Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallization
Abstract Rapid tooling (RT) has evolved into an emerging area in the field of manufacturing for fabricating tools potentially reducing machining time and cost allowing higher levels of geometric freedom. In this work, the application of RT technique in electrical discharge machining (EDM) has been e...
Saved in:
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Nature Portfolio
2025-07-01
|
| Series: | Scientific Reports |
| Subjects: | |
| Online Access: | https://doi.org/10.1038/s41598-025-07020-7 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849768658951208960 |
|---|---|
| author | Anshuman Kumar Sahu Siba Sankar Mahapatra André Martin Andreas Schubert Marco Leite Paulo Peças |
| author_facet | Anshuman Kumar Sahu Siba Sankar Mahapatra André Martin Andreas Schubert Marco Leite Paulo Peças |
| author_sort | Anshuman Kumar Sahu |
| collection | DOAJ |
| description | Abstract Rapid tooling (RT) has evolved into an emerging area in the field of manufacturing for fabricating tools potentially reducing machining time and cost allowing higher levels of geometric freedom. In this work, the application of RT technique in electrical discharge machining (EDM) has been explored. RT tools fabricated by micro stereo-lithography (micro-SLA) are coated with thick copper coatings by electroless metallization and electroplating to be used during EDM to machine 304 L stainless steel work piece material. The performance of the RT tools is compared with massive copper tool results considering output performance measures like material removal rate, tool wear rate, surface roughness, and surface crack density. The machined work piece surfaces and tool surfaces are analyzed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX). The proposed RT tools have shown a higher material removal rate than the conventionally used massive copper tool. In addition, micro-cracks formed on the machined surfaces using RT tools are comparatively less. Nevertheless, the RT tools have higher tool wear rate and higher surface roughness on the machined surfaces as compared to the massive copper tool. |
| format | Article |
| id | doaj-art-6a628d36eb5347f890fa0a7ffe542f9d |
| institution | DOAJ |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-6a628d36eb5347f890fa0a7ffe542f9d2025-08-20T03:03:42ZengNature PortfolioScientific Reports2045-23222025-07-0115111410.1038/s41598-025-07020-7Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallizationAnshuman Kumar Sahu0Siba Sankar Mahapatra1André Martin2Andreas Schubert3Marco Leite4Paulo Peças5IDMEC, Instituto Superior Técnico, Universidade de LisboaDepartment of Mechanical Engineering, National Institute of Technology RourkelaFaculty of Mechanical Engineering, Technische Universität ChemnitzFaculty of Mechanical Engineering, Technische Universität ChemnitzIDMEC, Instituto Superior Técnico, Universidade de LisboaIDMEC, Instituto Superior Técnico, Universidade de LisboaAbstract Rapid tooling (RT) has evolved into an emerging area in the field of manufacturing for fabricating tools potentially reducing machining time and cost allowing higher levels of geometric freedom. In this work, the application of RT technique in electrical discharge machining (EDM) has been explored. RT tools fabricated by micro stereo-lithography (micro-SLA) are coated with thick copper coatings by electroless metallization and electroplating to be used during EDM to machine 304 L stainless steel work piece material. The performance of the RT tools is compared with massive copper tool results considering output performance measures like material removal rate, tool wear rate, surface roughness, and surface crack density. The machined work piece surfaces and tool surfaces are analyzed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX). The proposed RT tools have shown a higher material removal rate than the conventionally used massive copper tool. In addition, micro-cracks formed on the machined surfaces using RT tools are comparatively less. Nevertheless, the RT tools have higher tool wear rate and higher surface roughness on the machined surfaces as compared to the massive copper tool.https://doi.org/10.1038/s41598-025-07020-7Electrical discharge machiningMicro stereo-lithographyRapid toolingElectroless coatingElectroplating |
| spellingShingle | Anshuman Kumar Sahu Siba Sankar Mahapatra André Martin Andreas Schubert Marco Leite Paulo Peças Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallization Scientific Reports Electrical discharge machining Micro stereo-lithography Rapid tooling Electroless coating Electroplating |
| title | Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallization |
| title_full | Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallization |
| title_fullStr | Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallization |
| title_full_unstemmed | Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallization |
| title_short | Electrical discharge machining by rapid tools prepared by micro stereo-lithography process with copper metallization |
| title_sort | electrical discharge machining by rapid tools prepared by micro stereo lithography process with copper metallization |
| topic | Electrical discharge machining Micro stereo-lithography Rapid tooling Electroless coating Electroplating |
| url | https://doi.org/10.1038/s41598-025-07020-7 |
| work_keys_str_mv | AT anshumankumarsahu electricaldischargemachiningbyrapidtoolspreparedbymicrostereolithographyprocesswithcoppermetallization AT sibasankarmahapatra electricaldischargemachiningbyrapidtoolspreparedbymicrostereolithographyprocesswithcoppermetallization AT andremartin electricaldischargemachiningbyrapidtoolspreparedbymicrostereolithographyprocesswithcoppermetallization AT andreasschubert electricaldischargemachiningbyrapidtoolspreparedbymicrostereolithographyprocesswithcoppermetallization AT marcoleite electricaldischargemachiningbyrapidtoolspreparedbymicrostereolithographyprocesswithcoppermetallization AT paulopecas electricaldischargemachiningbyrapidtoolspreparedbymicrostereolithographyprocesswithcoppermetallization |