Optimization the Machining Parameters of Electro Chemical Discharge Machining of NiTi Shape Memory Alloys

Abstract

The electrochemical discharge machining (ECDM) is a combination effect of electrochemical machining in which metal is removed through the electrochemical process and electrical discharge machining in which metal is removed by rapid current discharges between two electrodes which are separated by a dielectric liquid and subject to an electric voltage. Difficulty of machining nickel titanium alloys by conventional methods such as; the significant tool wear, the need of highly experienced operators, and an excessive degradation in the material performance due to the high thermal and mechanical effects of these methods. For these, reasons non-conventional methods such as electrical discharge machining and electro chemical machining are often used to fabricate NiTi alloys with better machining results. The experiments were conducted with various conditions of voltage (50,60,70 and 80)V, dielectric solution concentration (30 and 40% of NaOH) and nanoparticles silver, and copper content (0.5% Cu, 0.5% Ag, 0.5% Cu and Ag) in the (55% Ni-45%Ti) alloy samples. The machining experiments were designed according to Taguchi's design of experiments (L32). Grey relational analysis was used to optimize the responses of the ECDM process. Material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) represent the response parameters for machining of the alloy samples prepared by the powder metallurgy route. To achieve the objectives of this research work MiniTab17 software was employed. The optimal conditions were: voltage of 50V, solution concentration of 40% and the sample (NiTi+0.5%Cu+0.5%Ag) have the highest effect on machining characteristics with MRR value of 0.04991mg/sec., tool wear rate value of 0.00125mg/sec., and surface roughness of 0.0117μm.