Title: Performance analysis of Cu-B₄C metal matrix composite as an EDM electrode

Authors: V. Senthilkumar; M. Chandrasekar Reddy

Addresses: Department of Production Engineering, National Institute of Technology, Tiruchirappalli – 620 015, Tamil Nadu, India. ' Department of Production Engineering, National Institute of Technology, Tiruchirappalli – 620 015, Tamil Nadu, India

Abstract: Performance of electrode materials is one of the important factors that determine the quality of the machined component and the cost involved in the operation of electro discharge machining (EDM) process. Low electrode wear resistance in graphite and copper electrodes necessitated the development of sintered composite electrodes for EDM operation. In this paper, authors attempted to develop a new copper-based metal matrix composite (Cu-B₄C) to get an optimum combination of wear resistance, electrical and thermal conductivity. Here the copper-boron carbide composite was developed through powder metallurgy route and EDM experiments were carried out using mild steel specimen. Copper composite with 40% boron carbide reinforcement exhibits better metal removal rate (MRR) and tool removal rate (TRR) compared to conventional copper electrode. SEM and XRD results show the surface modification and formation of boron, B₄C reinforced layer on the surface of mild steel work piece when machined with composite electrode.

Keywords: EDM electrodes; metal matrix composites; MMC; sintering; metal removal rate; MRR; tool removal rate; TRR; electrode wear ratio; EWR; electro-discharge machining; electrical discharge machining; mild steel; wear resistance, electrical conductivity; thermal conductivity; copper boron carbide composites; powder metallurgy.

DOI: 10.1504/IJMMM.2012.044921

International Journal of Machining and Machinability of Materials, 2012 Vol.11 No.1, pp.36 - 50

Received: 28 Jun 2010
Accepted: 25 Sep 2010
Published online: 23 Aug 2014 *

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