OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method Timur Ablyaz a, Vladimir Blokhin b, Evgeniy Shlykov c, *, Karim Muratov d, Ilya Osinnikov e Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation a https://orcid.org/0000-0001-6607-4692, lowrider11-13-11@mail.ru; b https://orcid.org/0009-0009-2693-6580, warkk98@mail.ru; c https://orcid.org/0000-0001-8076-0509, Kruspert@mail.ru; d https://orcid.org/0000-0001-7612-8025, Karimur_80@mail.ru; e https://orcid.org/0009-0006-4478-3803, ilyuhaosinnikov@bk.ru 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. 4 pp. 138–152 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.4-138-152 ART I CLE I NFO Article history: Received: 13 September 2024 Revised: 08 October 2024 Accepted: 17 October 2024 Available online: 15 December 2024 Keywords: Rapid prototyping method Master model Precision Stereolithography Liquid photopolymer Copy-and-pierce electrical discharge machining Flatness deviation Funding The research was fi nancially supported by the Russian Science Foundation grant No. 23-79-01224, https://rscf.ru/ project/23-79-01224/. Acknowledgements The authors express their gratitude to Associate Professor of the department. ITM Federal Autonomous Educational Institution of Higher Education “Perm National Research Polytechnic University” Shumkov A.A. for assistance in obtaining and designing master models by the rapid prototyping method. ABSTRACT Introduction. This paper presents the results of obtaining a complex-profi le tool electrode (TE) for copy-and-pierce electrical discharge machining by casting technology. This method consists in using a master model by rapid prototyping method. The purpose of the work: experimental study of accuracy assurance in manufacturing of complex-profi le TE by casting with the use of rapid prototyping technology for copypiercing electrical discharge machining. Research Methods. The master model of TE was produced on the Envisiontec Perfactory XEDE machine using stereolithography technology. Si500 photopolymer was used as a starting material. Intermediate and fi nal surface deviation measurements were performed on a Contura Carl Zeiss G2 CMM. Calculation of the gutter and feed system was performed in ProCast software. A casting was obtained from casting brass LC40S (Cu-40 Zn-Pb). The study of the process of copy-piercing electrical discharge machining of TE made by casting with the use of rapid prototyping technology was carried out with the help of Smart CNC copy-piercing machine in the environment of transformer oil. Operating parameters: pulse turn-on time (Ton, μs), voltage (U, V), current (I, A). Results and discussion. The methodology of design and manufacturing of complex-profi le TE with application of rapid prototyping technology for copypiercing electrical discharge machining is developed. The analysis of shape deviation shows that errors occur during the manufacturing of the master model by stereolithography. An experimental study of the shape deviation of the master model shows surface concavity in the range of 0.03 to 0.07 mm depending on the arrangement of the sides. It is shown that the optimized master model has 25 % less shape deviation. A sprue-feeding system (SFS) is developed for the fabrication of TE by casting technology. When porosity is evaluated, it is found that pores are concentrated in the SFS and riser, which positively aff ects the quality of the casting. Manufacturing of the tool electrode with the help of casting technology showed that all accuracy and roughness parameters are within the specifi ed tolerance and correspond to the initial drawing data. Experimental study of the process of electroerosion machining of the profi le groove of the TE manufactured by casting on the investment casting model obtained with the use of rapid prototyping technology is carried out. It is established that the dimensions of the obtained groove meet the stated requirements. For citation: Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 4, pp. 138–152. DOI: 10.17212/1994-6309-2024-26.4-138-152. (In Russian). ______ * Corresponding author Shlykov Evgeniy S., Ph.D. (Engineering), Associate Professor Perm National Research Polytechnic University, 29 Komsomolsky prospect, 614990, Perm, Russian Federation Tel.: +7 961 759-88-49, e-mail: Kruspert@mail.ru
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