Effects of pulse ON and OFF time and electrode types on the material removal rate and tool wear rate of the Ti-6Al-4V Alloy using EDM machining with reverse polarity

Abstract

Electrical Discharge Machining (EDM) is an unconventional metal removal process that is extensively used for removing the difficult-to-machine metal such as Ti alloys, super alloys and metal matrix composites. This paper investigates the effects of pulse (ON/OFF) time on EDM machining characteristics of Ti-6Al-4V alloy using copper and graphite as electrodes in reverse polarity condition. Full factorial design method was used to design the experiments. Two variables (Pulse On and OFF) with three levels are considered. The output variables are the tool wear rate and the material removal rate. The important findings from the present work are: (1) the material removal rate (MRR) increases gradually with an increase of the Pulse ON time whereas the change is insignificant with an increase of the Pulse OFF time, (2) Between copper and graphite electrodes, the copper electrode is proved to be good in terms of MRR, (3) a combination of high pulse ON time and OFF time is desirable for high MRR rate in the Cu electrode whereas for the graphite electrode, a combination of high pulse ON time and low pulse OFF time is desirable for high MRR rate, (4) the tool wear rate (TWR) reduces with the Pulse On or OFF time, the rate of TWR is uniform for the graphite electrode in contrast to abrupt decrease from 25 to 50 μs (pulse ON time) in the copper electrode, (5) In order to keep the TWR as minimum possible, it is desirable to have a combination of high pulse ON time and OFF time for both the copper and the graphite electrode.