Optimization of EDM Process Parameters in Machining of Titanium Alloy Used for Aerospace Applications

Abstract

The present-day industries demand products with high surface finish and greater accuracy. EDM is the most sought operation in many industries for material removal, and the process is governed by many controlling parameters. To increase the process performance, optimization of process parameters is done. In the current study, the influence of process variables like “peak current (Ip), pulse on time (Ton), pulse off time (Toff), gap voltage (Vg), and Flushing Pressure (FP) on Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR)” has been investigated for EDM of TiBT20 alloy. The work material possesses exotic mechanical properties and has diverse industrial applications in aerospace industries. Taguchi’s L27 orthogonal array was used for the optimization of input parameters. “Analysis of variance (ANOVA)” was performed to analyse the impact of parameters on the output response. Grey Relational Analysis determines the preferable set of input variables for high MRR, low TWR, and SR. The confirmation test with the optimum set of process parameters shows an enhancement of 0.3128 in the preferred value. The most suitable set of process variables is Ip = 4 Amp, Ton = 100 µs, Toff = 15 µs Vg = 4 V, and FP = 0.1 (Kgf/cm2).