Effect of Electrode Materials on Different EDM Aspects of Titanium Alloy

Bhaumik, Munmun; Maity, Kalipada

doi:10.1007/s12633-018-9844-x

Cited by 63 publications

(18 citation statements)

References 15 publications

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“…This effect results in the generation of deep craters with re-cast layer on the workpiece. Since more melting and vaporization of the workpiece material occurs, this tends to increase the R DE as highlighted in Figure 9 [ 54 ].…”

Section: Resultsmentioning

confidence: 99%

EDM of Ti-6Al-4V under Nano-Graphene Mixed Dielectric: A Detailed Investigation on Axial and Radial Dimensional Overcuts

Ishfaq

Asad

Harris³

et al. 2022

Nanomaterials

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Ti-6Al-4V is considered a challenging material in terms of accurate machining. Therefore, electric discharge machining (EDM) is commonly engaged, but its low cutting rate depreciates its use. This issue is resolved if graphene nanoparticles are mixed in the dielectric. However, the control over the sparking phenomenon reduces because of the dispersion of graphene particles. Subsequently, the machined profile’s geometric accuracy is compromised. Furthermore, the presence of nanographene induces different sparks along axial and radial cutting orientations. This aspect has not been comprehensively examined yet and dedicatedly targeted in this study to improve the quality of EDM process for Ti-6Al-4V. A total of 18 experiments were conducted under Taguchi’s L18 design considering six parameters namely, electrode type, polarity, flushing time, spark voltage, pulse time ratio, and discharge current. The aluminum electrode proved to be the best choice to reduce the errors in both the cutting orientations. Despite the other parametric settings, negative tool polarity yields lower values of axial (ADE) and radial errors (RDE). The developed optimal settings ensure 4.4- and 6.3-times reduction in RDE and ADE, respectively. In comparison to kerosene, graphene-based dielectric yields 10.2% and 19.4% reduction in RDE and ADE, respectively.

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Section: Resultsmentioning

confidence: 99%

EDM of Ti-6Al-4V under Nano-Graphene Mixed Dielectric: A Detailed Investigation on Axial and Radial Dimensional Overcuts

Ishfaq

Asad

Harris³

et al. 2022

Nanomaterials

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“…The effect of each process parameters on the EDM responses (TWR, MRR, ROC and R a ) has been analyzed by Bhaumik and Maity (2018, 2019). For executing multi-response optimization using GRA method, the first step is to normalize the EDM responses to make scale free value ranging from zero to one.…”

Section: Resultsmentioning

confidence: 99%

“…This machining process has stupendous performance in machining advanced materials and can produce very highly complex shapes (Clijsters et al , 2010; Aliyu et al , 2014; Barman and Puri, 2014; Nanimina et al , 2014; Pachaury and Tandon, 2017). Bhaumik and Maity (2018, 2019) studied the different aspects of process parameters (TWR, ROC, R a , MRR, SCD and recast layer) using brass, copper and zinc electrodes during EDM operation of Ti-5Al-2.5Sn alloy. Rahman et al (2010, 2011) adopted surface response method and multi-layered perceptron neural network technique for the mathematical modeling of MRR during EDM operation of Ti-5Al-2.5Sn alloy.…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization of EDM parameters using grey relational analysis (GRA) for Ti-5Al-2.5Sn titanium alloy

Bhaumik¹,

Maity

2020

WJE

Self Cite

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Purpose In this research, electro discharge machining (EDM) of Ti-5Al-2.5Sn titanium alloy is performed taking gap voltage, pulse on time, peak current and duty cycle as process parameters. The purpose of this paper is to find out the optimal process parameters setting for getting higher machining efficiency. Design/methodology/approach For experimental design, a face-centered central composite design (FCCCD)-based response surface methodology (RSM) is used. Multi-objective optimization like grey relational analysis (GRA) is adopted to achieve the higher machining efficiency by means of lower radial overcut (ROC), surface roughness (Ra), tool wear rate (TWR) and higher material removal rate (MRR). For the statistical study, analysis of variance (ANOVA) has been carried out. Findings The result shows that gap voltage, peak current and pulse on time are the most efficient parameters for the responses. An optimal parameter setting has been obtained for achieving higher machining efficiency. For validation of the study, confirmation experiment has been performed at optimal parameters setting. Originality/value Optimum parameter level for higher machining performance of Ti-5Al-2.5Sn Titanium alloy has been achieved machined by copper electrode during EDM operation.

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“…Bai et al [16] found that, when using brass and copper electrode to process 45-carbon steel and W18Cr4V, brass electrode were able to achieve higher MRR compared to copper electrode. Munmun and Kalipada [17] used copper, brass, and zinc electrode subjected to electrical discharge machining of Ti-5Al-2.5Sn titanium alloy, comparing the machining results, it was found that thinner and more uniform recast layer and higher surface crack densities were found on surfaces which had undergone EDM surface machining by copper electrode, as compared to brass and zinc electrode. Therefore, they recommend using copper tool electrode in EDM products which require higher precision and superior surface nish.…”

Section: Introductionmentioning

confidence: 99%

Study on Recast Layer Thickness of Microstructures Machined in micro-EDM with Different Electrodes

Chen¹,

Lian²,

Wu³

et al. 2021

Preprint

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Functional-surface microstructures are widely used in industrial practice. During the fabrication of microstructures in micro-electrical discharge machining (micro-EDM), the thermal and physical characteristics of both workpieces and electrode materials at room temperature and high temperatures have an important influence on surface quality and distribution of recast layer. In order to study the influence of different electrode material characteristics on the surface integrity of microstructures machined using micro-EDM, red copper, brass, copper-tungsten and tungsten electrode were used to perform micro-EDM on both Ti-6Al-4V alloy and 304 stainless steel. In the experiment, electrode with groove arrays featuring high copying accuracy and surface quality was designed to carry out powder mixed electrical discharge machining (PMEDM) on Ti-6Al-4V alloy, and the machining results were evaluated based on four indicators: microstructure morphology, tool electrode wear (TEW), material removal rate (MRR), and recast layer thickness (RLT). Simultaneously, the surface morphology and recast layer thickness changes of 304 stainless steel workpieces machined using the above four types of electrodes, using both normal polarity and negative polarity micro-EDM were quantitatively analyzed. The results showed that copper-tungsten electrode is recommended to machine Ti-6Al-4V alloy because it has a smaller TEW (139 µm), the highest MRR (255.39 mm3/min), and a thinner recast layer thickness (3.35 µm). This was followed by copper electrode, which featured good machining performance and machinability. When machining 304 stainless steel with negative polarity, the TEW of copper electrode and tungsten electrode was the smallest, and the thickness of recast layer was able to be effectively reduced to about 3 µm.

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Effect of Electrode Materials on Different EDM Aspects of Titanium Alloy

Cited by 63 publications

References 15 publications

EDM of Ti-6Al-4V under Nano-Graphene Mixed Dielectric: A Detailed Investigation on Axial and Radial Dimensional Overcuts

EDM of Ti-6Al-4V under Nano-Graphene Mixed Dielectric: A Detailed Investigation on Axial and Radial Dimensional Overcuts

Multi-response optimization of EDM parameters using grey relational analysis (GRA) for Ti-5Al-2.5Sn titanium alloy

Study on Recast Layer Thickness of Microstructures Machined in micro-EDM with Different Electrodes

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