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2 2025

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Effect of Hybrid Composite Electrode (Cu/Cr/Wc/Ag) on Surface Integrity of Stainless Steel 304l Machined by EDM

Abdulwahhab Ahmed Basil, Ibrahim Abbas F.

Management Systems in Production Engineering

2025

nr 1 (33)

136--143

Electrical Discharge Machining (EDM) is a modern technique extensively utilized across various industries to eliminate material using electrical discharges. Within the realm of EDM, a key obstacle involves identifying appropriate electrode materials capable of withstanding elevated temperatures and effectively eroding material from workpieces. Composite electrodes are becoming more commonly employed to tackle this issue, as a result of their exceptional electrical and thermal properties. The performance of a composite electrode that has been specifically improvement with (Cu-3%Cr-0.5%WC-1%Ag) is evaluated in this study using the stir casting technique. The investigation utilized stainless steel 304L as the workpiece material, and the performance of the composite electrode was evaluated against traditional pure copper electrodes. The results indicate that composite electrodes can decrease electrode wear and increase machining efficiency. The tool wear rate (TWR) for the composite electrode decreased to 0.0398 gm/min with a current of 10 A and a pulse-on time of 50 µs, along with a pulse-off time of 50 µs. In contrast, under the same conditions, the copper tool exhibited a TWR of 0.514 gm/min. The composite electrode achieved the highest material removal rate (MRR) at 59.7917 mm3/min, surpassing the copper electrode which had the lowest MRR at 54.5588 mm3/min. Additionally, the Surface Roughness (SR) of the composite electrode was measured at 3.253 μm, lower than the 3.967 μm of the pure copper electrode. These findings suggest that composite electrodes could serve as a viable substitute for conventional EDM electrodes.

Optimization of fused deposition modeling parameters to enhance tensile strength and surface roughness of polyethylene terephthalate glycol

Shabeeb Alaa Hassan, Abdulwahhab Ahmed Basil, Ismael Hameed S., Ghazi Safaa Kadhim

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 8

345--358

The wide examination of FDM as an industrial additive manufacturing technique appears because it provides design freedom alongside improved material efficiency and reasonable cost. This study's main objective is to investigate the relationship of Fused Deposition Modeling (FDM) process parameters with the tensile properties and surface roughness of Polyethylene terephthalate glycol (PETG) parts. A response surface methodology (RSM) utilizing Box–Behnken design methodology studied three essential parameters consisting of infill density and layer height, together with plate temperature. The analysis demonstrated that layer height proved to be the main element affecting tensile strength because it contributed 80.9% of the experimental variations, while infill density stood out as the leading determinant of surface roughness, which was responsible for 78% of the contribution. Experimental testing proved that the predictive model showed accurate results when validated through measurements of tensile strength, which produced maximum errors of 1.28%, and surface roughness, which yielded maximum errors of 6.54%. A desirability analysis indicated that the ideal parameters of the roughness and tensile strength of the printed parts included an infill density of 64.24% combined with a layer height of 0.1813 mm and plate temperature of 51.46°C. These outcomes provide a comprehensive understanding of process parameter effects that result in quality PETG parts with mechanical performance. The two-axis optimization methodology for PETG also enhances its use in functional engineering systems that require simultaneous mechanical durability and manufacturing accuracy.