OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 1 2024 Introduction BeCu alloys, or beryllium copper alloys, are very reliable materials with outstanding fatigue strength, hardness, wear resistance, and non-magnetic characteristics that are utilized in a variety of industries. A consistent, homogeneous liquid solution is obtained by combining beryllium and copper, which is a distinctive feature of the microstructure. Copper frequently retains its face-centered cubic form, and beryllium becomes a crucial part of the copper crystal. When copper atoms are replaced by beryllium atoms in the same lattice regions, a substitutional solid solution is produced. BeCu alloys have been used to create breaker reeds, diaphragms, control valves, switchgear components, and all varieties of fl at and coil springs. High electrical conductivity and toughness have also been used in plastic extrusion dies and specialty tooling. However, there are several problems when utilizing traditional machining methods to cut BeCu alloys. Due to the high strength of BeCu alloys, it is problematic to maintain the integrity of the surface of the fi nished product, and increased tool wear occurs during machining. BeCu alloys have good thermal and electrical properties, which make electrical discharge machining safe and eff ective. For cutting hard materials, electrical discharge machining (EDM) is a practical technique [1–6]. Due to the complexity of the process, numerous studies on electrical discharge machining have been conducted to determine its’ optimal parameters [7–10]. The main objective of this research is to develop a production system that improves material removal rate (MRR). Using machine learning (ML) techniques, a group of researchers created performance prediction models for EDM, including MRR [11–13]. EDM process modeling development was discussed in detail by Ming et al. [14]. Shastri et al. [15] assessed the eff ects of cooling, ultrasonic machining, powder mixture machining, and cryogenic machining on performance indicators such MRR, tool wear rate (TWR), surface integrity, and recast layer. Boopathi [16] off ered a comprehensive analysis of the literature on diff erent dielectric fl uids, previously unknown and sustainable innovations, process parameters, machining characteristics, and optimization strategies used in various dry and near-dry EDMs. The purpose of combining dry and near-dry EDM research was to support environmentally friendly EDM research projects. The impact of EDM die sinking settings on the MRR of BeCu alloys was examined by Ali et al. [17]. The eff ects of EDM settings on the MRR, tool wear, relative electrode wear, and surface roughness of NiTi alloys were examined by Daneshmand et al. [18]. The voltage, discharge current, pulse-on time, and pulse-off time are some of these parameters. The tests were designed using the L18 orthogonal matrix using the Taguchi methodology. The eff ects of current, voltage, tool rotation, Al2O3 powder, MRR, TWR, and surface roughness were examined by Daneshmand et al. [19]. The results show that the MRR can be increased by using Al2O3 powder, rotating the tool, and raising the voltage, current strength, and pulse width. The eff ects of electrical discharge machining on the environment, human health, and safety were examined by Baroi et al. [20]. The eff ects of cryogenic treatment on Inconel 718 work material were investigated by Kannan et al. [21]. The cooling eff ect of copper electrodes during the electrical discharge die sinking of a titanium alloy (Ti-6Al-4V) was investigated by Abdulkareem et al. [22]. The eff ects of cooling on workpiece surface roughness and electrode wear have been studied. In order to fi nd out how the Ti 6246 alloy’s machinability was infl uenced by deep cryogenic treatment, Gill and Singh [23] used an electrolytic copper tool to drill blind holes 10 mm in diameter. Furthermore, a comparison was conducted between the untreated Ti 6246 alloy and the deep cryogenically treated Ti 6246 alloy in terms of surface roughness and overcut of holes. Copper electrode cooling during electrical discharge machining (EDM) of a workpiece composed of M2-grade high-speed steel was investigated by Srivastava and Pandey [24]. Machinability was evaluated using electrode wear ratio (EWR) and surface roughness (SR). A study by Yildiz et al. [25] investigated the eff ect of cryogenic and cold processing on the EDM machinability of BeCu alloy workpieces. The BeCu alloy was treated at temperatures of about −150°F (−100 °С) for cold treatment and −300°F (−185 °С) for cryogenic treatment in this investigation. The titanium EDM machining properties were studied by Singh and Singh [26] both before and after the tool and workpiece were cryogenically treated. The study’s output metrics included dimensional accuracy, surface roughness, TWR, and MRR. Copper’s thermal conductivity was greatly enhanced by
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