Three-dimensional surface topography analysis of die-sinking electrical discharge machined eco-friendly beryllium-free copper alloys
摘要
Beryllium-copper alloys, the most widely used copper alloys, are utilised extensively in diverse sectors, including the electrical, electronics, instrumentation, metallurgy, aerospace, automotive, petrochemical, machinery manufacturing, and die and mould-making industries. The main drawback of these alloys is that they produce the toxic component, beryllium oxide, which can lead to a chronic lung disease known as berylliosis. Beryllium-free copper alloys, such as copper-nickel-silicon-chromium, are eco-friendly, less costly, and possess properties similar to those of beryllium-copper alloys. Hence, they are now replacing beryllium-copper alloys in the applications mentioned earlier. Due to their high strength and hardness, these alloys are often fabricated into components using unconventional machining techniques, such as electrical discharge machining. Electrical discharge machining is particularly advantageous in industrial applications where precisely controlled random surface textures on these alloys are required. However, despite the industrial significance, research on the electrical discharge machining process of copper-nickel-silicon-chromium alloys is scarce. Therefore, the current work aims to address this research gap by conducting an experimental investigation of the random surfaces generated on copper-nickel-silicon-chromium alloy components after the die-sinking electrical discharge machining process through a comprehensive three-dimensional surface topography analysis. Three-dimensional surface topography parameters overcome the drawbacks of two-dimensional roughness parameters by considering the majority of surface points. This work investigates the effects of input factors, including electrode material, dielectric fluid material, flushing condition, and current on nearly all relevant areal texture (3D) parameters. ANOVA is performed to study the level of significance of each input parameter. The regression analyses reveal that current is the most significant input parameter for most areal texture parameters, followed by dielectric fluid and electrode materials. The flushing condition had minimal effect, marking a new direction for future research. The significance of each areal texture parameter was discussed from an application point of view, highlighting the potential impact of the findings. A SEM image analysis revealed that the thickness of white layer formed increased as roughness increases.