Obrabotka Metallov / Metal Working and Material ScienceObrabotka Metallov / Metal Working and Material ScienceОбработка металлов (технология • оборудование • инструменты)1994-63092541-819XНовосибирский государственный технический университет35666810.17212/1994-6309-2025-27.4-148-179EQUIPMENT. INSTRUMENTSОБОРУДОВАНИЕ. ИНСТРУМЕНТЫReview ArticleModern methods of manufacturing of complex-profile electrode-tools for electrical discharge machining: a literature reviewСовременные методы изготовления сложнопрофильных электродов-инструментов для электроэрозионной обработки (обзор исследований)https://orcid.org/0000-0001-6607-469256042858500O-3065-20177038-0533AblyazTimur R.АблязТимур Ризович
Russian Federation

Ph.D. (Engineering), Associate Professor

канд. техн. наук, доцент

lowrider11-13-11@mail.ruhttps://pstu.ru/basic/glossary/staff/?sid=1875https://orcid.org/0009-0006-4478-380357215008365AHE-7173-20228770-1384OsinnikovIlya V.ОсинниковИлья Владимирович
Russian Federation

Assistant

Ассистент

ilyuhaosinnikov@bk.ruhttps://pstu.ru/basic/glossary/staff/-sid=63/?sid=-3442https://orcid.org/0000-0001-8076-050956700243700G-9837-20193563-2987ShlykovEvgeniy S.ШлыковЕвгений Сергеевич
Russian Federation

Ph.D. (Engineering)

канд. техн. наук

Kruspert@mail.ruhttps://pstu.ru/basic/glossary/staff/?sid=-966https://orcid.org/0000-0001-7612-802536096206900H-3735-20116608-6251MuratovKarim R.МуратовКарим Равилевич
Russian Federation

D.Sc. (Engineering), Professor

доктор техн. наук, профессор

Karimur_80@mail.ruhttps://pstu.ru/basic/glossary/staff/?sid=1865https://orcid.org/0009-0009-2693-658059329692400KMY-6687-20245019-1979BlokhinVladimir B.БлохинВладимир Борисович
Russian Federation

Teaching Laboratory Specialist

учебный мастер

warkk98@mail.ruPerm National Research Polytechnic UniversityПермский национальный исследовательский политехнический университет274VOL 27, NO4 (2025)ТОМ 27, №4 (2025)14817907122025Copyright ©; 2025, Ablyaz T.R., Osinnikov I.V., Shlykov E.S., Muratov K.R., Blokhin V.B.Copyright ©; 2025, Абляз Т.Р., Осинников И.В., Шлыков Е.С., Муратов К.Р., Блохин В.Б.2025Ablyaz T.R., Osinnikov I.V., Shlykov E.S., Muratov K.R., Blokhin V.B.Абляз Т.Р., Осинников И.В., Шлыков Е.С., Муратов К.Р., Блохин В.Б.https://creativecommons.org/licenses/by/4.0https://journals.rcsi.science/1994-6309/article/view/356668

Introduction. Pilot production plays an important role in modern mechanical engineering. Copy-piercing electrical discharge machining (CPEDM) technology has become widespread in machining pilot parts manufactured in flexible production flows. Manufacturing tool-electrodes (TE) is one of the main stages of the CPEDM technological cycle. Purpose of the work. Review of existing studies of modern methods of manufacturing tool-electrodes for electrical discharge machining. Research methods. A literature review of studies in the field of electrical discharge machining devoted to tool-electrodes, carried out mainly over the past 20 years, is presented. Various configurations of structural elements machined using CPEDM technology, as well as TE configurations for their machining, are described. The dependences of the influence of the geometric parameters of the simplest TE configurations on the output parameters of CPEDM are shown. The main groups of TE manufacturing methods are identified. The limitations, advantages, and disadvantages of alternative methods to traditional ones are described. The main trends in the development of modern TE manufacturing methods are revealed. Results and discussion. Based on the literature review of modern research in the field of electrical discharge machining, current trends in the development of tool-electrode configurations are presented, and problems in the manufacture of complex-shaped tool-electrodes using traditional methods are identified. It has been established that among the alternative methods for manufacturing tool-electrodes, investment casting, powder metallurgy, and additive methods are of greatest interest to modern scientists. It has been shown that each method has its own advantages and disadvantages, confirmed by a number of studies. The following current areas of development of complex-shaped tool-electrodes and methods for their manufacture are highlighted: topological optimization of tool-electrodes, use of modern high-tech casting methods; expansion of the range of tool-electrodes materials with improved electrical discharge properties; optimization of powder metallurgy modes, FDM printing, and selective laser melting; increasing the thickness and quality of tool-electrodes coatings obtained using rapid prototyping technologies.

Введение. В современном машиностроении важную роль играет опытное производство. Технология копировально-прошивной электроэрозионной обработки (КПЭЭО) получила широкое распространение при обработке опытных деталей, изготавливаемых на потоках гибкого производства. Изготовление электродов-инструментов (ЭИ) является одним из основных этапов технологического цикла КПЭЭО. Цель работы. Обзор существующих исследований современных методов изготовления электродов-инструментов для электроэрозионной обработки. Методы исследования. Произведен обзор научной литературы на тему исследований в области электроэрозионной обработки, посвященных электродам-инструментам, преимущественно за последние 20 лет. Описаны различные конфигурации конструктивных элементов, обрабатываемых с помощью технологии КПЭЭО, а также конфигурации ЭИ для их обработки. Показаны зависимости влияния геометрических параметров ЭИ простейших конфигураций на выходные параметры КПЭЭО. Выделены основные группы методов изготовления ЭИ. Описаны ограничения, преимущества и недостатки методов, альтернативных традиционным. Выявлены основные тенденции развития современных методов изготовления ЭИ. Результаты и обсуждение. На основании обзора литературы, посвященной современным исследованиям в области электроэрозионной обработки, приведены современные тенденции развития конфигураций электродов-инструментов, выявлены проблемы изготовления сложнопрофильных электродов-инструментов традиционными методами. Установлено, что среди альтернативных методов изготовления электродов-инструментов наибольший интерес современных ученых вызывают литье по выплавляемым моделям, порошковая металлургия и аддитивные методы. Показано, что для каждого метода характерны свои преимущества и недостатки, подтвержденные рядом исследований. Выделены актуальные направления развития сложнопрофильных ЭИ и методов их изготовления: топологическая оптимизация электродов-инструментов, использование современных высокотехнологичных методов литья; расширение номенклатуры материалов ЭИ с повышенными электроэрозионными свойствами; оптимизация режимов порошковой металлургии, FDM-печати и селективного лазерного сплавления; повышение толщины и качества покрытий электродов-инструментов, полученных с применением технологий быстрого прототипирования.

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