Development of technologies to produce electrodes for Electro Discharge Machining by Layer Manufacturing Technique to machine moulds and complex shapes products

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This project proposes to develop and improve concurrent technologies on producing precision EDM electrodes by Layer Manufacturing Technique (LMT) to Electro-Discharge Machining advanced 3D products. The project workplan consists of 5 workpackages (WP) to be executed in 2 years (2009-2011). The electrodes will be manufactured with different materials using LMTechnique based on Laser sintering via IMW-TUClausthal facilities. The necessary powder material blends will be obtained using powder metallurgy know-how from the ZFW-TUClausthal. The assessment and improvement of EDMachining performance measures will be in charge of LAUS-PUCPR. The partners’ collaborative work will enable the specification of electrodes geometries and materials applicable for precision EDMachining The expected outputs are the electrode performance correlating EDMachining and LMT variables, the specification of adequate materials and postprocessing e.g. coatings for LMT-EDM electrodes, the development of EDM technology tables and procedures for design and fabrication of precision electrodes and an envelope with adequate process EDM parameters settings. The project results will be tested on a real industrial application of a particular electrode geometry using an adequate EDM procedure. This proposal is inserted into the agreement reached on July of 2007 between Technische Universitaet Clausthal - TUC and Pontifícia Universidade Católica do Paraná – PUCPR and as well as into the strategic interest of the BRAGECRIM Program. The sustainable development of the German-Brazilian production chain through innovative technology is considered in this project. The project will not only be an opportunity to manufacture EDM electrodes, but also to establish a communication channel for technology and human resources transfer between TUClausthal and PUCPR linked to the Brazilian/German industries.