EDM of Ti-6Al-4V: Electrode and polarity selection for minimum tool wear rate and overcut

Ahmed, Naveed; Ishfaq, Kashif; Rafaqat, Madiha; Pervaiz, Salman; Anwar, Saqib; Salah, Bashir

doi:10.1080/10426914.2019.1594278

Cited by 65 publications

(21 citation statements)

References 23 publications

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“…The salient characteristics of the graphene particles and their morphology are described in Table 4 and Figure 4, respec- Pulse time ratio (PTR) is the ratio of on-time to off-time. The selection of these control variables was made because their impact was rated significant with regard to MRR and TWR in the EDM of Ti6Al4V [20,[42][43][44]. Preliminary trials were initially conducted to seek the appropriate parametric levels.…”

Section: Methodsmentioning

confidence: 99%

A Comprehensive Analysis of the Effect of Graphene-Based Dielectric for Sustainable Electric Discharge Machining of Ti-6Al-4V

et al. 2020

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Titanium alloys, especially Ti-6Al-4V, which is considered a difficult-to-cut material, bears numerous applications in aerospace and biomedical sectors. The criticality of the accurate formation of the machined cavity for the said applications and properties of Ti-6Al-4V accentuated the use of electric discharge machining (EDM). However, the issues of lower material removal rate (MRR) and tool wear (TWR) discouraged the use of EDM. These inherent issues hold a pivotal role regarding the sustainable machining of Ti-alloy. Therefore, in this research the potentiality of kerosene-based dielectric, having graphene nanoparticles, is comprehensively examined for the sustainable EDM of Ti-6Al-4V, which was not focused upon yet. Experimentation was performed under Taguchi’s design (L18) with three types of electrodes, namely Aluminum, Brass and Copper. In total, 36 experiments were conducted, of which 18 were with graphene-mixed dielectric and the remaining were with kerosene. Experimental results reveal that the brass electrode with negative tool polarity yields higher MRR for both types of dielectrics. The maximum MRR (7.602 mm3/min) achieved with graphene mixed dielectric is 64.5% greater as compared to that obtained with kerosene (4.621 mm3/min). Moreover, the minimum TWR obtained for graphene-based dielectric, i.e., 0.17 mg/min is approximately 1.5 times less than that achieved with kerosene.

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Section: Methodsmentioning

confidence: 99%

A Comprehensive Analysis of the Effect of Graphene-Based Dielectric for Sustainable Electric Discharge Machining of Ti-6Al-4V

et al. 2020

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“…The process factors are divided into the electrical and non-electrical factors on which the machined surface characteristics depend. Current, applied voltage, pulse-on duration, and pulse-off duration are the most influential electrical variables, while the non-electrical input vari-ables include the physical properties of the tools, working liquid, particle size, and the amount of powder added [11,23,[181][182][183][184][185][186][187][188]. Considering that a PM-EDM system is complex in nature, optimization of the process factors is required to obtain the optimum responses.…”

Section: Pm-edm Process Variables Affecting the Treated Surface Propertiesmentioning

confidence: 99%

Investigation of Coatings, Corrosion and Wear Characteristics of Machined Biomaterials through Hydroxyapatite Mixed-EDM Process: A Review

et al. 2021

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Together, 316L steel, magnesium-alloy, Ni-Ti, titanium-alloy, and cobalt-alloy are commonly employed biomaterials for biomedical applications due to their excellent mechanical characteristics and resistance to corrosion, even though at times they can be incompatible with the body. This is attributed to their poor biofunction, whereby they tend to release contaminants from their attenuated surfaces. Coating of the surface is therefore required to mitigate the release of contaminants. The coating of biomaterials can be achieved through either physical or chemical deposition techniques. However, a newly developed manufacturing process, known as powder mixed-electro discharge machining (PM-EDM), is enabling these biomaterials to be concurrently machined and coated. Thermoelectrical processes allow the migration and removal of the materials from the machined surface caused by melting and chemical reactions during the machining. Hydroxyapatite powder (HAp), yielding Ca, P, and O, is widely used to form biocompatible coatings. The HAp added-EDM process has been reported to significantly improve the coating properties, corrosion, and wear resistance, and biofunctions of biomaterials. This article extensively explores the current development of bio-coatings and the wear and corrosion characteristics of biomaterials through the HAp mixed-EDM process, including the importance of these for biomaterial performance. This review presents a comparative analysis of machined surface properties using the existing deposition methods and the EDM technique employing HAp. The dominance of the process factors over the performance is discussed thoroughly. This study also discusses challenges and areas for future research.

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“…Titanium-based alloys are attracting considerable attention in a wide range of industries due to their unique mechanical and physical properties [ 1 ]. In particular, they have gained popularity in aircraft engine and airframe manufacture as they offer a strength to weight ratio higher than aluminum or steel, in addition to which they offer excellent corrosion and creep resistance [ 2 , 3 ]. Titanium alloys are widely used in industries where corrosion resistance is important, such as the marine industry to resist seawater corrosion, for components in chemical processing equipment and, increasingly important, in the biomedical industry for prosthetic joints and implants where their low elastic modulus and high strength are added advantages [ 4 , 5 ].…”

Section: Introductionmentioning

confidence: 99%

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

et al. 2020

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This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

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EDM of Ti-6Al-4V: Electrode and polarity selection for minimum tool wear rate and overcut

Cited by 65 publications

References 23 publications

A Comprehensive Analysis of the Effect of Graphene-Based Dielectric for Sustainable Electric Discharge Machining of Ti-6Al-4V

A Comprehensive Analysis of the Effect of Graphene-Based Dielectric for Sustainable Electric Discharge Machining of Ti-6Al-4V

Investigation of Coatings, Corrosion and Wear Characteristics of Machined Biomaterials through Hydroxyapatite Mixed-EDM Process: A Review

Precision Hard Turning of Ti6Al4V Using Polycrystalline Diamond Inserts: Surface Quality, Cutting Temperature and Productivity in Conventional and High-Speed Machining

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