Electro-discharge machining (EDM) is a useful non-conventional machining operation frequently applied to make different complex geometries in any conducting material. The objectives of the present paper are to study the effect of a variation of thermo-physical properties (TPP) of three different tool materials on EDM performances. The different performances compared in this paper are: material removal rate (MRR), tool-wear rate (TWR), surface roughness (SR), radial overcut (ROC), surface-crack density (SCD) and surface hardness. Two of the most widely used work piece materials, such as corrosion-resistant austenitic stainless steel (SS316) and high strength corrosion-resistance titanium alloy (Ti-6Al-4V), are machined with the help of three different tools by varying input current and maintaining constant pulse-on time, pulse-off time and flushing pressure. Microstructural studies of the tool tip surface after machining have also been carried out. It is found that among these three tool materials, the copper tool showed the best machining performance with respect to material removal rate, radial overcut, surface finish and surface-crack density. This work will help industry personnel to choose a suitable tool for a specific work piece material.

No abstract

No abstract

Electro-discharge machining (EDM) is a common non-conventional machining technique for cutting a variety of conducting materials. In this study, the machining performances of Ti-6Al-4V, SS316, and WC work pieces were examined using EDM while considering various thermophysical parameters. Surface roughness, material removal rate, tool wear rate, radial overcut, surface fracture density, and surface hardness have all been investigated using different input parameters such as discharge current, pulse on time, and pulse off time. There is a wide range of performance characteristics among the materials used in the workpieces. In comparison to Ti-6Al-4V and Tungsten Carbide materials, the rate of rise in MRR, TWR, and radial overcut in SS316 is quite high as current increases.

No abstract