Powder mixed electric discharge machining of Ti6Al4V machined using composite electrode

Abstract

In this research work, an attempt was made to machine the medical grade titanium alloy using aluminium composite tool. The AA6061/Graphite composite tool was manufactured using the stir casting technique in which graphite of varying percentage was added as the reinforcing particles. SEM with EDS mapping showed that the Gr particles were uniformly distributed over the matrix material. The void content was determined by comparing experimental and theoretical density and it lies well below the prescribed limed. newlineElectric Discharge Machining (EDM) was executed on the Ti-6Al-4V titanium alloy by altering the tool materials discharge current, pulse on time, and pulse off time, with the responses documented including material removal rate, electrode wear rate, and surface roughness. The aluminium (A), copper (C) and aluminium alloy reinforced with graphite particles of various weight percentage (5 A1,10 A2,15 A3) were used as tool materials. The results obtained for the composite tools were compared with the conventional tool material. The titanium alloy machined with the A1 composite tool has the highest MRR, the C tool has the lowest EWR, and the A2 composite tool has a superior surface quality. Due to the eczema surface, the surface quality of specimens generated with the A1 tool is low. A remelted layer, pockmarks, and an uneven fusion structure are evident in specimens machined with the C tool, which were absent in the specimens machined with the A2. From the ANOVA table it was found that tool material followed by the current was the most influential process parameters which impact the machining performance. The optimal process parameters were identified using MOORA-ELECTREE integrated optimization techniques and tool proffers best machining performance was selected for further investigation. newline newline