Structuring of wear-affected copper electrodes for electrical discharge machining using Pulse Electrochemical Machining

The wear in electrical discharge machining exerts a great influence on the result and quality of the workpiece being machined. Especially complex structures can lead to high costs for electrode preparation. In this investigation a process chain is set up using copper electrodes machined by Pulse Electrochemical Machining for structuring hard metal by die-sinking electrical discharge machining. After investigating the electrochemical machining behavior of copper, suitable parameters are defined for this wear-free working process. In the succeeding electrical discharge machining three consecutive structuring steps are performed using a new tool electrode each time. Reproducing four complex structures and estimating a validation factor for the reproducibility, it is shown that the introduced sequence can be used for machining complex shapes on hard metal. (C) 2015 Elsevier Ltd. All rights reserved.