EDM workpieces have been investigated. The EWR after the ECAP and the ECAP + DCT was reduced to the minimum after two passes of ECAP. The EWR and WCS after the ECAP + DCT were less than that after the ECAP due to the higher hardness and electrical conductivity. The Ra of EDM workpieces using electrodes processed by the ECAP + DCT was slightly less than that after ECAP. An analogous Hall–Petch relation between the Ra of EDM workpieces and the grain size of electrodes was observed, indicating that ultrafine-grained electrodes processed by ECAP and the additional DCT would enhance the surface finish. The surface finish of EDM workpieces was discussed based on the features of the surface morphology. Keywords
copper electrode, deep cryogenic treatment, electrode wear, equal channel angular pressing, surface roughness
1. Introduction There is no contact between the electrode and the work piece during the electrical discharge machining (EDM) process. That is why this a non-contact machining process helps to eliminate mechanical stresses during machining, and facilitate machining of high-hardness conductive materials with complex geometries. However, it exhibits major drawbacks in the EDM process including deterioration of electrode wear, surface damage and formation of a thin and brittle heat-affected zone. Kun Xia Wei and Zhu Qi Chu have contributed equally to this work. Kun Xia Wei, Zhu Qi Chu, Li Chen Yang, Wei Wei, Qing Bo Du, and Jing Hu, School of Materials Science and Engineering, Changzhou University, 1 Gehu Road, Changzhou 213164, Peoples Republic of China; and Jiangsu Key Laboratory of Materials Surface Science and Technology, Sino-Russia Joint Laboratory of Functional Nanostructured Materials, Changzhou University, Changzhou 213164, Peoples Republic of China; and Igor V. Alexandrov, Jiangsu Key Laboratory of Materials Surface Science and Technology, SinoRussia Joint Laboratory of Functional Nanostructured Materials, Changzhou University, Changzhou 213164, Peoples Republic of China;
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