Assessment of material removal capability with vibration-assisted wire electrical discharge machining

Abstract

Titanium alloys are prevalently used in automotive, aerospace and biomedical applications. It is identified as not easy to machine by conventional machining process because of fast tool wear. Hence, for machining of titanium alloy, non-conventional machining processes are generally recommended. In non-conventional machining, vibration assisted Wire Electrical Discharge Machining has shown promising results to improve the machining rate. The present work will focus on machining of titanium alloy workpiece by vibrating the wire in lateral direction with varied frequency of excitation to enhance the material removal rate and to obtain the required kerf width in Wire Electrical Discharge Machining. Experiments were performed on Ti-6Al-4V alloy material during a wire electrical discharging machine operation using zinc coated brass wire and brass wire electrode. Roughness with all those irregularities on machined surface, with varied vibration condition, are measured with contact stylus type surface roughness measuring instrument. Machined kerf size was measured using non-contact optical Co-ordinate Measuring Machine. White layer formed and surface integrity were examined through Scanning Electron Microscope with provision of Energy Dispersive Spectroscopy. The developed vibrating system worked effectively, improved material removal rate and their surface modification has been obtained and reported.