Abstract
This article introduces a new method for creating embossed-shaped selective deposition as patterns using powder metallurgical green compact tools in electrical discharge machining (EDM). Polyethylene masking is used to cover specific areas of the work surface. Copper and tungsten powders of mesh size 325 are employed for tool fabrication. The selective deposition resulted from variations in compact load, peak current and pulse on-time. Performance is assessed through measurements of surface roughness and edge deviation. At the optimum conditions of compact load of 20 ton, peak current of 2 A and pulse on-time of 50 µs, the lowest surface roughness of 4.10 µm, and edge deviation of 25.11 µm are observed. The masking guided the flow of tool particles to targeted regions, ensuring efficient material deposition while maintaining minimum deviation during the process. The Precision in pattern shape and size depends on selecting suitable process parameters and accurately sculpting the pattern on the masking material. Surface analysis examines the presence of metallic tool powders through morphology studies.
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