Investigation of Surface Quality in Cost of Goods Manufactured (COGM) method of µ-Al2O3 Powder-Mixed-EDM Process on Machining of Ti-6Al-4V

Abstract

It is very essential to form such high stregth and hard-to-cut materials by using modern machining methods. It is important to introduce the efforts on modification of the process for improving the machining quality. In the present investigation, an effort was made to analyze the effects of micro size aluminium particles mixed dielectric medium under different powder concentration on machining titanium alloy in electro erosion process. The response-surface-methodology(RSM) based algorithm was utilized to analyze the performance measures by considering machinning time with Cost of Goods Manufactured (COGM) method in PMEDM process. It was found that the micron size powders can significantly help to enhance the surface quality of the Ti-6Al-4V surface during machining in EDM process. The presence of carbon, oxygen elements and the formation of surface oxides and carbides has been found due to the decomposition of dielectric fluid in PMEDM process. The lower deep cavities and uniform machining surface have been produced with the aluminum oxide powder EDM process owing to lower surface cracks density, conductivity. To sum up, investigation and comparison of surface scanning showed that this setting has been implied could be considered by the industries needs more precision.

Multi-criteria decision making in electrical discharge machining with nickel coated aluminium electrode for titanium alloy using preferential selection index

“…Step 3: Standardization of the indicators: MRR is normalized according to equation (2a) and TWR is normalized according to equation (2b), the results are shown in Table 4. Step 4 to step 8: The results are calculated according to the equations ( 3)- (8). The values of the calculated results are shown in Table 5.…”

“…The large number of process parameters with wide range makes high difficult to optimize process parameters in EDM [6]. Hence the optimization for improving machining productivity and machined surface quality in EDM is still attracting the attention of many researches and experts [7][8][9][10]. Using coated electrode in EDM is a new research direction, its results are very feasible in practice and industrial manufacturing [11,12].…”

Multi-objects optimization in μ-EDM using AlCrN coated tungsten carbide electrode by Deng's method

“…There are many particles on the machined surface, and this will affect the surface texture after machining. The cause of the appearance of adherent particles on the machined surface is that the electrode and workpiece materials are melted and evaporated, and they are rapidly cooled by the dielectric solution [3]. However, they were not pushed out of the discharge gap by the dielectric solution.…”

“…In addition, the EDX analysis of the machined surface also shows that the composition of the chemical elements of the machined surface layer is changed compared to the base layer, and electrode materials created a coating on the machined surface, Figure 8. The cause may be that the worn electrode material has penetrated into the machined surface, and this causes a change in the chemical composition of the machined surface [3]. The above changes will directly affect the working condition of the machined surface.…”

“…Improving machining productivity, machining accuracy and machining quality are the main current research directions in this field [2]. Several technical solutions have been introduced to achieve these goals, but the technical complexity of use and application costs are high and this has affected their application in practice [3][4][5]. Currently, research on optimizing technological parameters in micro-EDM and micro-EDM using coated electrodes is a promising research path with high potential [6][7][8].…”