Experimental Investigation on Surface Morphology of Micro-EDMed Ti-6Al-4 V Alloy

Ramver,; Yadav, Vineet Kumar; Kumar, Pradeep; Dvivedi, Akshay

doi:10.1007/978-981-32-9971-9_8

Cited by 10 publications

(5 citation statements)

References 11 publications

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“…The mean plot in figure 4(b) depicts that MRR surges as the input voltage and capacitance is increased, which results in higher discharge intensity, facilitating better material erosion of workpiece [12]. Similar results have also been reported in [13,14] for other materials.…”

Section: Resultssupporting

confidence: 74%

“…With an increase in capacitance, the spark intensity increases and leads to the formation of a strong and intense plasma channel. This situation leads to lower control over machining accuracy and formation of irregularities in the microholes, which results in an increased CE [13]. As the feed rate increases, the CE initially increases then slightly decreases.…”

Section: Resultsmentioning

confidence: 99%

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Experimental study on Titanium diamond by fabricating micro-holes using Micro-EDM with Taguchi’s method and response surface method

2020

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Titanium alloys are very hard to machine materials, which can be machined effectively by using advanced manufacturing processes. Electro discharge machining (EDM) process is one of the most efficient methods of machining electrically conductive materials. EDM is focused more on the precision and accuracy of the machined parts. This particular work focuses on the machinability study of titanium diamond using micro-EDM. Input parameters such as voltage, capacitance, feed rate and tool rotation speed (TRS) are varied and their effects are analyzed by evaluating responses such as material removal rate (MRR), machining time (MT), overcut (OC) and circularity error (CE). X-ray diffraction (XRD) analysis of the material is also conducted to observe the material phases and elements. The observed responses are simultaneously optimized by formulating overall evaluation criteria (OEC) for generating the optimal value of process parameters. Further, the analysis of variance (ANOVA) provides the influence of input parameters on each output response. The variation of different response measures with respect to input parameters is shown through 3D response surface plots. It is observed in micro EDM that the MT decreases with the increase in voltage, capacitance, feed rate and TRS, whereas MRR and OC increase with an increase in voltage and capacitance. In the case of CE, it decreases with the increase in voltage and it increases with the increase in capacitance.

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Section: Resultssupporting

confidence: 74%

Section: Resultsmentioning

confidence: 99%

Experimental study on Titanium diamond by fabricating micro-holes using Micro-EDM with Taguchi’s method and response surface method

2020

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“…25 In EDM for fabricating initial holes, the servomechanism-equipped vertical axis allowed the tool to move adaptively, ensuring the desired IEG value in the longitudinal direction as the tool advanced. 26 In the context of ECM, controlling and maintaining a specific IEG value was crucial. Various strategies for controlling tool motion to achieve the desired IEG values in the ECM process were suggested in the literature.…”

Section: Methodsmentioning

confidence: 99%

Editors' Choice—Improving Quality of EDMed Micro-Holes on Titanium via In Situ Electrochemical Post-processing: A Transient Simulation and Experimental Study

Singh,

Rakurty,

Dvivedi

et al. 2024

J. Electrochem. Soc.

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Electrical discharge micromachining (EDM) poses challenges to the fatigue-life performance of machined surfaces due to thermal damage, including recast layers, heat-affected zones, residual stress, micro-cracks, and pores. Existing literature proposes various ex-situ post-processing techniques to mitigate these effects, albeit requiring separate facilities, leading to increased time and costs. This research involves an in-situ sequential electrochemical post-processing (ECPP) technique to enhance the quality of EDMed micro-holes on titanium. The study develops an understanding of the evolution of overcutting during ECPP, conducting unique experiments that involve adjusting the initial radial interelectrode gap (utilizing in-situ wire-electrical discharge grinding) and applied voltage. Additionally, an experimentally validated transient finite element method model is developed, incorporating the passive film formation phenomenon for improved accuracy. Compared to EDM alone, the sequential EDM-ECPP approach produced micro-holes with superior surface integrity and form accuracy, completely eliminating thermal damage. Notably, surface roughness (Sa) was reduced by 80% after the ECPP. Increasing the voltage from 8 to 16 V or decreasing the gap from 60 to 20 µm rendered a larger overcut. This research's novelty lies in using a two-phase dielectric (water-air), effectively addressing dielectric and electrolyte cross-contamination issues, rendering it suitable for commercial applications.

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“…Whereas, FR and TRS doesn't have any significant impact on the CE of the drilled microhole. With an increase in capacitance and voltage, there is an increase in spark intensity and formation of a strong and intense plasma channel[18,19]. This scenario reduces machining precision and formation of irregularities in the microhole, which results in an increased CE.…”

mentioning

confidence: 99%

Micro electrical discharge drilling in SS304 and its multiparameter optimization using desirability function analysis

Majumder,

Kebede,

Patowari

et al. 2024

Eng. Res. Express

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The present investigation examines the use of micro-electrical discharge machining (μEDM) for microhole drilling in stainless steel grade 304. In this experiment, a Taguchi L18 orthogonal array is considered with four process parameters, viz. capacitance, voltage, feed rate and tool rotation. Material removal rate and microhole precision, such as circularity, overcut, and taperness, have been studied to assess machinability. Parametric variation of response measures with process variables are studied and their corresponding impacts are calculated using ANOVA. Desirability function analysis (DFA) is selected to optimize the process parameter for the best possible response and most desirable condition of the experiment, and results show an improvement in overall desirability by 10.47% at optimum parameter settings of capacitance = 103pF, voltage = 150 V, feed rate = 20 μm sec−1 and tool rotation = 2800 rpm.

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Experimental Investigation on Surface Morphology of Micro-EDMed Ti-6Al-4 V Alloy

Cited by 10 publications

References 11 publications

Experimental study on Titanium diamond by fabricating micro-holes using Micro-EDM with Taguchi’s method and response surface method

Experimental study on Titanium diamond by fabricating micro-holes using Micro-EDM with Taguchi’s method and response surface method

Editors' Choice—Improving Quality of EDMed Micro-Holes on Titanium via In Situ Electrochemical Post-processing: A Transient Simulation and Experimental Study

Micro electrical discharge drilling in SS304 and its multiparameter optimization using desirability function analysis

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