Parameters optimization for sustainable machining of Ti6Al4V using a novel high-speed dry electrical discharge milling

Cleaner production and sustainability are of crucial importance in the field of machining processes where great amount of energy is being consumed. This paper outlines the application of gray relational theory in order to optimize the machining parameters for Ti6Al4V in high-speed dry electrical discharge milling (EDM) using a tubular graphite electrode. The objective of optimization is to achieve simultaneously the minimum power consumption and the maximum material removal rate (MRR). The maximum MRR 5634 mm3/min was obtained with a power consumption of 7.61 kW. MRR stayed in the similar level, and power consumption was reduced by 17.82 % compared with that of the parameters in our previous study. Current is the main effect factor on MRR and power consumption. The corresponding single pulsed experiments were conducted to deeply explore the reasons for the influence of air pressure and electrode rotation speed on the MRR and power consumption.

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