Improvement of Performance Evaluation Using Hybrid Composite Electrode (Cu/Cr/WC/Ag) in Electric Discharge Machining

Abstract

is a major difficulty in electrical discharge machining (EDM). Due to their exceptional electrical and thermal properties, composite electrodes of various metals have become extremely popular. In this study, a composite electrode (Cu-1%Cr-0.5%WC-1%Ag) manufactured using the stir casting technique will be utilized to evaluate the electrical discharge machining (EDM) process. The study compares the performance between conventional pure copper electrodes and composite electrode utilization of stainless steel 304L as the workpiece material. The results indicate composite electrodes can increase machining effectiveness and reduce electrode wear. Utilizing a current of 10 A, with a pulse on time of 50µs followed by a pulse off time of 50 µs, reduced the tool wear rate to 0.215 gm/min for the composite electrode. By comparison, it was observed that the copper electrodes displayed a tool wear rate of 0.514 gm/min under the same conditions. While the pure copper electrode had the lowest material removal rate (MRR) at 54.5588 mm 3 /min, the composite electrode had the greatest MRR at 56.8689 mm 3 /min. The surface Roughness (SR) of the composite electrode was 3.747 μm; this value was lower than that of t he pure copper electrode, 3.967 μm. As a result, composite electrodes present a potentially viable substitute for traditional EDM electrodes.