Effect of coated and treated electrodes on Micro-EDM characteristics of Ti-6Al-4V
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(2020) 42:517
TECHNICAL PAPER
Effect of coated and treated electrodes on Micro‑EDM characteristics of Ti‑6Al‑4V R. Naveen Anthuvan1 · V. Krishnaraj1 Received: 7 August 2019 / Accepted: 18 August 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020
Abstract This research work was carried out to find a suitably treated electrode for the required machining output response like MRR and TWR. The experimental design was formed using Box–Behnken design. Experiments were conducted to machine 500 µm holes on titanium (Ti-6Al-4V) alloy using copper electrodes. Input parameters selected were input current (Ip), pulse-on time (Ton), and pulse-off time (Toff). Material removal rate and tool wear rate were analyzed using contour plots. Based on these experimental data, the grey relational analysis technique was applied to find the optimal parameters for achieving maximum MRR and minimum TWR. Optimal parametric values obtained were input current (Ip) 4.0 A, pulse on time (Ton) 2.0 µs and pulse off time (Toff) 6.4 µs. The achieved optimized parameters were further used to conduct experiments with cryogenic treated and coated electrodes. Electrodes were coated with conductive materials (silver, nickel, and zinc) and non-conductive material (epoxy). The experimental results showed each type of electrode enhances a particular machining characteristic such as silver-coated electrode produced a higher value of MRR, epoxy-coated electrode achieved minimum TWR. It is observed from the results that this work can be applied to identify the suitable electrode for producing the desired machining output characteristics. Keywords EDM · Ti-6Al-4V · MRR · TWR · SR · GRA · Copper · Nickel · Silver · Zinc · Cryogenic
1 Introduction EDM is an electrothermal non-conventional machining process, in which the material removal mainly occurs due to the thermal energy of the electrical spark generated during machining. The electrical spark is generated by the means of short-duration electrical impulses between the tool and the workpiece. In EDM, the shape machined in the workpiece is the replica of the shape of the tool. On the contrary to conventional machining processes, there will be no contact between the workpiece and the tool in EDM. Also, the machining force is very low when compared with the conventional machining process and the hardness of the tool is not higher than that of the workpiece as in the conventional machining process. Technical Editor: Lincoln Cardoso Brandao, Ph.D.. * R. Naveen Anthuvan [email protected] 1
Department of Production Engineering, PSG College of Technology, Coimbatore, Tamilnadu, India
The desired properties in the recent application of automotive, aerospace, and medical instruments are high strength to weight ratio, high hardness, low wear, and corrosion resistance. These conditions lead to the replacement of conventional materials with advanced materials like titanium alloy, Inconel, magnesium alloy, and composites. [1] But these advanced materials had poor machinability on the c
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