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

Emmanouil L Papazoglou,Panagiotis Karmiris-Obratański,Beata Leszczyńska-Madej,Angelos P Markopoulos

doi:10.1038/s41598-021-88534-8

Emmanouil L Papazoglou, Panagiotis Karmiris-Obratański + Show 2 more

Open Access

https://doi.org/10.1038/s41598-021-88534-8

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Abstract

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.

Highlights

Electrical Discharge Machining (EDM) is classified as one of the earliest non-conventional machining processes, but it still finds extensive use and application in modern industry as a leading edge machining process in treating hard-to-cut m aterials[1]
The decrease of Tool Wear Ratio (TWR) are vital, in order for EDM to become economically competitive in comparison to conventional machining processes
The aim of the current paper is to present a comprehensive investigation of machining Titanium Grade[2] with EDM, providing experimental, and simulation data, while via the semi-empirical correlations, a predictability, regarding the process, is gained

Summary

Introduction

Electrical Discharge Machining (EDM) is classified as one of the earliest non-conventional machining processes, but it still finds extensive use and application in modern industry as a leading edge machining process in treating hard-to-cut m aterials[1]. The fundamental principle of EDM is that material removal is resulted by means of rapid repetitive spark discharges, which occur between a working electrode and the workpiece. EDM is a non-contact machining process, since no contact exists between the working electrode and the workpiece, no cutting forces are developed, leading to absence of mechanically induced residual stresses in the workpiece material. Aiming on a simplified approach, in some simulations the PFE is considered 100%25 or silently neglected, implying that molten material is totally removed by the formatted crater. Such a hypothesis is clearly inaccurate, since it cannot interpret the White Layer (WL) formation and be in agreement with experimental results. It pertains to a model that explains and describes the occurring physical phenomena, but is capable of predicting the results of the machining process

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