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Electric Discharge Machining (EDM) is one of the most popular non-traditional machining processes applied for machining very hard conductive materials with desired shape, size and dimensional accuracy. In this paper, copper-coated aluminum alloy is applied as EDM electrode instead of copper electrode. Electrodeposition, simple and economical process, was used for preparation of copper coating on aluminum alloy. The method of anodization was applied in order to get a strong adhesive copper coating on aluminum alloy substrate. Taguchi-based design of experiment technique were used to form relationship of process parameters and response variables. The copper-coated surface was characterized with XRD report. Lower tool wear rate (TWR), surface roughness (SR) and higher material removal irate (MRR) were found for copper-coated aluminum alloy EDM electrode compare to uncoated aluminum alloy electrode.

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Performance Analysis of Copper-Coated Aluminum Tool in Electro Discharge Machining of Ti-6Al-4V Alloy

  • 会议论文

  • 发表日期：

    2025年

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  • Van Dua Tran,
  • Shailesh S. Shirguppikar,
  • L. Selvarajan,
  • Van Bong Pham,
  • Anh Nguyen Mai

摘要

Electric Discharge Machining (EDM) is one of the most popular non-traditional machining processes applied for machining very hard conductive materials with desired shape, size and dimensional accuracy. In this paper, copper-coated aluminum alloy is applied as EDM electrode instead of copper electrode. Electrodeposition, simple and economical process, was used for preparation of copper coating on aluminum alloy. The method of anodization was applied in order to get a strong adhesive copper coating on aluminum alloy substrate. Taguchi-based design of experiment technique were used to form relationship of process parameters and response variables. The copper-coated surface was characterized with XRD report. Lower tool wear rate (TWR), surface roughness (SR) and higher material removal irate (MRR) were found for copper-coated aluminum alloy EDM electrode compare to uncoated aluminum alloy electrode.