Optimization of Overcut in EDM of Mirrax Steel Using Copper Alloyed Electrodes

Abstract

In this study, the optimization of overcut in electrical discharge machining (EDM) processes, with a focus on the effects of various process parameters on machining performance, particularly when challenging materials such as Mirrax steel are investigated. A Taguchi-based experimental design was employed to systematically analyze three distinct copper-based alloy electrodes; CuCoNiBe, CuNi2SiCr, and CuCr1Zr under varying discharge currents (6 A, 12 A, 25 A), pulse on-times (50 μs, 100 μs, 200 μs), and pulse off-times (200 μs, 400 μs, 800 μs). It was found that overcut is significantly influenced by the electrode type, discharge current, and pulse duration, with the CuCoNiBe electrode exhibiting the highest overcut values. Analysis of Variance (ANOVA) was conducted to confirm the significant contributions of these parameters to overcut variability. This research contributes to a deeper understanding of the interplay between EDM parameters, in advanced manufacturing applications.

Keywords

• EDM
• Copper
• Overcut
• Taguchi
• Optimization

Bakır Alaşımlı Elektrotlar Kullanılarak Mirrax Çeliğinin EEİ'sinde Yanal Açıklık Optimizasyonu

Abstract

Bu çalışma, Mirrax çeliği gibi işlenmesi zor malzemelerin, işleme parametrelerinin işlebilirlik performansı üzerindeki etkilerine odaklanılarak, Elektrik Erozyon ile İşleme (EEİ) süreçlerinde yanal açıklık optimizasyonu araştırılmıştır. Üç farklı bakır alaşımı elektrotun (CuCoNiBe, CuNi2SiCr ve CuCr1Zr) değişen boşalım akımları (6 A, 12 A, 25 A), vurum süreleri süreleri (50 μs, 100 μs, 200 μs) ve bekleme süreleri (200 μs, 400 μs, 800 μs) altında sistematik olarak analiz etmek için Taguchi tabanlı bir deneysel tasarım kullanılmıştır. Yanal açıklığın elektrot tipi, boşalım akımı ve vurum süresinden önemli ölçüde etkilendiği ve CuCoNiBe elektrotun en yüksek yanal açıklık değerlerini gösterdiği bulunmuştur. Bu parametrelerin yanal açıklık üzerindeki etkilerini belirlemek için Varyans Analizi (ANOVA) kullanılmıştır. Bu çalışma, gelişmiş imalat uygulamalarında EDM parametreleri arasındaki etkileşimin daha iyi anlaşılmasına katkı sağlamaktadır.

Keywords

• EEİ
• Yanal açıklık
• Taguchi
• Optimizasyon
• Bakır

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