OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 1 2024 Investigation on the electrical discharge machining of cryogenic treated beryllium copper (BeCu) alloys Dhruv Sawant 1, a, Rujuta Bulakh 1, b, Vijaykumar Jatti 1, c, *, Satish Chinchanikar 2, d, Akshansh Mishra 3, e, Eyob Messele Sefene 4, 5, f 1 Symbiosis Institute of Technology, Pune-412115, Maharashtra State, India 2 Vishwakarma Institute of Information Technology, Kondhwa (Budruk), Pune - 411039, Maharashtra, India 3 School of Industrial and Information Engineering, Politecnico Di Milano, 22 Leoanardo str., Milan, Italy 4 National Taiwan University of Science and Technology, 43 Keelung Rd., Taipei, 106335, Taiwan 5 Bahir Dar Institute of Technology, Bahir Dar, Amhara, Ethiopia a https://orcid.org/0009-0009-9543-690X, dhruv.sawant.btech2022@sitpune.edu.in; b https://orcid.org/0009-0000-4594-3385, rujuta.bulakh.btech2022@sitpune.edu.in; c https://orcid.org/0000-0001-7949-2551, vijaykumar.jatti@sitpune.edu.in; d https://orcid.org/0000-0002-4175-3098, satish.chinchanikar@viit.ac.in; e https://orcid.org/0000-0003-4939-359X, akshansh.mishra@mail.polimi.it; f https://orcid.org/0000-0003-4660-6262, eyobsmart27@gmail.com Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2024 vol. 26 no. 1 pp. 175–193 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.1-175-193 ART I CLE I NFO Article history: Received: 18 November 2023 Revised: 08 January 2024 Accepted: 22 January 2024 Available online: 15 March 2024 Keywords: Beryllium copper Cryogenic treatment Material removal rate White layer thickness Surface crack formation ABSTRACT Introduction. In modern manufacturing world, industries should adapt technological advancements for precision machining of diffi cult-to-machine metals, especially for beryllium copper (BeCu) alloys. The electrical discharge machining of alloys has proven its viability. The purpose of the work. A literature review indicated that the investigation of electrical discharge machining of BeCu alloys is still in its infancy. Furthermore, the cryogenic treatment of workpieces and electrodes in electrical discharge machining has not received much attention from researchers. Moreover, the impact of magnetic fi eld strength on surface integrity and productivity during electrical discharge machining has not attracted much attention from researchers. The methods of investigation. This paper describes the use of electrolytic copper with diff erent gap current values, pulse on periods, and external magnetic strength for electrical discharge machining of BeCu alloys. This paper examines how the material removal rate, the thickness of the white layer, and the formation of surface cracks are aff ected by cryogenic treatment of the workpiece and tool, pulse-on time, gap current, and magnetic strength. Results and Discussion. The combination of the cryogenically treated BeCu workpiece and the untreated Cu electrode had the highest material removal rate among all the combinations of workpieces and tools used in this study. The pulse on-time and the strength of the magnetic fi eld had little infl uence on material removal rate, whereas the gap current had the greatest eff ect. The maximum achieved material removal rate was 11.807 mm3/min. At a high material removal rate, the observed thickness of the white layer on the horizontal surface ranged from 12.92 μm to 14.24 μm. In the same way, the maximum and minimum values for the vertical surface were determined to be 15.58 μm and 11.67 μm, respectively. According to scanning electron microscopy, the layer thickness was less than 20 μm, and barely noticeable surface cracks were observed in specimens with low, medium and high material removal rates. Obviously, due to the cryogenic processing of the workpiece and the external magnetic strength, there was a slight cracking of the surface and the formation of a white layer. For citation: Sawant D., Bulakh R., Jatti V., Chinchanikar S., Mishra A., Sefene E.M. Investigation on the electrical discharge machining of cryogenic treated beryllium copper (BeCu) alloys. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 1, pp. 175–193. DOI: 10.17212/1994-6309-2024-26.1-175-193. (In Russian). ______ * Corresponding author Jatti Vijaykumar S., Ph.D. (Engineering), Professor Symbiosis Institute of Technology, Pune – 412115, Maharashtra State, India Tel.: 91-2028116300, e-mail: vijaykumar.jatti@sitpune.edu.in
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