Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

doi:10.1007/s40436-018-0238-5

Advances in Manufacturing ›› 2018, Vol. 6 ›› Issue (4): 442-456.doi: 10.1007/s40436-018-0238-5

Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

Saroj Kumar Padhi¹, S. S. Mahapatra², Rosalin Padhi³, Harish Chandra Das⁴

1 Department of Mechanical Engineering, Koneru Lakshmiah Education Foundation, Deemed to be University, Vaddeswarm 522502, India;
2 Department of Mechanical Engineering, National Institute of Technology Rourkela, Rourkela 769008, India;
3 Department of Physics, Berhampur University, Berhampur 760007, India;
4 Department of Mechanical Engineering, National Institute of Technology Meghalaya, Shillong 793003, India

收稿日期:2017-09-07 修回日期:2018-10-30 出版日期:2018-12-25 发布日期:2018-12-08
通讯作者: Saroj Kumar Padhi,padhisaroj1@gmail.com E-mail:padhisaroj1@gmail.com

Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

Saroj Kumar Padhi¹, S. S. Mahapatra², Rosalin Padhi³, Harish Chandra Das⁴

1 Department of Mechanical Engineering, Koneru Lakshmiah Education Foundation, Deemed to be University, Vaddeswarm 522502, India;
2 Department of Mechanical Engineering, National Institute of Technology Rourkela, Rourkela 769008, India;
3 Department of Physics, Berhampur University, Berhampur 760007, India;
4 Department of Mechanical Engineering, National Institute of Technology Meghalaya, Shillong 793003, India

Received:2017-09-07 Revised:2018-10-30 Online:2018-12-25 Published:2018-12-08
Contact: Saroj Kumar Padhi,padhisaroj1@gmail.com E-mail:padhisaroj1@gmail.com

摘要/Abstract

摘要： The importance of rapid tooling (RT) and additive manufacturing (AM) appears to be indispensable for boosting the process of manufacturing and expanding the horizon of production technology worldwide. This concept draws the attention of numerous scholars to arrive at a conclusive theory for the widespread utilization of RT. This study attempts to determine the viability and performance of an RT electrode in the field of electro discharge machining (EDM). The electrode prototype is made using an acrylonitrile butadiene styrene (ABS) plastic by fused deposition modeling (FDM), an AM technique, electroplated with copper of desired thickness, and used in die sinking EDM of D2 steel. The scanning electron microscope analysis of the electroplated samples confirms that it is possible to obtain the desired thickness of the metal by electroplating on any electrically conductive surface. In the present work, an experimental study is performed for examining the electroplated copper thickness of the plastic EDM electrode and its performances. It is found that the electroplated ABS plastic EDM RT electrode successfully performs the machining operation of D2 steel, and the results are comparable with a solid electrode. The study reveals that the RT electrode can be regarded as a viable tool for rough cutting or semi-finishing cut EDM functions. The experimental results are thoroughly discussed, examined, analyzed, and evaluated for the purpose of developing the appropriate form of the concept.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0238-5

关键词: Additive manufacturing (AM), Fused deposition modeling (FDM), Metallization of acrylonitrile butadiene styrene (ABS) plastic, Reduced silver colloidal, Rapid tooling (RT), Electro discharge machining (EDM)

Abstract: The importance of rapid tooling (RT) and additive manufacturing (AM) appears to be indispensable for boosting the process of manufacturing and expanding the horizon of production technology worldwide. This concept draws the attention of numerous scholars to arrive at a conclusive theory for the widespread utilization of RT. This study attempts to determine the viability and performance of an RT electrode in the field of electro discharge machining (EDM). The electrode prototype is made using an acrylonitrile butadiene styrene (ABS) plastic by fused deposition modeling (FDM), an AM technique, electroplated with copper of desired thickness, and used in die sinking EDM of D2 steel. The scanning electron microscope analysis of the electroplated samples confirms that it is possible to obtain the desired thickness of the metal by electroplating on any electrically conductive surface. In the present work, an experimental study is performed for examining the electroplated copper thickness of the plastic EDM electrode and its performances. It is found that the electroplated ABS plastic EDM RT electrode successfully performs the machining operation of D2 steel, and the results are comparable with a solid electrode. The study reveals that the RT electrode can be regarded as a viable tool for rough cutting or semi-finishing cut EDM functions. The experimental results are thoroughly discussed, examined, analyzed, and evaluated for the purpose of developing the appropriate form of the concept.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0238-5

Key words: Additive manufacturing (AM), Fused deposition modeling (FDM), Metallization of acrylonitrile butadiene styrene (ABS) plastic, Reduced silver colloidal, Rapid tooling (RT), Electro discharge machining (EDM)

Saroj Kumar Padhi, S. S. Mahapatra, Rosalin Padhi, Harish Chandra Das. Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode[J]. Advances in Manufacturing, 2018, 6(4): 442-456.

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Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

Performance analysis of a thick copper-electroplated FDM ABS plastic rapid tool EDM electrode

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