Process parameter optimization of die-sinking EDM on Titanium grade – V alloy (Ti6Al4V) using full factorial design approach.

Verma, Vijay; Sahu, Rohit

doi:10.1016/j.matpr.2017.02.034

Cited by 34 publications

(16 citation statements)

References 3 publications

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“…The experimental results revealed an increase in material removal rate, surface roughness, electrode wear and average recast layer thickness with increasing current and pulse duration. Similar results were obtained by Verma et al [42], when applying full factorial approach for optimization of process parameter when EDmachining Ti-6Al-4V. Tsai et al [43] applied vibration assistant methods to EDM Ti-6Al-4V and compared to unassisted EDM.…”

Section: Edm Of Metals and Their Alloyssupporting

confidence: 73%

Materials used for sinking EDM electrodes: a review

Czelusniak

Higa

Torres

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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Over the years, sinking electrical discharge machining has become one of the most important production technologies to manufacture very accurate three-dimensional complex components on any electrically conductive material. This article reports a literature review on the diversity of conventional and non-conventional materials that are used or have potential to be used as EDM electrodes. In addition, additive manufacturing of EDM electrodes are also reviewed. Keywords Sinking electrical discharge machining • EDM electrodes • Materials for electrodes • Additive manufacturing List of symbols î e Discharge current (A) t 0 Pulse interval time (μs) p in Dielectric inlet pressure (Pa) t d Ignition delay time (μs) t e Discharge duration (μs) t i Pulse duration (μs) t p Pulse cycle time (μs) u e Discharge voltage (V) û i Open-circuit voltage (V) V e Electrode wear rate (mm 3 /min) V w Material removal rate (mm 3 /min) W e Discharge energy (J)

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Section: Edm Of Metals and Their Alloyssupporting

confidence: 73%

Materials used for sinking EDM electrodes: a review

Czelusniak

Higa

Torres

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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show abstract

“…At the same time, increased material removal rate results in a higher debris concentration in between the electrode and workpiece, which, from one point onwards, cannot be efficiently removed. Those debris may destabilize the process and/or cause arcing conditions, while, at the same time, machining power is spent on their re-melt [ 42 ]. Finally, decomposed carbon, coming from both the electrode (when a graphite electrode is utilized) and the dielectric fluid (when hydrocarbon oil is used), bonded on the surfaces, forming a “shield layer”, which, although it may act protectively for the tool electrode, may also be unbeneficial for the MRR [ 18 ].…”

Section: Resultsmentioning

confidence: 99%

A Comprehensive Study on Processing Ti–6Al–4V ELI with High Power EDM

et al. 2021

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Electrical Discharge Machining (EDM) consists of a non-conventional machining process, which is widely used in modern industry, and especially in machining hard-to-cut materials. By employing EDM, complex shapes and geometries can be produced, with high dimensional accuracy. Titanium alloys, due to their unique inherent properties, are extensively utilized in high end applications. Nevertheless, they suffer from poor machinability, and thus, EDM is commonly employed for their machining. The current study presents an experimental investigation regarding the process of Ti–6Al–4V ELI with high power EDM, using a graphite electrode. Control parameters were the pulse-on current (Ip) and time (Ton), while Machining performances were estimated in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The machined Surface Roughness was calculated according to the Ra and the Rt values, by following the ISO 25178-2 standards. Furthermore, the EDMed surfaces were observed under optical and SEM microscopy, while their cross sections were also studied in order the Average White Layer Thickness (AWLT) and the Heat Affected Zone (HAZ) to be measured. Finally, for the aforementioned indexes, Analysis Of Variance was performed, whilst for the MRR and TMRR, based on the Response Surface Method (RSM), semi-empirical correlations were presented. The scope of the current paper is, through a series of experiments and by employing statistical tools, to present how two main machining parameters, i.e., pulse-on current and time, affect major machining performance indexes and the surface roughness.

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“…The latter investigators, in a conceptually similar study, ascertained the differences in machining titanium alloys according to their Al content, emphasizing on the major role of polarity and dielectric fluid type. Although many researches have been carried out concerning the machining of Ti–6Al–4V and Ti–6Al–4V ELI with EDM 38 – 41 , research regarding other titanium grades is limited and probably inadequate 42 – 44 . Ahuja et al 45 presented a study regarding the bioactivity of commercially pure titanium processed by micro-electric discharge drilling, establishing that EDM is a feasible method for titanium machining.…”

Section: Introductionmentioning

confidence: 99%

A study on Electrical Discharge Machining of Titanium Grade2 with experimental and theoretical analysis

Papazoglou

Karmiris-Obratański

Leszczyńska-Madej

et al. 2021

Sci Rep

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Titanium alloys, due to their unique properties, are utilized in numerous modern high-end applications. Electrical Discharge Machining (EDM) is a non-conventional machining process, commonly used in machining of hard-to-cut materials. The current paper, presents an experimental study regarding the machining of Titanium Grade2 with EDM, coupled with the development of a simulation model. The machining performance indexes of Material Removal Rate, Tool Wear Ratio, and Average White Layer Thickness were measured and calculated for different pulse-on currents and pulse-on times. Moreover, the developed model that integrates a heat transfer analysis with deformed geometry, allows to estimate the power distribution between the electrode and the workpiece, as well as the Plasma Flushing Efficiency, giving an insight view of the process. Finally, by employing the Response Surface Methodology, educed regression models that correlate the machining parameters with the corresponding results, while for all the aforementioned indexes, ANOVA was performed.

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Process parameter optimization of die-sinking EDM on Titanium grade – V alloy (Ti6Al4V) using full factorial design approach.

Cited by 34 publications

References 3 publications

Materials used for sinking EDM electrodes: a review

Materials used for sinking EDM electrodes: a review

A Comprehensive Study on Processing Ti–6Al–4V ELI with High Power EDM

A study on Electrical Discharge Machining of Titanium Grade2 with experimental and theoretical analysis

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