Title: Particle strengthening of the surface of copper electrode for electrical discharge machining

Authors: D.M. Guo, M. Zhang, Z.J. Jin, B.X. Zuo

Addresses: Key laboratory for Precision and Non-traditional Machining of Ministry of Education, Dalian University of Technology, Dalian 116023, P.R. China. ' Key laboratory for Precision and Non-traditional Machining of Ministry of Education, Dalian University of Technology, Dalian 116023, P.R. China. ' Key laboratory for Precision and Non-traditional Machining of Ministry of Education, Dalian University of Technology, Dalian 116023, P.R. China. ' Key laboratory for Precision and Non-traditional Machining of Ministry of Education, Dalian University of Technology, Dalian 116023, P.R. China

Abstract: The manufacture of Electrical Discharge Machining (EDM) electrodes for the machining of mould cavities is often an intractable problem, which consumes much money and time. The combination of Rapid Prototyping (RP) with electroforming paves a way to fabricate copper EDM electrodes more rapidly and economically. However, the spark-resistance of the electroformed copper electrode is still not satisfying. To enhance the surface quality of copper electrodes, Cu-ZrB₂ composite coating was electrodeposited and the EDM performance of this new material was studied. The hardness of the composite coatings increases with the increase in ZrB₂ percentage, whereas the incorporation of ZrB₂ particles has little effect on the electrical resistivity of composites. The effects of EDM parameters on the Material Removal Rate (MRR) and Tool Wear Ratio (TWR) of electrodes were investigated. The Cu-ZrB₂ composite coating shows better EDM performance than that of the electroformed copper electrode.

Keywords: composite coatings; electrical discharge machining; EDM parameters; electro-discharge machining; electrodeposition; surface strengthening; copper electrodes; mould cavities; material removal rate; MRR; tool wear ratio.

DOI: 10.1504/IJMPT.2008.015898

International Journal of Materials and Product Technology, 2008 Vol.31 No.1, pp.81 - 87

Published online: 02 Dec 2007 *

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