ELECTROCHEMICAL LABELING OF METAL NON-PLANAR SURFACES

Student: Rodrigo Folgueira

Supervisor: Mr Ruslan Gareev

MAIN IDEA

Constructing of electrochemical tool for labeling metal parts with complex surfaces, and calculating regimes of the labeling.

WHY THIS TOPIC Companies working in the metal sector are

faced with the problem of labeling the metals when they do not have planar surfaces.

There are more than hundred different kinds of metals and many more alloys. For a metal sector company must be necessary to label all this metals and alloys.

ELECTROCHEMICAL DISCHARGUE MACHINING

Scheme of the process:

ABOUT THE PROCESS

ADVANTAGES OF EDM Complex shapes. Extremely hard material to very close

tolerances. Very small work pieces. No direct contact between tool and work piece.

Therefore delicate sections and weak materials can be machined without any distortion.

A good surface finish.

Disadvantages of EDM The slow rate of material removal. The additional time and cost used for creating

electrodes. Reproducing sharp corners on the workpiece is

difficult due to electrode wear. Power consumption is very high. Excessive tool wear occurs during machining. Electrically non-conductive materials can´t be

machined.

THE ELECTRODE Electrode is an electrical conductor used to

make contact with metallic parts of the circuit. (tool and workpiece).

Material of the electrodeThe electrode is made from graphite because it has a high vaporization temperature and is more resistant to wear.

For work in wet/dry. Low termal expansión. Corrosion resistance. Low coefficient of friction. Excelent termal shock. Self-lubricating.

Caracteristics of the Graphite:

Dielectric fluid Dielectric fluid: In EDM, a liquid medium that fills

the gap between the electrode and workpiece and acts as an insulator until a specific gap and voltage are achieved. Used to remove chips and cool the electrode/wire and workpiece.

Kerosene is a good liquid dielectric liquid because it has: high dielectric strength, high thermal stability, low toxicity, good heat transfer properties, and low cost.

The only problem is the flammability.

Design process

Ventilator and filter The function of the ventilator is to move the

fluid inside the distribution channel. The ventilator has a filter in its backside that

cleans the fluid, all the rubbish that is generated will be stopped in the filter.

Electrode

Distribution channel

The principal reasons of the construction of a distribution channel are because the dielectric fluid must be filtered, cooled and recirculated.

Holder The holder is the place where everything will

be joined. Is where the process occurs.

It must be a tight place, as this will solve the problem of combustion in the case of the use of kerosene as a dielectric fuid.

CapacitorA capacitor is a device that stores an electric charge. EDMs require capacitors to generate the electric current used for machining.

Electrode support The Graphite tool must be fixed in a piece that

will be connected to the electricity and provides the energy for the tool.

Thank you for your listening.

Rodrigo Folgueira

Questions