Study on the effect of air and argon assisted short electric arc machining on Ti6Al4V titanium alloy

Abstract

The use of an argon–water medium rather than air–water medium is proposed to increase the material removal rate (MRR) and decrease surface oxide production for short electric arc machining. To provide a more stable discharge state during high-temperature processing, this approach uses argon to reduce the production of highly resistant refractory materials (e.g. titanium oxide). For short-arc machining of Ti6Al4V titanium alloy, the effects of the voltage, milling depth, electrode speed and gas flow rate on the MRR, relative electrode loss rate and surface roughness were compared for air–water and argon–water mixtures. It was discovered that the milling depth and voltage had the greatest impact on the MRR, voltage and electrode rotational speed had the greatest impact on the relative tool electrode wear rate (REWR), and voltage had the greatest impact on the surface roughness. In contrast to the air–water mixture, the MRR with the argon–water working medium was as high as 9391 mm3/min, with a 13% improvement in MRR, as well as a smooth and flat surface of the machined workpiece. Nevertheless, the REWR increased to 2.46% and the surface roughness was at least 432 μm with the argon–water medium, increasing by 59 μm compared with the air–water medium. Moreover, the addition of argon reduced the types of surface compound on the workpiece and decreased the residual stress defects, including the recast layer, microcracks and holes.

Investigation of enhancing EDM machining performance of INCONEL alloy using composite electrodes

“…When machined with A3 composite tool, globules of diameters greater than 100 μm was observed as depicted in the figure 6(a) the result portrayed that when composite tool of higher weight percentage was used poor quality surface was attained. The coating of globules was observed which elucidate that the flushing was very worse, and this feature confirmed that almost all of the machined materials were redeposited over the surface [50]. At higher magnification, globules and uneven machined surface were clearly visible and a new creature called pock marks were observed as shown in figure 6(b).…”