Abstract
Ti-6Al-4V is an alloy that has a high strength-to-weight ratio. It is known as an alpha-beta titanium alloy with excellent corrosion resistance. This alloy has a wide range of applications, e.g., in the aerospace and biomedical industries. Examples of alpha stabilizers are aluminum, oxygen, nitrogen, and carbon, which are added to titanium. Examples of beta stabilizers are titanium–iron, titanium–chromium, and titanium–manganese. Despite the exceptional properties, the processing of this titanium alloy is challenging when using conventional methods as it is quite a hard and tough material. Nonconventional methods are required to create intricate and complex geometries, which are difficult with the traditional methods. The present study focused on machining Ti-6Al-4V using wire electrical discharge machining (WEDM) and conducting numerous experiments to establish the machining parameters. The optimal setting of the machining parameters was predicted using a multiresponse optimization technique. Experiments were planned using the response surface methodology (RSM) technique and analysis of variance (ANOVA) was used to determine the significance and contribution of the input parameters to changes in the output characteristics (cutting speed and surface roughness). The cutting speed obtained during the processing of the annealed titanium alloy using WEDM was quite large as compared to the cutting speed obtained in the case of processing the pure, quenched, and hardened titanium alloys using WEDM. The maximum cutting speed obtained while processing the annealed titanium alloy was 1.75 mm/min.
Highlights
Experimentation was performed on the titanium alloy under various heat-treated conditions and cutting was done as per the defined process parameters
The analysis for the machining of the titanium alloys was studied with the use of expert design software (DOE, V 13, StatEase, Minneapolis, MN, USA) and 3D graphs were analyzed to study the behavior of the cutting speed in response to the variations in the process parameters
In the wire electrical discharge machining (WEDM) of the titanium superalloy (Ti-6Al-4V), the response surface methodology (RSM) was used to build a mathematical model in the form of multiple regression equations that correlated the dependent and independent parameters
Summary
Excellent mechanical properties (hardness, fatigue resistance, tensile strength, toughness, etc.), high wear and corrosion resistance, good weldability, and a high strength-toweight ratio are some of the major properties of titanium that make it suitable for making different dies, parts, molds, cavities, etc. Different reinforcements are added to the base material to improve the physical and mechanical properties of the material, which makes the material more suitable for different applications [2]. Titanium and its alloys have wide applications in different fields, such as in the marine engineering, aerospace engineering, petroleum refining, and chemical industries. Ti-6Al-4V (6% aluminum and 4% vanadium) is a titanium-based alloy that is widely used because of its high fatigue resistance and good corrosion resistance capacity.
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