Improving the Productivity of Copy-Piercing Electrical Discharge Machining by Additive Manufacturing of Tool Electrodes

The use of additive technology—in particular, selective laser melting (SLM)—in producing wire electrodes for electrical discharge machining is considered. By this means it is possible to produce electrodes of high precision and complex geometry, with distinctive properties. In addition, the results of topological optimization in electrode design are presented. Topological optimization permits the production of wire electrodes that are more efficient in the given operating conditions. It is shown that, on the basis of additive technology and optimized electrode geometry with internal supply channels for dielectric liquid, the removal of sludge from the machining area may be improved, with consequent stabilization of the machining process.