Three-Dimensional Surface Topography Analysis of Die Sinking Electrical Discharge Machined Eco-friendly Beryllium Free Cu Alloys

Beryllium-free Cu alloys, such as Copper-Nickel-Silicon-Chromium (Cu-Ni-Si-Cr) alloys, are utilised extensively in diverse sectors such as the electrical, electronics, instrument, metallurgy, aerospace, automotive, petrochemical, machinery manufacturing, and die and mould-making industries. Due to their high strength and hardness, these alloys are often fabricated into components for the above-mentioned industries using unconventional machining techniques like electrical discharge machining (EDM). EDM is particularly advantageous in industrial applications where precisely controlled random surface textures on these alloys are required. However, despite the industrial significance, experimental investigations into the EDM process of Cu-Ni-Si-Cr alloys are scarce. Therefore, the current work aims to address this research gap by conducting an experimental investigation of the random surfaces generated on Cu-Ni-Si-Cr alloy components after the die-sinking EDM process, utilising a comprehensive three-dimensional (3D) surface topography analysis. This work investigates the effects of input factors such as the electrode material, dielectric fluid material, flushing condition, and current on nearly all relevant areal texture (3D) parameters. The regression analyses reveal that current is the most significant input parameter for most areal texture parameters, followed by dielectric fluid and electrode materials. The flushing condition had minimal effect, marking a new direction for future research. The significance of each areal texture parameter was discussed from an application point of view, highlighting the potential impact of the findings.