OBRABOTKAMETALLOV Vol. 26 No. 3 2024 146 EQUIPMENT. INSTRUMENTS Features of the use of tool electrodes manufactured by additive technologies in electrical discharge machining of products 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. 3 pp. 135–148 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.3-135-148 ART I CLE I NFO Article history: Received: 11 June 2024 Revised: 25 June 2024 Accepted: 28 June 2024 Available online: 15 September 2024 Keywords: Additive technologies Selective laser melting Copy-piercing electrical discharge machining Current Voltage Pulse on time Surface roughness Tool electrode wear Funding The research was fi nancially supported by the Russian Science Foundation under grant No. 23-29-00104. https:// rscf.ru/project/23-29-00104/ Acknowledgements The authors express their gratitude to Associate Professor of the department. ITM FSAOU VO “PNRPU” Morozov E.A. for assistance in the manufacture of samples of electrode-tools using the SLS method from maraging steel MS1. ABSTRACT Introduction. The paper presents the results of a study of the use of a tool electrode (TE), manufactured by selective laser alloying from MS1 maraging steel powder for copy-piercing electrical discharge machining (EDM). Purpose of the work: experimental study of the features of the use of additively manufactured TE in the EDM of critical products. Research methods. The specimens were prepared using a ReaLizer SLM 50 system. The starting material was spherical MS1 powder with an average particle size of 30 μm. To test the modes and select a TE sample with the least number of surface defects, four manufacturing modes were tested, and the best TE sample was selected for further research. The EDM was carried out on EMT Smart CNC equipment in a dielectric oil environment. The specimens were installed in a clamp with straight polarity and were used as TE; a 0.12C-18Сr-10Ni-Тi steel plate served as the workpiece electrode. The study was conducted using a factorial experiment (type 23) with a central design. The input data of the factorial experiment is the current I (A), voltage U (W), pulse on time Ton (μs). The output parameters were the roughness parameter Ra and tool electrode wear γ. The roughness parameter Ra was measured using a Mahr Perthometer S2. Results and discussion. TE samples were made from MS1 powder using the SLS method; the highest quality TE sample No. 4 was selected for EDM. Empirical equations are obtained that describe the relationship between the roughness parameter Ra and tool electrode wear γ, depending on the EDM modes. At the minimum mode with a current I = 4 A and a voltage U = 50 V, the tool electrode wear is γ = 0.0063875 g. The maximum tool electrode wear is γ = 0.13938 g with a current I = 8 A and a voltage U = 50 V. It is established that at a constant pulse on time Ton = 75 μs, the smallest roughness Ra = 2.83 μm is obtained at a current of I = 4 A and a voltage U = 100 V, and the maximum roughness is Ra = 4.1568 μm at I = 8 A and U = 100 V. For citation: Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Features of the use of tool electrodes manufactured by additive technologies in electrical discharge machining of products. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 3, pp. 135–148. DOI: 10.17212/1994-6309-2024-26.3-135-148. (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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