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<p>The electrical discharge machining (EDM) performance of AlSi10Mg lattice structures, a high strength lightweight alloy used extensively in aerospace and automobile industries, was investigated in this work. Electrode made of materials like tungsten copper (WCu), tungsten carbide (WC), and beryllium copper (BeCu) was used. Taguchi L<sub>18</sub> orthogonal array was utilized before examining the input parameters: polarity, pulse-on/off time, peak current, spark gap, lift time, dielectric pressure, and electrode type. Through a series of 18 tests, geometric correctness, surface roughness (Ra), taper angle, tool wear rate (TWR), and material removal rate (MRR) were measured and assessed. For high efficiency machining, the ideal electrodes to use are WCu electrodes since they have the best MRR (0.0769&#xa0;g/min) and wear ratio (43.91). In addition to performing well in precision essential applications with little taper and runout, WC electrodes have the lowest TWR at 0.0003&#xa0;g/min. By attaining the lowest taper angle of 0.0006° and highly constant circularity at moderate energy and high flush settings, BeCu electrodes also accomplish a fantastic job of balancing tool wear and surface polish. This work provides the optimal electrode parameter settings for high-performance EDM of AlSi10Mg based on a unique multi-response approach that looks at both geometric and volumetric quality measures (MRR, TWR).</p>

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Comparative Analysis of WCu, WC, and BeCu Electrodes Using Taguchi L18 Design for High-Performance EDM of Additively Manufactured AlSi10Mg Lattice Structures

  • 期刊论文

  • 发表日期：

    2026年4月16日

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  • L. Selvarajan,
  • C. K. Murugesan,
  • S. Senthil Kumar,
  • C. Arun

摘要

The electrical discharge machining (EDM) performance of AlSi10Mg lattice structures, a high strength lightweight alloy used extensively in aerospace and automobile industries, was investigated in this work. Electrode made of materials like tungsten copper (WCu), tungsten carbide (WC), and beryllium copper (BeCu) was used. Taguchi L18 orthogonal array was utilized before examining the input parameters: polarity, pulse-on/off time, peak current, spark gap, lift time, dielectric pressure, and electrode type. Through a series of 18 tests, geometric correctness, surface roughness (Ra), taper angle, tool wear rate (TWR), and material removal rate (MRR) were measured and assessed. For high efficiency machining, the ideal electrodes to use are WCu electrodes since they have the best MRR (0.0769 g/min) and wear ratio (43.91). In addition to performing well in precision essential applications with little taper and runout, WC electrodes have the lowest TWR at 0.0003 g/min. By attaining the lowest taper angle of 0.0006° and highly constant circularity at moderate energy and high flush settings, BeCu electrodes also accomplish a fantastic job of balancing tool wear and surface polish. This work provides the optimal electrode parameter settings for high-performance EDM of AlSi10Mg based on a unique multi-response approach that looks at both geometric and volumetric quality measures (MRR, TWR).