Manufacturing of tool electrodes with optimized configuration for copy-piercing electrical discharge machining by rapid prototyping method

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Introduction. This paper presents the results of obtaining a complex-profile tool electrode (TE) for copy-and-pierce electrical discharge machining by casting technology. This method consists in using a master model by rapid prototyping method. The purpose of the work: experimental study of accuracy assurance in manufacturing of complex-profile TE by casting with the use of rapid prototyping technology for copy-piercing electrical discharge machining. Research Methods. The master model of TE was produced on the Envisiontec Perfactory XEDE machine using stereolithography technology. Si500 photopolymer was used as a starting material. Intermediate and final surface deviation measurements were performed on a Contura Carl Zeiss G2 CMM. Calculation of the gutter and feed system was performed in ProCast software. A casting was obtained from casting brass LC40S (Cu-40 Zn-Pb). The study of the process of copy-piercing electrical discharge machining of TE made by casting with the use of rapid prototyping technology was carried out with the help of Smart CNC copy-piercing machine in the environment of transformer oil. Operating parameters: pulse turn-on time (Ton, μs), voltage (U, V), current (I, A). Results and discussion. The methodology of design and manufacturing of complex-profile TE with application of rapid prototyping technology for copy-piercing electrical discharge machining is developed. The analysis of shape deviation shows that errors occur during the manufacturing of the master model by stereolithography. An experimental study of the shape deviation of the master model shows surface concavity in the range of 0.03 to 0.07 mm depending on the arrangement of the sides. It is shown that the optimized master model has 25 % less shape deviation. A sprue-feeding system (SFS) is developed for the fabrication of TE by casting technology. When porosity is evaluated, it is found that pores are concentrated in the SFS and riser, which positively affects the quality of the casting. Manufacturing of the tool electrode with the help of casting technology showed that all accuracy and roughness parameters are within the specified tolerance and correspond to the initial drawing data. Experimental study of the process of electroerosion machining of the profile groove of the TE manufactured by casting on the investment casting model obtained with the use of rapid prototyping technology is carried out. It is established that the dimensions of the obtained groove meet the stated requirements.

About the authors

T. R. Ablyaz

Email: lowrider11-13-11@mail.ru
ORCID iD: 0000-0001-6607-4692
Ph.D. (Engineering), Associate Professor, Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation, lowrider11-13-11@mail.ru

V. B. Blokhin

Email: warkk98@mail.ru
ORCID iD: 0009-0009-2693-6580
Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation, warkk98@mail.ru

E. S. Shlykov

Email: Kruspert@mail.ru
ORCID iD: 0000-0001-8076-0509
Ph.D. (Engineering), Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation, Kruspert@mail.ru

K. R. Muratov

Email: Karimur_80@mail.ru
ORCID iD: 0000-0001-7612-8025
D.Sc. (Engineering), Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation, Karimur_80@mail.ru

I. V. Osinnikov

Email: ilyuhaosinnikov@bk.ru
ORCID iD: 0009-0006-4478-3803
Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation, ilyuhaosinnikov@bk.ru

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