Experimental Investigation and Optimization of Process Parameters in Ti – (6242) Alpha–Beta Alloy Using Electrical Discharge Machining

Perumal, A.; Azhagurajan, A.; Prithivirajan, R.; Kumar, S. Suresh

doi:10.1007/s10904-020-01786-1

Cited by 18 publications

(9 citation statements)

References 25 publications

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“…e experiments were performed using the Taguchi perfectly straight display method. e essential factors identified from the observable analysis of test results were peak current, spark on time, and voltage [8][9][10][11]. Optimized process variables for optimum MRR and minimal surface integrity of Inconel 718 and states that process input variables have such a direct influence on those variables [12].…”

Section: Introductionmentioning

confidence: 99%

Multiresponse Optimization of Wire Electrical Discharge Machining Parameters for Ti-6Al-2Sn-4Zr-2Mo (α-β) Alloy Using Taguchi-Grey Relational Approach

Perumal¹,

Kailasanathan²,

Stalin³

et al. 2022

Advances in Materials Science and Engineering

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The Ti-6Al-2Sn-4Zr-2Mo alloy was machined using the wire electrical discharge machining (WEDM) method in this research. The consequences of input values like pulse on duration, wire tension, and wire feed on metal removal rate (MRR) and surface roughness (SR) have indeed been observed. After conducting 27 experiments using Taguchi’s L27 type of research technique, empirical designing and analysis of variance (ANOVA) were performed. For process optimization, the Taguchi technique, which is based on the grey relational analysis approach, is used. The results show that a material removal rate of 0.293 mm3/min was obtained with factors of 10 µs pulse on duration, 7 m/min of wire feed, and 12 g of wire tension (the higher the better), and surface roughness of 2.129 µm was obtained with factors of 6 µs pulse on duration, 3 m/min of wire feed, and 8 g of wire tension (the lower the better). The percentage of errors between results obtained and grey relational analysis (GRA) predicted results varies around 6%. Wire electrical discharge machining with Ti-6242 alloy to optimum conditions resulted in better MRR and surface integrity with good surface finish and integrity as evidenced by a substantial reduction in the crack formation, lumps, and accumulated surfaces.

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Section: Introductionmentioning

confidence: 99%

Multiresponse Optimization of Wire Electrical Discharge Machining Parameters for Ti-6Al-2Sn-4Zr-2Mo (α-β) Alloy Using Taguchi-Grey Relational Approach

Perumal¹,

Kailasanathan²,

Stalin³

et al. 2022

Advances in Materials Science and Engineering

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“…Also, the high vacuum of 10 − 4 mbar in the work chamber provides protection against the contamination from the atmosphere. Especially, it is suitable for reactive materials such as titanium alloys which is extensively used in the aircraft components, automotive components and biomedical components [3,4].Though the titanium alloys are made ready in different forms such as cast, wrought, and powder sintered [5], realized through casting, and powder metallurgy, additive manufacturing is one more added with that owing to its merits. Neikter et al produced the titanium alloy Ti6Al4V through two different additive manufacturing process (EBM and SLM) and detailed the microstructural characterization of the produced alloy [6].…”

Section: Introductionmentioning

confidence: 99%

Tribological analysis of wire additive manufactured Ti6Al4V by Electron Beam source

Manjunath

Anandakrishnan

Ramachandra

et al. 2021

Preprint

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Additive manufacturing through electron beam, is an attractive and fast growing additive manufacturing process for complex geometry in the aerospace, automotive and rapid tooling industry. Ti6Al4V is the material which is widely used in aerospace industry owing to its good strength-to-weight ratio, higher strength and toughness and admirable corrosion resistance. Ti6Al4V samples were realized through wire electron beam additive manufacturing by Pre-positioning the wire and then fusing it to the substrate material. The samples were subjected to standard dry sliding wear test to explore the wear behaviour. The wear analysis exposed the substantial effects of parameters on the wear rate. Likewise, the mechanisms that significantly influenced the wear rate was identified with worn surface and debris analysis.

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“…It has been observed from the exhaustive literature review that most of the investigations in EDM process of Ti-6242 super alloy has focused on the optimization of quality characteristics such as material removal rate MRR, over cut, tool wear rate and surface roughness as representing important indicators for machined surface quality and to assess the effectiveness of the process. Perumal et al (2020) [23] studied the effect of discharge current, spark on time and tool diameter on MRR, over cut and tool wear rate in EDM of Ti-6242. In an earlier study, Perumal et al (2019) [18] have analyzed statistically, for the same grade of titanium, the surface roughness and used SEM analysis to characterize surface integrity in terms of microstructure and surface cracks.…”

Section: Introductionmentioning

confidence: 99%

“…(2020) [23]. Taguchi method was employed by Prasanna et al (2021) [25] to identify optimal parameter combination for attaining minimal surface roughness in WEDM of Ti-6242.…”

Section: Introductionmentioning

confidence: 99%

“…Accordingly, various approaches have been employed for predicting and optimizing process parameters in EDM and WEDM of Ti-6242. These approaches are based on the notion of metal machining, design of experiment (DOE) method, Taguchi method and the response surface methodology approach (RSA) [19,23,[25][26][27][28][29]. For instance, to improve the MRR and reduce the over cut and tool wear rate in EDM of Ti-6242, Taguchi based grey relational analysis method using L27 orthogonal array with multi response optimization has been used by Perumal et al…”

Section: Introductionmentioning

confidence: 99%

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An Investigation To Achieve a Good Surface Integrity in WEDM of Ti-6242 Super Alloy

Ezeddini

Rajhi

Boujelbene

et al. 2021

Preprint

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Ti-6242 is a super alloy which exhibits the best creep resistance among available titanium alloys and is widely used in the manufacture by WEDM of aircraft engine turbomachinery components. However, the final quality of wire EDMed surface is a great challenge as it is affected by various factors that need optimization for surface integrity and machine efficiency improvement. The aim of this study is to investigate the effect of a set of cutting process parameters such as pulse on time (Ton), servo voltage (U), feed rate (S) and flushing pressure (p) on surface roughness (SR) when machining Ti-6242 super alloy by WEDM process using a brass tool electrode and deionized water as a dielectric fluid. WEDM experiments were conducted, and SR (Ra) measurement was carried out using a 3D optical surface roughness-meter (3D–SurfaScan). As a tool to optimize cutting parameters for SR improvement, Taguchi's signal‐to‐noise ratio (S/N) approach was applied using L9 (3^4) orthogonal array and Lower-The-Better (LTB) criteria. Substantially, the findings from current investigation suggest the application of the values 0.9 µs, 100V, 29 mm/min, and 60 bar for Ton, U, S and p cutting parameters, respectively, for producing a good surface finish quality. Percent contributions of the machining parameters on SR (Ra) assessed based on ANOVA analysis are 62.94%, 20.84%, 11.46% and 4.74% for U, S, Ton and p, respectively. Subsequently, accurate predictive model for SR (Ra) is established based on response surface analysis (RSA). The contour plots for SR (Ra) indicate that when flushing pressure p converges to a critical value (80 bar), a poor-quality surface finish is highly expected with the excessive increase in U and S. Electron microscope scanning (SEM) observations have been performed on machined surface for a wide range of cutting parameters to characterize wire EDMed surface of Ti-6242. SEM micrographs indicate that the machined surface acquires a foamy structure and shows white layer and machining-induced damage that the characteristics are highly dependent on cutting parameters. At high servo-voltage, the decrease in pulse on time Ton and feed rate S results in a large decrease in overall machining-induced surface damage. Moreover, for high servo-voltage and feed rate levels, it has been observed that pulse on time could play a role of controlling the surface microcracks density. In fact, the use of a low pulse duration of cut combined with high servo-voltage and feed rate has been shown to inhibit surface microcracks formation giving the material surface a better resistance to cracking than at high pulse duration.

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Experimental Investigation and Optimization of Process Parameters in Ti – (6242) Alpha–Beta Alloy Using Electrical Discharge Machining

Cited by 18 publications

References 25 publications

Multiresponse Optimization of Wire Electrical Discharge Machining Parameters for Ti-6Al-2Sn-4Zr-2Mo (α-β) Alloy Using Taguchi-Grey Relational Approach

Multiresponse Optimization of Wire Electrical Discharge Machining Parameters for Ti-6Al-2Sn-4Zr-2Mo (α-β) Alloy Using Taguchi-Grey Relational Approach

Tribological analysis of wire additive manufactured Ti6Al4V by Electron Beam source

An Investigation To Achieve a Good Surface Integrity in WEDM of Ti-6242 Super Alloy

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