FW: lom parts for edm

From: Stuart Hogarth (stuart.hogarth@unn.ac.uk)
Date: Sat Nov 02 1996 - 02:58:00 EET


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From: jfdegug
To: Phil Hackney
Subject: Re: RP and Electro discharge machining
Date: 21 October 1996 09:39

Phil Hackney wrote:
>
> I am currently looking at research posibilities in Rapid tooling
>
> What work is being undertaken, if any, with RP masters for use as
> electrodes,
> for electro discharge machining.
> I've come across electro plating of SLA masters any references or other work
> in this area.
>
> Phil Hackney Centre Manager
> (0191) 227 3644 FAX (0191) 227 3854
> Phil.Hackney@UNN.ac.uk
>
Brent Stucker at Texas A&M has developed a process that uses the SLS
machine to create EDM's. I think the material is ziconia diboride or
something like that. Brent's email address is stucker@tamu.edu and his
phone # is 409-847-9234. Also Millan Yueng has developed one for SLA
where a part is copper coated and used as a EDM. You can reach Millan at
millan.yeung@nrc.ca or 613-991-1276. Millan is from NRC which is a
research center in Canada.

-- 

Regards,

Joe DeGuglielmo Eastman Kodak Company Rapid Prototyping Center 901 Elmgrove Rd. Rochester, NY 14653-5315 (716)-726-7046 jfdegug@kodak.com

From: rod To: phil.hackney Subject: Re: RP and Electro discharge machining Date: 21 October 1996 09:42

Check out our home page in specific regards to LTAVD (Low Temperature Arc Vapor Deposition) on SLA parts, cast parts and metals. Rod Ward - president Rapid Prototyping Corp.

From: Dan Davis To: Phil Hackney Cc: rp-ml Subject: Re: RP and Electro discharge machining Date: 21 October 1996 08:35

Phil Hackney wrote: > > I am currently looking at research posibilities in Rapid tooling > > What work is being undertaken, if any, with RP masters for use as > electrodes, > for electro discharge machining. > I've come across electro plating of SLA masters any references or other work > in this area.

I have used LOM masters in the following methods (except #4):

Method 1: The LOM model is finished to the standard required and used to produce a mold in plaster. The cavity is metal-sprayed to a thickness of 2mm, taken from the mold and the face of the electrode is copper plated. A tool-holding fixture is attached to the back of the metal-sprayed, copper-plated shell to suit the EDM machine.

Method 2: EDM electrodes can be produced for both internal and external cavities by coating the carriers (molded from LOM models) with epoxy/silicon carbide grit. The abrading die thus created is mounted in an abrading machine and, using a mini-cycle orbital movement, the die is sunk into or over the carbon electrode blank to produce an accurate electrode.

Method 3: (verbage copied from an earlier post in this mailing list) Keltool is a technology for replicating a physical master into metal -- that is, using a LOM master and this technology, you can reproduce one or more copies in metal. The materials from which to choose are Stellite, A6 tool steel, or copper-tungsten (perfect for EDM electrodes). The technology uses a powder-metallurgy process. The process results in a very predictable shrinkage (scale up your LOM masters) of .20mm/mm for the first two materials and .25mm/mm for the Cu-Tungsten. There are no constraints on the material during the shrinkage (unlike investment casting) so it is very uniform, with little resultant distortion. It has the ability to pick up even the tiniest features, so surface finish of the LOM master is important. 3D-Keltool claims an accuracy of +/-.025mm/mm for up to a 100mm cube (yes, this is for relatively small inserts).

Method 4: It is believed, but yet to be developed, that EDM electrodes can be molded using one of several methods of producing molds with precise cavities (epoxy, etc.). This would presumably require heating the carbon grains, coated with epoxy or a similar bonding agent, until they fused. A LOM master would be used as the master to generate a mold for this procedure.

From: jbondy To: Phil Hackney Subject: Re: RP and Electro discharge machining Date: 21 October 1996 10:41

Phil: Try Brent Stucker at Texas A&M University. Sorry I don't have a number but he has been doing quite a bit of research on developing EDM electrodes using the SLS process. Jeff Bondy Howmet Corporation jbondy@howmet.com

______________________________ Reply Separator _________________________________ Subject: RP and Electro discharge machining Author: Phil Hackney <phil.hackney@unn.ac.uk> at Internet Date: 10/21/96 12:24 PM

I am currently looking at research posibilities in Rapid tooling What work is being undertaken, if any, with RP masters for use as electrodes, for electro discharge machining. I've come across electro plating of SLA masters any references or other work in this area. Phil Hackney Centre Manager (0191) 227 3644 FAX (0191) 227 3854 Phil.Hackney@UNN.ac.uk

From: rp-adm To: rp-ml@bart.lpt.fi Subject: Re: RP and Electro discharge machining Date: 21 October 1996 09:34

Some good work is being done at Texas A&M University using Selective Laser Sintering. They have made electrodes with better performance than conventional materials. They showed several impressive electrodes and cavities at the SLS Users Group meeting two weeks ago. Contact:

Walter Bradley Texas A&M University Department of Mechanical Engineering College Station TX 77843

Sorry, I could not find his phone # in my files.

Good luck,

Carl Deckard.

>I am currently looking at research posibilities in Rapid tooling > >What work is being undertaken, if any, with RP masters for use as >electrodes, > for electro discharge machining. >I've come across electro plating of SLA masters any references or other work >in this area. > >Phil Hackney Centre Manager >(0191) 227 3644 FAX (0191) 227 3854 >Phil.Hackney@UNN.ac.uk >

________________________________________________________

Dr. Carl Deckard Assistant Professor of Mechanical Engineering EIB205 Clemson University P.O. Box 340921 Clemson South Carolina 29634-0921 (864) 656-5642 (864) 656-4435 fax carl.deckard@ces.clemson.edu

________________________________________________________

From: Raymond Hope To: Phil Hackney Cc: rp-ml@bart.lpt.fi Subject: Re: RP and Electro discharge machining Date: 22 October 1996 11:09

On Mon, 21 Oct 1996, Phil Hackney wrote:

> What work is being undertaken, if any, with RP masters for use as > electrodes, > for electro discharge machining. > I've come across electro plating of SLA masters any references or other work > in this area.

I know Nottingham Uni. has done some work with plating SLA masters.

The person to contact there is Alan Arthur.

tel (0)115 9514068, fax (0)115 9514150 EPZRP1@epn1.maneng.nottingham.ac.uk

From: dbourell To: Phil Hackney Cc: owner-rp-ml Subject: Re: RP and Electro discharge machining Date: 21 October 1996 10:09

>What work is being undertaken, if any, with RP masters for use as >electrodes, > for electro discharge machining.

Here's some work I'm aware of.

Alan Arthur, Phill Dickens, Chris Bocking, Richard Cobb University of Nottingham (England) (Wear & Failure Mechanisms for SL EDM Electrodes) email: philip.dickens@nottingham.ac.uk

S.J. Dover, A.E.W. Rennie, G.R. Bennett Buckinghamshire College (UK) (Rapid Prototyping Using Electrodeposition of Copper) email: arenni01@buckscol.ac.uk

R. Ippolito, L. Iuliano, A. Gatto Politecnico di Torino (Italy) (EDM Tooling by Solid Freeform Fabrication & Electroplating Techniques) email: ippolito@polito.it

B. Stucker, W. Bradley, S. Norasetthekul, P. Eubank Texas A&M University (Production of EDM Electrodes Using SLS) email: stucker@tamu.edu

***************** Dr. Dave Bourell Professor and Temple Foundation Fellow University of Texas at Austin MC C2200 Austin, Texas 78712-1063

512-471-3170 voice 512-471-7681 fax

dbourell@mail.utexas.edu

From: jfdegug To: Phil Hackney Subject: Re: RP and Electro discharge machining Date: 21 October 1996 09:39

Phil Hackney wrote: > > I am currently looking at research posibilities in Rapid tooling > > What work is being undertaken, if any, with RP masters for use as > electrodes, > for electro discharge machining. > I've come across electro plating of SLA masters any references or other work > in this area. > > Phil Hackney Centre Manager > (0191) 227 3644 FAX (0191) 227 3854 > Phil.Hackney@UNN.ac.uk > Brent Stucker at Texas A&M has developed a process that uses the SLS machine to create EDM's. I think the material is ziconia diboride or something like that. Brent's email address is stucker@tamu.edu and his phone # is 409-847-9234. Also Millan Yueng has developed one for SLA where a part is copper coated and used as a EDM. You can reach Millan at millan.yeung@nrc.ca or 613-991-1276. Millan is from NRC which is a research center in Canada. --

Regards,

Joe DeGuglielmo Eastman Kodak Company Rapid Prototyping Center 901 Elmgrove Rd. Rochester, NY 14653-5315 (716)-726-7046 jfdegug@kodak.com



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