Electric discharge machining of titanium and its alloys: a review

Titanium alloys have been widely used in many industries because of their high strength-to-weight ratio, resistance to corrosion and high temperature stability. However, inherent properties like low thermal conductivity and chemical reactivity at elevated temperatures pose a major problem in machining of these alloys. Electric discharge machining (EDM) is a non-traditional material removal process used for machining of high strength-high temperature resistant (HSTR) alloys, tough and fragile components of electrically conductive materials by using shaped tools in the presence of dielectric fluid. The present paper reviews the fundamental principles of EDM and work done with regard to effect of operating parameters on material removal rate (MRR), tool wear rate (TWR), surface roughness and surface improvements on titanium alloys work piece.

[1]  David K. Aspinwall,et al.  Workpiece surface modification using electrical discharge machining , 2003 .

[2]  M. Shunmugam,et al.  Improvement of wear resistance by EDM with tungsten carbide P/M electrode , 1994 .

[3]  B. Yan,et al.  Improvement of surface finish on SKD steel using electro-discharge machining with aluminum and surfactant added dielectric , 2005 .

[4]  V. Firouzdor,et al.  Effect of deep cryogenic treatment on wear resistance and tool life of M2 HSS drill , 2008 .

[5]  I. Puertas,et al.  A study on the machining parameters optimisation of electrical discharge machining , 2003 .

[6]  Yun-lai Deng,et al.  Effects of cryogenic treatment on mechanical properties of extruded Mg-Gd-Y-Zr(Mn) alloys , 2007 .

[7]  J. S. Khamba,et al.  Investigation for ultrasonic machining of titanium and its alloys , 2007 .

[8]  Yue Jiao,et al.  Rotary ultrasonic machining of ceramic matrix composites: feasibility study and designed experiments , 2005 .

[9]  Naotake Mohri,et al.  Simultaneous finishing a pair of dies by electrical discharge grinding , 1997 .

[10]  Nobuhiro Nakajima,et al.  High Speed 3D Milling by Dry EDM , 2003 .

[11]  S. K. Ho,et al.  Use of powder metallurgy (PM) compacted electrodes for electrical discharge surface alloying/modification of Ti–6Al–4V alloy , 2007 .

[12]  V. N. Moiseev Titanium in Russia , 2005 .

[13]  Paolo Baldissera Fatigue scatter reduction through deep cryogenic treatment on the 18NiCrMo5 carburized steel , 2009 .

[14]  Z. M. Wang,et al.  Titanium alloys and their machinability—a review , 1997 .

[15]  Mark A.M. Bourke,et al.  Microstructure of cryogenic treated M2 tool steel , 2003 .

[16]  B. Sethi,et al.  To Investigate the Phenomenon of Surface Modification in Die Steels Using EDM Process , 2008 .

[17]  M. Barash,et al.  Experiments with electric spark toughening , 1964 .

[18]  Ulaş Çaydaş,et al.  A comparative study of surface integrity of Ti–6Al–4V alloy machined by EDM and AECG , 2007 .

[19]  Naotake Mohri,et al.  Metal Surface Modification by Electrical Discharge Machining with Composite Electrode , 1993 .

[20]  A. Khan,et al.  Reducing electrode wear ratio using cryogenic cooling during electrical discharge machining , 2009 .

[21]  Shane Y. Hong,et al.  New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4V , 2001 .

[22]  Biing-Hwa Yan,et al.  Machining characteristics of titanium alloy (Ti–6Al–4V) using a combination process of EDM with USM , 2000 .

[23]  S. Kumar,et al.  Comparison of material transfer in electrical discharge machining of AISI H13 die steel , 2009 .

[24]  Norliana Mohd Abbas,et al.  A review on current research trends in electrical discharge machining (EDM) , 2007 .

[25]  Yan-Cherng Lin,et al.  Surface modifications of Al–Zn–Mg alloy using combined EDM with ultrasonic machining and addition of TiC particles into the dielectric , 2009 .

[26]  W. J. Kroll,et al.  How commercial titanium and zirconium were born , 1955 .

[27]  A. Khanra,et al.  Electrical discharge machining studies on reactive sintered FeAl , 2006 .

[28]  Liam Blunt,et al.  Effect of EDM process parameters on 3D surface topography , 2004 .

[29]  S. Kalia Cryogenic Processing: A Study of Materials at Low Temperatures , 2010 .

[30]  A. Amin,et al.  Improved tool life in end milling Ti-6Al-4V through workpiece preheating , 2009 .

[31]  Stephen T. Newman,et al.  State of the art electrical discharge machining (EDM) , 2003 .

[32]  Makoto Miyazaki,et al.  Electrical discharge machining with ultralow discharge energy , 2006 .

[33]  K. J. Stout,et al.  Electrical discharge texturing , 1992 .

[34]  Wang Zhenlong,et al.  Ultrasonic and electric discharge machining to deep and small hole on titanium alloy , 2002 .

[35]  Zhimin Yin,et al.  Effects of cryogenic treatment on mechanical properties and microstructure of Fe-Cr-Mo-Ni-C-Co alloy , 2008 .

[36]  Kalyan Kumar Ray,et al.  Correlation of microstructure with wear behaviour of deep cryogenically treated AISI D2 steel , 2009 .

[37]  O. A. Abu Zeid,et al.  On the effect of electrodischarge machining parameters on the fatigue life of AISI D6 tool steel , 1997 .

[38]  David Dornfeld,et al.  Drilling Burr Formation in Titanium Alloy, Ti-6AI-4V , 1999 .

[39]  Ajit Behera NON-CONVENTIONAL MACHINING , 2012 .

[40]  B. Yan,et al.  Study of added powder in kerosene for the micro-slit machining of titanium alloy using electro-discharge machining , 2000 .

[41]  M. I. Ahmed,et al.  Effectiveness of cryogenic machining with modified tool holder , 2007 .

[42]  C. Çoǧun A technique and its application for evaluation of material removal contributions of pulses in electric discharge machining (EDM) , 1990 .

[43]  K. Furutani,et al.  Influence of electrical conditions on performance of electrical discharge machining with powder suspended in working oil for titanium carbide deposition process , 2009 .

[44]  Kazuo Yamazaki,et al.  A fundamental study on Ti–6Al–4V's thermal and electrical properties and their relation to EDM productivity , 2008 .

[45]  G. K. Lal,et al.  Experimental investigations into electrical discharge machining with a rotating disk electrode , 1993 .

[46]  R. J. Grieve,et al.  Ultrasonic machining—a review , 1975 .

[47]  Jun Wang,et al.  Effects of high temperature and cryogenic treatment on the microstructure and abrasion resistance of a high chromium cast iron , 2009 .

[48]  Asit Baran Puri,et al.  An analysis and optimisation of the geometrical inaccuracy due to wire lag phenomenon in WEDM , 2003 .

[49]  Rupinder Singh,et al.  Surface modification by electrical discharge machining: A review , 2009 .

[50]  Yih-fong Tzeng,et al.  Effects of Powder Characteristics on Electrodischarge Machining Efficiency , 2001 .

[51]  Kamlakar P Rajurkar,et al.  Material Removal in WEDM of PCD Blanks , 1993 .

[52]  S. K. Choudhury,et al.  Investigation of tool wear and cutting force in cryogenic machining using design of experiments , 2008 .

[53]  L. Froyen,et al.  Study of the white layer of a surface machined by die sinking electro discharge machining , 1995 .

[54]  Pradeep Kumar,et al.  PARAMETRIC OPTIMIZATION OF POWDER MIXED ELECTRICAL DISCHARGE MACHINING BY RESPONSE SURFACE METHODOLOGY , 2005 .

[55]  Yakup Yildiz,et al.  A review of cryogenic cooling in machining processes , 2008 .

[56]  Tai Chiu Lee,et al.  Study on the machining mechanism of WEDM with ultrasonic vibration of the wire , 1997 .

[57]  Y. Wong,et al.  EDM performance of TiC/copper-based sintered electrodes , 2001 .

[58]  J. S. Khamba,et al.  Ultrasonic machining of titanium and its alloys : A review , 2006 .

[59]  B. Yan,et al.  The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium , 2005 .

[60]  J. Soni,et al.  Machining characteristics of titanium with rotary electro-discharge machining , 1994 .

[61]  E. C. Jameson,et al.  DESCRIPTION AND DEVELOPMENT OF ELECTRICAL DISCHARGE MACHINING , 2001 .

[62]  J. S. Soni Microanalysis of debris formed during rotary EDM of titanium alloy (Ti 6A1 4V) and die steel (T 215 Cr12) , 1994 .

[63]  Bijoy Bhattacharyya,et al.  Investigation of electro-discharge micro-machining of titanium super alloy , 2009 .

[64]  K. Ray,et al.  Optimization of the duration of cryogenic processing to maximize wear resistance of AISI D2 steel , 2009 .

[65]  Bijoy Bhattacharyya,et al.  Comparative study of different dielectrics for micro-EDM performance during microhole machining of Ti-6Al-4V alloy , 2010 .

[66]  B. Yan,et al.  Use of micro ultrasonic vibration lapping to enhance the precision of microholes drilled by micro electro-discharge machining , 2002 .