ArticlePolymers2024
Enhancing EDM Productivity for Plastic Injection Mold Manufacturing: An Experimental Optimization Study.
Article in Polymers, 2024. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Cited by 2 papers.
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Who cites it
2 citing papers in PubMed.
- Polymer Micro/Nanofabrication and Manufacturing II.Polymers · 2025Article
- High-Efficiency Surface-Cooled Rapid Tooling Development for Injection Molding of Low-Density Polyethylene.Polymers · 2025Article
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Authors and funding
2 authors.
Funding
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Abstract
Electrical erosion molding (EDM) is an unconventional machining technology widely used in the manufacture of injection molds for plastics injection molding for the creation of complex cavities and geometries. However, EDM productivity can be challenging, directly influencing mold manufacturing time and cost. This work aims to improve EDM productivity in the context of mold manufacturing for plastics injection molding. The research focuses on the optimization of processing parameters and strategies to reduce manufacturing time and increase process efficiency. Through a rigorous experimental approach, this work demonstrates that the optimization of EDM parameters and strategies can lead to significant productivity gains in the manufacture of plastic injection molds without compromising part quality and accuracy. This research involved a series of controlled experiments on a Mitsubishi EA28V Advance die-sinking EDM machine. Different combinations of pre-cutting parameters and processing strategies were investigated using copper electrodes on a heat-treated steel plate. Productivity was evaluated by measuring the volume of material removed, and geometrical accuracy was checked on a coordinate measuring machine. The experimental results showed a significant increase in productivity (up to 61%) by using the "processing speed priority" function of the EDM machine, with minimal impact on geometric accuracy. Furthermore, the optimized parameters led to an average reduction of 12% in dimensional deviations, indicating improved geometric accuracy of the machined parts. This paper also provides practical recommendations on the selection of optimal EDM processing parameters and strategies, depending on the specific requirements of plastic injection mold manufacturing.
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