Process parameter optimization of die-sinking EDM on Titanium grade – V alloy (Ti6Al4V) using full factorial design approach.

Abstract

EDM is the most versatile and universally accepted modern machining process having vast application in manufacturing industries. The main drawback of this process is lower machining yield and less dimensional control. In this process the machining rate is independent of the work material hardness as the machining is not due to physical contact between work material and tool. The titanium alloy is an important material having vast application in aerospace and other important engineering and bio-medical field. Due to low machining yield and dimensional control, there is an strict requirement for optimizing the governing machining parameters of EDM. In the present study the process parameters of die-sinking EDM was experimentally, optimized by using full factorial technique for machining titanium grade – V alloy. Peak current, gap voltage, pulse on time and dielectric fluid pressure was taken as input control parameter while material removal rate and surface roughness were taken as response parameters. It was found that peak current and gap voltage are the main control parameters for increasing material removal rate. The scanning electron microscope images of the machined surface were analyzed to determine the effect of increasing control parameter on the response output.