ABSTRACT This work has described about the generation of complex shaped pattern using reverse electro discharge machining process. Powder metallurgical green compact tool has been used to generate a predefined pattern by depositing its constituent materials. A predefined star shaped pattern has been generated on the aluminum 6061 work surface. The pattern has been created by adjusting the process factors like compact load, current and pulse duration. The edge deviation and surface roughness have been considered as the performance measures in this experimentation. An optimum condition has been obtained at compact load of 20 tons, current of 1 A and pulse duration of 100 µs. Minimum surface roughness of 1.7 µm and minimum edge deviation of 13.07 µm have been achieved at this condition. The patterns are characterized by SEM, EDS and XRD analyses. The surface of the patterns is evaluated by a surface profilometer. The layer thickness is evaluated by an optical microscope. The microhardness of newly generated surface of pattern has been found to be of 329 Hv.

中文翻译：

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使用粉末冶金生坯模具生成图案的反向 EDM 工艺

摘要 这项工作描述了使用反向放电加工工艺生成复杂形状的图案。粉末冶金生坯模具已被用于通过沉积其组成材料来生成预定义的图案。在铝 6061 工作表面上生成了预定义的星形图案。该模式是通过调整诸如紧凑负载、电流和脉冲持续时间等工艺因素来创建的。在本实验中，边缘偏差和表面粗糙度被视为性能指标。在 20 吨的紧凑负载、1 A 的电流和 100 µs 的脉冲持续时间下获得了最佳条件。在此条件下已实现 1.7 µm 的最小表面粗糙度和 13.07 µm 的最小边缘偏差。通过SEM、EDS和XRD分析表征图案。通过表面轮廓仪评估图案的表面。通过光学显微镜评估层厚度。已发现新生成的图案表面的显微硬度为 329 Hv。