Abstract
Titanium alloy is widely used for orthodontic technology and easily machined using the EDM process. In the EDM process, the workpiece and tool electrode must be separated by a continuous air gap during the machining operation to generate discharge energy in this method. In the present study, an endeavor was made to analyze the effects of a servo feed air gap control and tool electrode in the EDM process. The developed mechanical setup consists of a linear action movement with zero backlash along the X-axis, which can be controlled up to 0.03 mm. It was observed that the suggested air gap control scheme can enhance the servo feed mechanism on a machining titanium alloy. A tungsten carbide electrode can enhance the surface measures owing to its ability to produce tiny craters with uniform distribution. Since it produces a little crater and has a higher melting point, a tungsten carbide electrode can create lesser surface roughness than a copper tool and brass tool electrode.
Highlights
Titanium alloy (Ti-6Al-4V) is mostly used in the orthodontic field due to its lower weight and higher corrosion resistance [1]
Since the electrical conductive electrode and specimen were separated by a dielectric medium, electrical discharge happened across the machining zone [12]
The electrical conductivity of the tool electrode can modify the energy developed during the machining process [21]
Summary
Titanium alloy (Ti-6Al-4V) is mostly used in the orthodontic field due to its lower weight and higher corrosion resistance [1]. Since the electrical discharge energy can be controlled by an air gap or stand-off distance (SOD) across the machining zone, the distance between the tool and the electrode should remain constant by implementing a servo tool feed mechanism in the EDM process [6]. It was discovered that just a few studies were conducted to examine the effect of the tool electrode on the surface quality during the die sinking EDM process when machining a titanium alloy. The purpose of this work is to develop a gap voltage sensing-based servo feed control system for efficient monitoring of the electrical discharge machining process. To implement an adaptive gap control mechanism to reduce the arcing effect while machining a titanium alloy;. To conduct an analysis of the tool electrode’s impacts on the surface roughness and morphology in the die sinking EDM process
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