Levent URTEKİN, Fatih BOZKURT, Hacı ÖZERKAN, Can ÇOĞUN, İbrahim USLAN

Ti6Al4V Alaşımının Elektro Erozyon ile İşlemesinde Elektrolitik Cu ve CuBe Takım Elektrotlarının Performansının Karşılaştırılması

Elektro erozyonla işlemede en önemli maliyet unsuru takım elektrodunun (elektrodun) üretimidir. Bakır, bakır alaşımları ve grafit en yaygın kullanılan elektrot malzemeleridir. Yüksek iş parçası işleme hızlı (MRR), düşük takım aşınma hızlı (TWR), düşük üretim ve malzeme maliyetli uygun elektrot malzemesinin seçilmesi, EDM ile işleme maliyetlerini düşürmenin anahtarıdır. Bu çalışmada, Ti6Al4V alaşımının işlenmesinde CuBe takım elektrotlarının EDM performansı, farklı bekleme süresi (ts) ve akım boşalımı (I) ayarları için elektrolitik Cu (E-Cu) elektrotlara kıyasla deneysel olarak incelenmiştir. CuBe elektrotlarla işlemede MRR'de bir artış, TWR'de ve relatif aşınmada (RW = TWR / MRR) bir azalma gözlenmiştir. Bununla birlikte, CuBe alaşımının yüksek hammadde maliyeti, bu elektrotların endüstriyel uygulamalarda yaygın olarak kullanılmasında önemli bir dezavantajdır. Elektrodun üretim maliyetini ve ömrünü etkileyen EDM uygulamaları için yeni bir performans indeks formülasyonu tanıtıldı. Sonuçlarımıza göre CuBe, orta akım ayarlarında elektrot malzemesi olarak avantajlı bir şekilde kullanılabilir. Ancak düşük ve yüksek akım ayarlarında E-Cu'nun hammadde maliyetinin düşük olması onu daha avantajlı hale getirmektedir.

Anahtar Kelimeler:

Elektoerozyon ile işleme, takım elektrodu, CuBe alaşımı, elektrolitik bakır, Ti6Al4V

The Comparison of Performance of Electrolytic Cu and CuBe Tool Electrodes in Electric Discharge Machining of Ti6Al4V Alloy

The most crucial cost element of Electric Discharge Machining (EDM) is the production of tool electrode (shortly electrode). Copper, its alloys, and graphite are the most commonly used electrode materials. Selecting the proper electrode material with low production and material cost, high workpiece material removal rate (MRR) and low tool electrode wear rate (TWR) is key to reducing machining costs with EDM. In this study, the EDM performance of CuBe tool electrodes in the machining of Ti6Al4V alloy was experimentally investigated in comparison to electrolytic Cu (E-Cu) electrodes for different pulse time (ts) and discharge current (I) settings. An increase in MRR and a decrease in TWR and relative wear (RW=TWR/MRR) were observed in machining with CuBe electrodes. However, the high raw material cost of CuBe alloy is an essential drawback in widely using these electrodes in industrial applications. A new performance index formulation is introduced for EDM applications that factor in the production cost of the electrode and its life (i.e., RW). According to our results, the CuBe could be used advantageously as the electrode material at medium current settings. However, at low and high current settings, the low raw material cost of E-Cu makes it more favorable.

Keywords:

Electrical discharge machining, tool electrode, CuBe alloy, electrolytic copper, Ti6Al4V,

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