Complex-Shaped Tool Fabrication using Powder Metallurgy in EDM.

This paper presents an innovative technique for fabricating complex-shaped powder metallurgical (PM) tool electrodes using electrical discharge machining (EDM). This approach enhances design flexibility in tool fabrication, enabling selective surface treatments and pattern generation. The tool made of 75% tungsten (W) and 25% copper (Cu), is compacted and pasted to a copper shank by conductive materials. The tool design is initially generated using AutoCAD software and processed on the wire-cut EDM machine. The final tool is then produced through die-sinking EDM operations in reverse polarity. Key input parameters include compact load (CL), peak current (I p ) and pulse on-time (Ton), while the output responses are tool wear rate (TWR), unwanted material transfer rate (MTRU) and edge deviation (ED). The study reports several significant numerical findings related to the fabrication of complex-shaped PM tool electrodes using the EDM process. These parameters lead to notable performance outcomes, with a minimum TWR of 10.14 mg/min, MTRU of 1.56 mg/min and ED of 18.71 μ m, showcasing the effectiveness of the process in achieving the desired tool characteristics. The process offers an efficient solution for producing complex geometries suitable for different applications. [ABSTRACT FROM AUTHOR]