Modeling of Material Removal on Machining of Ti-6Al-4V through EDM using Copper Tungsten Electrode and Positive Polarity

This paper deals optimized model to investigate the effects of peak current, pulse on time and pulse off time in EDM performance on material removal rate of titanium alloy utilizing copper tungsten as electrode and positive polarity of the electrode. The experiments are carried out on Ti6Al4V. Experiments were conducted by varying the peak current, pulse on time and pulse off time. A mathematical model is developed to correlate the influences of these variables and material removal rate of workpiece. Design of experiments (DOE) method and response surface methodology (RSM) techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance (ANOVA). The obtained results evidence that as the material removal rate increases as peak current and pulse on time increases. The effect of pulse off time on MRR changes with peak ampere. The optimum machining conditions in favor of material removal rate are verified and compared. The optimum machining conditions in favor of material removal rate are estimated and verified with proposed optimized results. It is observed that the developed model is within the limits of the agreeable error (about 4%) when compared to experimental results. This result leads to desirable material removal rate and economical industrial machining to optimize the input parameters.

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

[2]  G. G. Stokes.  "J." , 1890, The New Yale Book of Quotations.

[3]  Sameh Habib,et al.  Study of the parameters in electrical discharge machining through response surface methodology approach , 2009 .

[4]  U. Çaydas,et al.  Electrical discharge machining of titanium alloy (Ti–6Al–4V) , 2007 .

[5]  J. Y Kao,et al.  A neutral-network approach for the on-line monitoring of the electrical discharge machining process , 1997 .

[6]  Mohan Kumar Pradhan,et al.  Modelling of machining parameters for MRR in EDM using response surface methodology , 2008 .

[7]  Mahmudur Rahman,et al.  Machinability of titanium alloys , 2003 .

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

[9]  Masanori Kunieda,et al.  Advancing EDM through fundamental insight into the process , 2005 .

[10]  S. H. Lee,et al.  Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide , 2001 .

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

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

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

[14]  Andrew Kusiak,et al.  Handbook of design, manufacturing and automation , 1994 .

[15]  Pedro J. Arrazola,et al.  Comparison of the machinabilities of Ti6Al4V and TIMETAL® 54M using uncoated WC–Co tools , 2010 .

[16]  Pradeep Kumar,et al.  Numerical simulation of powder mixed electric discharge machining (PMEDM) using finite element method , 2008, Math. Comput. Model..

[17]  B. Yan,et al.  Study on the characteristics of electrical discharge machining using dielectric with surfactant , 2009 .

[18]  P. V. Rao,et al.  The effect of process parameters on machining of magnesium nano alumina composites through EDM , 2010 .

[19]  C. L. Lin,et al.  Optimisation of the EDM Process Based on the Orthogonal Array with Fuzzy Logic and Grey Relational Analysis Method , 2002 .