Effect of Peak Current and Pulse-On Time on MRR and TWR in EDM of Ti-6Al-4 V

Abstract

AbstractElectro discharge machining is the non-conventional process of machining useful for manufacturing intricate shapes and difficult-to-cut materials like titanium, tungsten, etc. It removes the material from the workpiece by a series of sparks and the spark vibrancy depends on various parameters. Material removal rate and tool wear rate are used to determine the performance of any machining process. In case of EDM, MRR is very low and depends on various factors so having in-depth knowledge of the impact of process constants on MRR and TWR is necessary. In the current investigation, Ti-6Al-4 V (Ti64) alloy was machined with a copper electrode and various process parameters, namely, peak current and pulse-on time by an electrical discharge machining process to study its effect on Material Removal Rate (MRR) and Tool Wear Rate (TWR) of Ti-6Al-4 V. The depletion in weight of the sample is considered as a basis for determining MRR and TWR. The experimental outcomes showed that as peak current and pulse-on time rise, the MRR also rises, despite that the impact of pulse-on time was not that much considerable. Maximum material removal rate (3.2379 mm3/min) is obtained at Ip = 25 A, Ton = 150 µs. While in case of TWR, results showed that TWR rises with a rise in a peak current. Though longer pulse-on time resulted in a decrease in TWR. At Ip = 5A, Ton = 200 μs, the minimum tool wear rate (TWR) (0.0082 mm3/min) is observed.KeywordsEDMMRRTi-6Al-4 VTWR