Alumina Nano Powder Impact on Electrical Discharge Machining of Titanium Alloy Wire

Abstract

WEDM is an unconventional method of thermal machining that produces products with irregular shapes. The results of milling titanium (TI-6242) under various machining conditions that affect the WEDM process are provided. Pulse on time (Ton), pulse off time (Toff), peak current (Ip), voltage (V), wire tension (Wt), and wire feed are all considered machining parameters (Wf). They are established using an experimental design and the Box–Behnken approach to optimize the machining factors. The optimization goal is to attain the highest Material Removal Rate (MRR) and the least amount of recast layer (RL). ANOVA determines the most important factor. Moreover, a regression analysis is used to predict MRR and RL based on defined machining parameters. Ton = 120s, Toff = 50s, Ip = 11 A, Wt = 1kg, and V = 50 volt are the optimal regulatory factors for obtaining the highest MRR, depending on the consequences. Ton = 130s, Toff = 60s, Ip = 12 A, Wt = 3 kilogram, and V= 30 volt are the best control variables for achieving the lowest RL. Ton = 120s, Toff = 50s, Ip=10 A, and Wt=1kg are thought to be the ideal control parameters for achieving minimum RL and greatest MRR. In ideal machining circumstances, the microstructure of the machined surface exhibits a recast layer on the machined surface.