Development of electrical discharge machining (EDM) electrode using fused deposition modeling (FDM)

Abstract

Rapid prototyping (RP) is an innovating additive technology for creating functional prototypes and physical models directly from CAD model. Rapid Tooling (RT) is typically used to describe a process which either uses a Rapid Prototyping (RP) model as a pattern to create a mold quickly or uses the Rapid Prototyping process directly to fabricate a tool for a limited volume of prototypes. In this work, ABS electrode was metalized by electroless copper coating to make the RP electrode conductive. Applying a thin coating of copper to prototyped parts by electroless metallization has provided direct method from model to tool. Fused deposition modeling (FDM) process of rapid prototyping is employed to develop the electrode for electro-discharge machining (EDM). This revolutionary approach offer both designers and manufacturers attractive advantages of time compression and cost reduction. Time saving is of vital significance in production of EDM electrode for the fabrication of moulds and dies. The performance of these new type of electrode were compared with those obtained conventionally in term of, Surface Roughness (Ra), Tool Wear Rate (TWR), Working Time, Material Removal Rate (MRR) by using input parameters such as discharge Current, discharge Time, and discharge Voltage.