Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

Abstract

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

“…One sample measurement of R a is illustrated in Supplemental Figure 1. Based on the past research work, 9,13,18,21,22 pilot experiments, and machine limitations, four parameters are considered for analyzing the responses such as MRR and SR in the present investigation. The selected input settings were T off , T on , I p , and PC, and their range was given in Supplemental Table 1.…”

“…Several dielectrics with suspended powder in the WEDM process also play an important role and provide better output. 18 Singh et al 19 explored the impact of tungsten powder mixed dielectric on EDM performance, such as MRR and machined surface characteristics. The result showed that a 48.43% improvement in MRR could be achieved in tungsten mixed kerosene.…”

Optimization of Material Removal Rate, Surface Roughness and Kerf Width in Wire-ED Machining of Ti-6Al-4V Using RSM and Grey Relation

“…However, molybdenum electrode wires have garnered comparatively lesser attention [23,24]. For the dielectric fluid media, oil and water are the key candidates, and water has been observed to be superior to oil in terms of its chemical stability and electrode wear rate [25]. In the present study, the electrode is made up of molybdenum and deionized water is used as the dielectric fluid.…”

Performance evaluation of electric discharge machining of titanium alloy-a review

“…Chakraborty et al [56] presented the performance of Ti-6Al-4V by mixing the powder in different dielectrics during WEDM. In the first stage, the experiment was conducted using a brass electrode of diameter 0.25 mm.…”