Electric discharge machining of titanium and its alloys: review

Qudeiri, Jaber Abu; Mourad, Abdel-Hamed I.; Ziout, Aiman; Abidi, Mustufa Haider; Elkaseer, Ahmed

doi:10.1007/s00170-018-1574-0

Cited by 109 publications

(66 citation statements)

References 125 publications

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“…In recent years, rapid developments in aerospace, medical instruments, transportation, and many other industrial sectors increased the need for new materials with favorable characteristics. In addition to unique characteristics, most modern materials need special manufacturing processes to enable them to be machined with ease [1,2]. Most of these materials are usually difficult to cut by conventional manufacturing processes [3][4][5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

et al. 2020

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Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with regard to selection of the process, material, and operating parameters, the effect on responses, various process variants, and new techniques adopted to enhance process performance. This paper reviews research studies on the EDM of different grades of tool steel materials. This article (i) pans out the reported literature in a modular manner with a focus on experimental and theoretical studies aimed at improving process performance, including material removal rate, surface quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used to determine process conditions, and (iii) discusses the developments in EDM and outlines the trends for future research. The conclusion section of the article carves out precise highlights and gaps from each section, thus making the article easy to navigate and extremely useful to the related research community.

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Section: Introductionmentioning

confidence: 99%

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

et al. 2020

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“…These above stated examples focused on one or more aspects of machining techniques that involve direct contact between cutting tool and the workpiece. In other reviews, Gupta et al [24] among other researchers [25] have focused on machining techniques that do not require contact between the tool and the workpiece.…”

Section: Introductionmentioning

confidence: 99%

“…The experienced and new researchers can easily refer to the wide range of other research and review articles that are captured in this paper for further reading. This paper did not cover the description of machining operations as there are numerous comprehensive reviews [8,[25][26][27][28][29] on a specific type of machining technique for titanium alloys.…”

Section: Introductionmentioning

confidence: 99%

An overview of conventional and non-conventional techniques for machining of titanium alloys

et al. 2020

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Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

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“…The integration of vibrations into the EDM process has resulted in a significant improvement in machining efficiency [19]. However, the accuracy of the hole size in l-EDM needs to be improved.…”

Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of process parameter in EDM using low-frequency vibration of workpiece assigned for SKD61

et al. 2019

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Integrated vibration in electrical discharge machining (EDM) plays a key role in achieving high efficiency. High levels of variables can be employed in this approach due to integration. However, simultaneous optimization of the EDM parameters to achieve multi-objectives is still very complex and challenging. Studies on integrated vibration are still in a preliminary stage. This report addresses multi-objective optimization in EDM for SKD61 die steel using low-frequency vibration. MOORA (Multi-objective optimization based on ratio analysis) was chosen to resolve this multi-objective optimization problem. The material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were selected as performance measures in the EDM process. An analytical hierarchical process (AHP) was used to determine the weight value of the quality indicators. The results indicate that low-frequency vibrations significantly improve machining efficiency. When the frequency of the vibrations increased, MRR increased significantly such that MRR MAX = 64.48%. TWR and SR are smaller and their increase are given as TWR MAX = 20.3% and SR MAX = 18.47%. MOORA has been identified as a suitable alternative to multi-objective optimization in an EDM process using low-frequency vibrations for an assigned workpiece. The optimum parameters required to achieve the multi-objective were Ton = 25 ls, I = 8 A, Tof = 5.5 ls and F = 512 Hz, at the resultant quality criteria of MRR = 9.564 mm 3 /min, TWR = 1.944 mm 3 /min and SR = 3.24 lm with a maximum error of 8.24%.

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Electric discharge machining of titanium and its alloys: review

Cited by 109 publications

References 125 publications

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

An overview of conventional and non-conventional techniques for machining of titanium alloys

Multi-objective optimization of process parameter in EDM using low-frequency vibration of workpiece assigned for SKD61

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