MATERIAL DEPOSITION FOR PATTERN GENERATION USING W–Cu SINTERED TOOL IN REVERSE EDM

Rashed Mustafa Mazarbhuiya () and Maneswar Rahang
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Rashed Mustafa Mazarbhuiya: Department of Mechanical Engineering, National Institute of Technology, Meghalaya, Shillong 793003, India
Maneswar Rahang: Department of Mechanical Engineering, National Institute of Technology, Meghalaya, Shillong 793003, India

Surface Review and Letters (SRL), 2025, vol. 32, issue 02, 1-13

Abstract: This experimental study explores the possibility of pattern generation in the reverse electric discharge machining (EDM) process using powder metallurgical (PM) sintered tool electrodes. The experimentation is conducted to generate a complex-shaped pattern by transferring tool materials using PM sintered tools on the surface of Aluminium 6061. The selected controlling process parameters are compact load (CL), pulse on-time (Ton), and peak current (Ip) where surface roughness (Ra) and edge deviation (ED) are chosen as output parameters. A minimum Ra of 2.6μm and minimum ED of 14.79μm are obtained at CL of 20 tons, Ip of 2A and Ton of 100μs. The surface characteristics of the deposited pattern are analyzed by FESEM, EDS, and XRD studies which confirm the migration of tool constituents on the pattern surface. The thickness of the deposit is found to be 86.25μm. The migration of tool particles increases the surface hardness more than four times of base material.

Keywords: EDM; reverse; sintered; powder; metallurgy; pattern (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X24501105

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