Study of Machining Parameters by Pure Copper and Brass Powder Metallurgy Tool Electrode in EDM

Abstract

In manufacturing today powder metallurgy has become competitive with processes such as casting, forging and machining particularly for relatively complex parts made of high-strength and hard alloys. Recent advances in this technology now permit manufacture of structural parts of aircraft such as landing gear, engine mount supports, engine disks, impellers and engine nacelle frames to be made by powder metallurgy operation. The aim of this paper is to design an appropriate electrode for EDM equipment by powder metallurgy operation. Based on appropriate design conditions and economic factors this paper performs a detailed study on various air cooled and furnace cooled Cu and brass electrodes and the most appropriate electrode is chosen so that machining with the electrode would be suitable for carrying out large machining operations. EDM gives highly accurate dimensional tolerances and better surface finish. So the whole paper investigates the appropriate electrode and proper production and machining parameters to optimize the machining costs occurring during machining by EDM. From production point of view the electrodes fabricated by powder metallurgy technique is more economical than electrodes manufactured by other manufacturing processes. Based on the economic considerations, quality factors and ease of availability copper and brass were selected as appropriate materials for the electrode. Comparatively air cooled copper electrode was found to be more suitable than brass electrode for machining on EDM