Laser-assisted production of electrical discharge machining (EDM) electrodes: A comparative study between rapid prototyping by selective laser sintering and laser surface cladding techniques

2008 ◽  
Author(s):  
R. Comesaña ◽  
F. Lusquiños ◽  
J. del Val ◽  
V. Ventosinos ◽  
R. Vázquez ◽  
...  
Keyword(s):  
Rapid Prototyping ◽  
Comparative Study ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Selective Laser Sintering ◽  
Laser Sintering ◽  
Laser Surface ◽  
Edm Electrodes

Electrical Discharge Machining Electrodes Manufactured via Selective Laser Sintering Technique Using New Composite Materials

2013 ◽  
Author(s):  
Fred Lacerda Amorim ◽  
Tiago Czelusniak ◽  
Camila Higa
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Selective Laser Sintering ◽  
Research Work ◽  
Laser Sintering ◽  
Superior Performance ◽  
Future Research ◽  
Machining Processes ◽  
Functional Components

The cost of a part manufactured by Electrical Discharge Machining (EDM) is mainly determined by electrode cost. The production of electrodes by conventional machining processes is complex, time consuming and can account for over fifty percent of the total EDM process costs. The emerging Additive Manufacturing (AM) technologies provide the possibility of direct fabrication of EDM electrodes. Selective Laser Sintering (SLS) is an alternative AM technique because it has the possibility to directly produce functional components, reducing the tool-room lead time and total EDM costs. The main difficulty of manufacturing an EDM electrode using SLS is the selection of an appropriate material, once both processes require different material properties. The current work focused on the investigation of appropriate materials that fulfill EDM and SLS process demands. Three new metal-matrix materials composed of Mo-CuNi, TiB2-CuNi and ZrB2-CuNi were developed and electrodes under adequate SLS conditions were manufactured. EDM experiments using different discharge energies were carried out and the performance evaluated in terms of material removal rate and volumetric relative wear. The results showed the powder systems composed of Mo-CuNi, TiB2-CuNi and ZrB2-CuNi revealed to be successfully processed by SLS and the EDM experiments demonstrated that the newly composite electrodes possess superior performance when compared to copper powder electrodes made with SLS. The work also suggests important topics for future research work on this field.

An Assessment of Geometric Methods in Trajectory Synthesis for Shape Creating Operations

1998 ◽  
Author(s):  
Radha Sarma
Keyword(s):  
Rapid Prototyping ◽  
Functional Properties ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Trajectory Generation ◽  
Manufacturing Operations ◽  
Geometric Methods

Abstract This paper presents an assessment of the steps involved in trajectory synthesis (e.g., trajectory layout, trajectory generation, trajectory spacing, trajectory postprocessing, and trajectory physics) for shape creating manufacturing operations, e.g., rapid prototyping, milling, electrical discharge machining. The rationale for this paper is that the trajectory plays an important role in determining the productivity as explained below. Shape creating manufacturing operations are those that make use of a “tool” which operates on a “workpiece” to create the desired shape. The tool operates on the workpiece as dictated by the trajectory of the tool, resulting in the manufactured shape. Often, the geometric and functional properties of the end product are dependent on the trajectory of the tool. Moreover, the trajectory dictates the accuracy of the end product and the time taken to manufacture the product. Recognizing the important contribution of the trajectory in shape creating operations, this paper focuses on trajectory synthesis.

An investigation of rapid prototyping of sand casting molds by selective laser sintering

2002 ◽  
Vol 14 (2) ◽  
pp. 100-106 ◽  
Author(s):  
G. Casalino ◽  
L. A. C. De Filippis ◽  
A. D. Ludovico ◽  
L. Tricarico
Keyword(s):  
Rapid Prototyping ◽  
Selective Laser Sintering ◽  
Laser Sintering ◽  
Sand Casting

Laser Compensation for Ceramics Accuracy Improvement of Selective Laser Sintering

2014 ◽  
Vol 902 ◽  
pp. 12-17 ◽  
Author(s):  
Ruey Tsung Lee ◽  
Fwu Hsing Liu ◽  
Ku En Ting ◽  
Sheng Lih Yeh ◽  
Wen Hsueng Lin
Keyword(s):  
Control System ◽  
Feedback Control ◽  
Rapid Prototyping ◽  
Laser Energy ◽  
Selective Laser Sintering ◽  
Laser Sintering ◽  
Feedback Control System ◽  
Well Performance ◽  
Layer Deposition ◽  
Slurry Layer

This research developed a feedback control system of laser compensation for the rapid prototyping (RP) machine using layer-wise slurry deposition and selective laser sintering (SLS). The slurry was prepared by silica power and silica sol with 60 and 40 wt.% with suitable rheological properties for 0.1 mm layer deposition. Four ceramics for comparison of the formability of fabricated ceramic green parts with/without the feedback control system of laser energy density for models were designed With this laser feedback control, batter quality ceramic green parts can be manufactured and the rapid prototyping machine with steady laser energy radiated on slurry layer was achieved. Experimental results validate the well performance of the measuring laser power and feedback control system.

Laser Surface Modification of Wire-Electric Discharge Machined Graphene Nanoparticle Reinforced SiC Composites

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Meinam Annebushan Singh ◽  
Ondrej Hanzel ◽  
Ramesh Kumar Singh ◽  
Pavol Šajgalík ◽  
Deepak Marla
Keyword(s):  
Surface Modification ◽  
Repetition Rate ◽  
Pulse Repetition Rate ◽  
Laser Processing ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Surface Characteristics ◽  
Scanning Speed ◽  
Laser Surface ◽  
Laser Surface Modification

Abstract Electrical discharge machining of conducting ceramics is often associated with high roughness and porosity, which hinders their application. This porosity-laden surface morphology necessitates a postprocessing technique to reduce the severity of the surface defects. Hence, this study focuses on the utilization of a nanosecond pulsed laser as a surface modification tool to minimize the debris and pores formed on the surface after the wire-electrical discharge machining process. This paper presents a study on the influence of laser parameters, viz., power, number of scans, scanning speed, and pulse repetition rate on the overall surface characteristics. The concentration of surface debris and pores were observed to significantly decrease with laser surface modification (LSM). The improvement in the surface characteristics after laser processing with low fluence was mainly attributed to melting, vaporization, and subsequent flow of molten material, which led to filling of the surface pores. This resulted in a more even surface postlaser surface modification. The surface roughness was observed to decrease by ∼49% after the laser processing at lower values of laser power, number of scans, and scanning speed and at higher values of pulse repetition rate. Furthermore, spatial, hybrid, and functional volume characteristics were observed to improve postlaser modification. However, at higher laser fluence, the processed surfaces were observed to get further worsened with the formation of deep ridges.

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