Electro Discharge Machining of Ti-Alloy (Ti6Al4V) and 316L Stainless Steel and Optimization of Process Parameters by Gre
Increasing demand on micro-product leads to the development of innovative manufacturing process in nonconventional machining process to these micro-scale applications. In the medical field a huge variety of products can be found in prosthesis, surgery dev
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Abstract Increasing demand on micro-product leads to the development of innovative manufacturing process in nonconventional machining process to these micro-scale applications. In the medical field a huge variety of products can be found in prosthesis, surgery devices and tissue engineering, which required the application of the EDM process to manufacture micro cavities. Now-a-days the materials like Ti-alloy (Ti6Al4V) and 316L Stainless Steel are widely used in biomedical fields, which are very difficult to machine. These materials are also used in additive manufacturing process. Here it presents an experimental study of electro-discharge machining (EDM) of titanium alloy (Ti6Al4V) and 316L Stainless Steel. The objective of this work is to study the effect and optimization of machining process parameters like pulse-on-time, discharge current and duty cycle on process performance parameters such as material removal rate (MRR), tool wear rate (TWR) and Radial over cut (ROC). A Taguchi L9 design of experiment (DOE) has been applied and three levels of process parameters have been taken. The optimization method Grey relational analysis (GRA) method was used to optimize the parameters. The Analysis of Variance (ANOVA) also indicated the percentage contribution of machining parameters that influence response performance parameters. By the GRA method it was found that for Ti-alloy the machining parameter duty cycle (DC) has maximum percentage contribution on the output responses followed by discharge current (Ip) and pulse on time (TON). Similarly for 316L Stainless Steel the
A.K. Sahu (&) P.P. Mohanty S.K. Sahoo Department of Mechanical Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India e-mail: [email protected] P.P. Mohanty e-mail: [email protected] S.K. Sahoo e-mail: [email protected] © Springer Science+Business Media Singapore 2017 D.I. Wimpenny et al. (eds.), Advances in 3D Printing & Additive Manufacturing Technologies, DOI 10.1007/978-981-10-0812-2_6
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machining parameter discharge current (Ip) has maximum percentage contribution on the output responses followed by pulse-on-time (TON) and duty cycle (DC).
Keywords EDM Taguchi design Multi-response optimization method relational analysis method ANOVA
Grey
1 Introduction Electro discharge machining (EDM) is a non-traditional machining process, which is very widely used in recent days. In EDM both the work piece and tool are immersed inside a dielectric medium. When a voltage is applied to the work piece and tool circuit, there is a generation of spark in between the electrodes (tool and work piece). Therefore, very high temperature is generated in the spark gap region. Due to the high temperature, the material removal occurs from the work piece by the process of melting and evaporation. In EDM both tool and work piece are electrically conducting [1, 2]. Titanium is a metal with high corrosion resistance, temperature resistance and high strength to weight ratio [3
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