Abstract

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.

Highlights

  • Electro Discharge Machining (EDM) is a technologically advanced, high precision, non-conventional machining process

  • For all the aforementioned indexes (MRR, Tool Material Removal Rate (TMRR), Tool Wear Ratio (TWR), Ra, Rt, Average White Layer Thickness (AWLT), Heat Affected Zone (HAZ)) ANOVA was performed, to define how they are affected by the machining parameters, namely the pulse-on current and time

  • We find that for 25 A the increase in Ton does not significantly affect the Material Removal Rate (MRR), while for 25 and 33 A, as the pulse-on time increased from 100 to 200 μs, MRR slightly decreased

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Summary

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

Panagiotis Karmiris-Obratański 1,2, * , Emmanouil L. Papazoglou 1 , Beata Leszczyńska-Madej 3 , Krzysztof Zagórski 2 and Angelos P.

Introduction
Materials and Methods
Results and Discussion
Surface Roughness and Surface Quality
Conclusions
Full Text
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