Abstract
Titanium alloys, especially Ti-6Al-4V, which is considered a difficult-to-cut material, bears numerous applications in aerospace and biomedical sectors. The criticality of the accurate formation of the machined cavity for the said applications and properties of Ti-6Al-4V accentuated the use of electric discharge machining (EDM). However, the issues of lower material removal rate (MRR) and tool wear (TWR) discouraged the use of EDM. These inherent issues hold a pivotal role regarding the sustainable machining of Ti-alloy. Therefore, in this research the potentiality of kerosene-based dielectric, having graphene nanoparticles, is comprehensively examined for the sustainable EDM of Ti-6Al-4V, which was not focused upon yet. Experimentation was performed under Taguchi’s design (L18) with three types of electrodes, namely Aluminum, Brass and Copper. In total, 36 experiments were conducted, of which 18 were with graphene-mixed dielectric and the remaining were with kerosene. Experimental results reveal that the brass electrode with negative tool polarity yields higher MRR for both types of dielectrics. The maximum MRR (7.602 mm3/min) achieved with graphene mixed dielectric is 64.5% greater as compared to that obtained with kerosene (4.621 mm3/min). Moreover, the minimum TWR obtained for graphene-based dielectric, i.e., 0.17 mg/min is approximately 1.5 times less than that achieved with kerosene.
Highlights
Titanium (Ti) and its alloys are extensively employed in the manufacturing of different parts/products in many industrial and commercial applications
The results revealed that the application of Ti nano-powder in the dielectric yields better material removal rate (MRR) and surface finish [34]
This research focuses on evaluating the cutting performance of the graphene-based kerosene dielectric for the two core contributing aspects (MRR and Tool Wear Rate (TWR)) of the sustainable electric discharge machining of titanium alloy (Ti6Al4V)
Summary
Titanium (Ti) and its alloys are extensively employed in the manufacturing of different parts/products in many industrial and commercial applications. Another researcher [19] investigated the performance of machining attributes of Ti-6Al-4V in combination with ultrasonic machining They studied the effect of different factors, which include type of dielectric, size and concentration of particles, discharge current and pulse on time, on the multiple responses (MRR, EWR, roughness, and depth of redeposited layer). The inclusion of Al2O3 nanoparticles in deionized water lowers the micro-cracks on the machined cavity in the EDM of super alloy Inconel 825 with a copper electrode [38] Another important attribute that determines the efficacy of a powdered mixed dielectric in EDM is its concentration. Significant efforts have been made in the past for achieving high MRR and low TWR in the EDM of Ti6Al4V, considering different means, i.e., by adding certain additives or by adjusting the parameters or by some modification in the cutting mechanism. Aannaloypstiischalasmailcsroosbceoepnidc oannealfyosrisprhoavsidalisnog btheeenindsoignhet foofrtpheropvairdaimngettrhice einffseicgths tinofrethlaetipoanrtaomtheetsreicleecftfeedctrseisnporenlsaetsio. nOptotitmhaelsseeltetcintegds rheasvpeoanlsseosb. eOepntdimevaellsoeptetidn,gbsahseadveoanlsthoebpeaernamdeevtreilcotrpeendd,sb. ased on the parametric trends
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