Optimization of Machining Process on Coated Tungsten Carbide Electrode Tool and Titanium Alloy Workpiece Using EDM: A Critical Review

Article Preview

Abstract:

Commercial applications for Ti 6Al 4V, an alloy composed of titanium, aluminium, and vanadium, are possible. The features of titanium alloy include: Lightweight, non-magnetic, high melting point, outstanding fatigue strength, superior specific strength, great corrosion resistance, and biocompatibility. Reviewing the electro-discharge machining of titanium alloy (Ti 6Al 4V) as a workpiece, silicon carbide particle combined with EDM oil, and coated tungsten carbide electrode, this research examines this process. Dielectric fluid's impact on microhardness, surface finishing, TWR, and MRR. MRR is raised by silicon particles and coated tungsten carbide electrodes with EDM fluid. According to the study, the most important input parameters for determining TWR, MRR, surface finishing, and micro-hardness are voltage, current, pulse on time (Tonne), and pulse off time (Toff).

You might also be interested in these eBooks

Info:

Periodical:

Pages:

77-85

Citation:

Online since:

August 2024

Export:

Price:

Permissions CCC:

Permissions PLS:

Сopyright:

© 2024 Trans Tech Publications Ltd. All Rights Reserved

Share:

Citation:

* - Corresponding Author

[1] Rizwee, M., & Rao, Dr. P. S. (2021). Analysis & Optimization of Parameters During EDM of Aluminium Metal Matrix Composite. Journal of University of Shanghai for Science and Technology, 23(3).

DOI: 10.51201/jusst12671

Google Scholar

[2] Huu, P. N., Muthuramalingam T, Van, D. P., Shirguppikar, S., Tien, D. H., Van, T. N., & Trong, L. N. (2022a). Multi-objects optimization in µ-EDM using AlCrNi-coated tungsten carbide electrode for Ti-6AL-4 V. International Journal of Advanced Manufacturing Technology, 122(5–6), 2267–2276.

DOI: 10.1007/s00170-022-10022-8

Google Scholar

[3] Kunal, P. Sudhakar Rao, Mohd. Yunus Khan, K. Saidaiah (2022). A review of electrical discharge machining on various superalloy.

DOI: 10.1016/j.matpr.2022.04.429

Google Scholar

[4] Palanisamy, D., Devaraju, A., Manikandan, N., Balasubramanian, K., & Arulkirubakaran, D. (2020). Experimental investigation and optimization of process parameters in EDM of aluminium metal matrix composites. Materials Today: Proceedings, 22, 525–530.

DOI: 10.1016/j.matpr.2019.08.145

Google Scholar

[5] Panchal, V. A., Patel, R. K., Patel, B. A., & Patel, H. A. (2014). International Journal on Recent and Innovation Trends in Computing and Communication Effect of Process Parameters on Surface Quality and MRR in EDM of SS 440 C Using ANN.

Google Scholar

[6] Banu, A., & Ali, M. Y. (2016). Electrical Discharge Machining (EDM): A Review. International Journal of Engineering Materials and Manufacture, 1(1), 3–10.

DOI: 10.26776/ijemm.01.01.2016.02

Google Scholar

[7] Harish, I., & Sai Phani Kumar, K. (2022). Comparative Analysis Of Two Different Wire Electrodes In A Wire EDM Machining Using TOPSIS Technique. In International Journal of Mechanical Engineering (Vol. 7, Issue 5).

Google Scholar

[8] Abhilash, P. M., & Chakradhar, D. (2022). Multi-response Optimization of Wire EDM of Inconel 718 Using a Hybrid Entropy Weighted GRA-TOPSIS Method. Process Integration and Optimization for Sustainability, 6(1), 61–72.

DOI: 10.1007/s41660-021-00202-6

Google Scholar

[9] D'Urso, G., Maccarini, G., & Ravasio, C. (2016). Influence of electrode material in micro-EDM drilling of stainless steel and tungsten carbide. International Journal of Advanced Manufacturing Technology, 85(9–12), 2013–2025.

DOI: 10.1007/s00170-015-7010-9

Google Scholar

[10] Phan huu nguyen, Muthuramalingam T, Dong van pham, Shailesh Shirguppikar, Tung Nhu Nguye, Tam Chi Nguyen andTrong Nguyen(2022). Multi-Objective optimization of micro EDM using TOPSIS method with Tungsten carbide. Indian Academy of Sciences.

DOI: 10.1007/s12046-022-01900-8

Google Scholar

[11] Das, A. K., Kumar, P., Sethi, A., Singh, P. K., & Hussain, M. (2016). Influence of process parameters on the surface integrity of micro-holes of SS304 obtained by micro-EDM. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 38(7), 2029–2037.

DOI: 10.1007/s40430-016-0488-8

Google Scholar

[12] Huu, P. N., Muthuramalingam T, Van, D. P., Shirguppikar, S., Tien, D. H., Van, T. N., & Trong, L. N. (2022b). Multi-objects optimization in µ-EDM using AlCrNi-coated tungsten carbide electrode for Ti-6AL-4 V. International Journal of Advanced Manufacturing Technology, 122(5–6), 2267–2276.

DOI: 10.1007/s00170-022-10022-8

Google Scholar

[13] Boopathi, S. (2022). An Extensive Review on Sustainable Developments of Dry and Near-Dry Electrical Discharge Machining Processes. In Journal of Manufacturing Science and Engineering (Vol. 144, Issue 5). American Society of Mechanical Engineers (ASME).

DOI: 10.1115/1.4052527

Google Scholar

[14] Janardhana, K., Anushkannan, N. K., Dinakaran, K. P., Puse, R. K., & Boopathi, S. (2023). Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM. Engineering Research Express, 5(2), 025022.

DOI: 10.1088/2631-8695/acce8f

Google Scholar

[15] Khan, M. Y., & Rao, P. S. (2019). Hybridization of electrical discharge machining process. International Journal of Engineering and Advanced Technology, 9(1), 1059–1065.

Google Scholar

[16] Liu, S., Thangaraj, M., Moiduddin, K., & Al-Ahmari, A. M. (2022). Influence of Adaptive Gap Control Mechanism and Tool Electrodes on Machining Titanium (Ti-6Al-4V) Alloy in EDM Process. Materials, 15(2).

DOI: 10.3390/ma15020513

Google Scholar

[17] Huang, C. H., Yang, A. B., & Hsu, C. Y. (2018). The optimization of micro EDM milling of Ti–6Al–4V using a grey Taguchi method and its improvement by electrode coating. International Journal of Advanced Manufacturing Technology, 96(9–12), 3851–3859.

DOI: 10.1007/s00170-018-1841-0

Google Scholar

[18] Pham Van, D., Shirguppikar, S., Nguyen Huu, P., Nguyen Duc, M., Bui Tien, T., Le Thi Phuong, T., & Nguyen Trong, L. (2022). Multi-objects optimization in μ-EDM using AlCrN coated tungsten carbide electrode by Deng's method. Manufacturing Review.

DOI: 10.1051/mfreview/2022018

Google Scholar

[19] Mac, B., shirguppikar, shailesh, &Ganachari, V. (2023). The Optimization of Micro-Edm Machining Process when Using Carbon Coated Micro Electrode as a Tool. Journal of Machine Engineering.

DOI: 10.36897/jme/165929

Google Scholar

[20] Naveen Anthuvan, R., &Krishnaraj, V. (2020). Effect of coated and treated electrodes on Micro-EDM characteristics of Ti-6Al-4V. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 42(10).

DOI: 10.1007/s40430-020-02578-x

Google Scholar

[21] Thakur, A., Rao, P. S., & Khan, M. Y. (2021). Study and optimization of surface roughness parameter during electrical discharge machining of titanium alloy (Ti-6246). Materials Today: Proceedings, 44, 838–847.

DOI: 10.1016/j.matpr.2020.10.785

Google Scholar

[22] Manikandan, N., Arulkirubakaran, D., Palanisamy, D., & Raju, R. (2019). Influence of wire-EDM textured conventional tungsten carbide inserts in machining of aerospace materials (Ti–6Al–4V alloy). Materials and Manufacturing Processes, 34(1), 103–111.

DOI: 10.1080/10426914.2018.1544712

Google Scholar

[23] Phan, N. H., Pham, &, Dong, V., Hoang, &, Dung, T., Van Thien, N., Muthuramalingam, & T., Shirguppikar, S., Nguyen, &, Tam, C., & Ly, T. (n.d.). Multi-object optimization of EDM by Taguchi-DEAR method using AlCrNi coated electrode.

DOI: 10.1007/s00170-021-07032-3

Google Scholar

[24] Kumar, R., Roy, S., Gunjan, P., Sahoo, A., Sarkar, D. D., & Das, R. K. (2018). Analysis of MRR and Surface Roughness in Machining Ti-6Al-4V ELI Titanium Alloy Using EDM Process. Procedia Manufacturing, 20, 358–364.

DOI: 10.1016/j.promfg.2018.02.052

Google Scholar

[25] Rahul, Mishra, D. K., Datta, S., &Masanta, M. (2018). Effects of Tool Electrode on EDM Performance of Ti-6Al-4V. Silicon, 10(5), 2263–2277.

DOI: 10.1007/s12633-018-9760-0

Google Scholar

[26] Patel, V. D., Patel2, D. M., Patel, U. J., Patel, B., Butani, N., Scholar, R., & Tech Student, M. (2014). Review of Wire-Cut EDM Process on Titanium alloy. In Journal of Engineering Research and Applications www.ijera.com (Vol. 4).

Google Scholar

[27] Sawant, S. N., Patil, S. K., Unune, D. R., Nazare, P., & Wojciechowski, S. (2023). Effect of copper, tungsten copper and tungsten carbide tools on micro-electric discharge drilling of Ti–6Al–4V alloy. Journal of Materials Research and Technology, 24, 4242–4257.

DOI: 10.1016/j.jmrt.2023.04.067

Google Scholar

[28] Chen, S.-G., Lian, M.-Q., Wu, X.-Y., Lei, J.-G., Zhao, H., Peng, T.-J., Luo, F., Yang, J., & Xu, B. (n.d.). Study on the micro-EDM processing characteristics of Ti-6Al-4V alloy with different electrode materials.

DOI: 10.1007/s00170-021-07664-5

Google Scholar

[29] Razak, M. A., Abdul-Rani, A. M., &Nanimina, A. M. (2015). Improving EDM Efficiency with Silicon Carbide Powder-Mixed Dielectric Fluid. International Journal of Materials, Mechanics and Manufacturing, 3(1), 40–43.

DOI: 10.7763/ijmmm.2015.v3.163

Google Scholar

[30] Shirguppikar, S., Patil, M. S., Phan, N. H., Muthuramalingam, T., Dong, P. V., Tam, N. C., Tai, B. T., Minh, N. D., & Duc, N. V. (2021). Assessing the effects of uncoated and coated electrode on response variables in electrical discharge machining for ti-6al-4v titanium alloy. Tribology in Industry, 43(4), 524–534.

DOI: 10.24874/ti.1020.12.20.03

Google Scholar

[31] Rathod, R., Kamble, D., &Ambhore, N. (2022). Performance evaluation of electric discharge machining of titanium alloy-a review. In Journal of Engineering and Applied Science (Vol. 69, Issue 1). Springer Science and Business Media B.V.

DOI: 10.1186/s44147-022-00118-z

Google Scholar

[32] Singh, A. K., Mahajan, R., Tiwari, A., Kumar, D., &Ghadai, R. K. (2018). Effect of Dielectric on Electrical Discharge Machining: A Review. IOP Conference Series: Materials Science and Engineering, 377(1).

DOI: 10.1088/1757-899x/377/1/012184

Google Scholar

[33] Mohd. Yunus Khan , P. Sudhakar Rao , B.S. Pabla (2019) Investigations on the feasibility of jatropha curcas oil based biodiesel for sustainable dielectric fluid in EDM process Materials Today: Proceeding.

DOI: 10.1016/j.matpr.2019.11.325

Google Scholar

[34] Mohd. Yunus Khan, P. Sudhakar Rao (2019). Optimization of Process Parameters of Electrical Discharge Machining Process For Performance Improvement. International Journal of Innovative Technology and Exploring Engineering.

Google Scholar

[35] Mumtaz Rizwee, Dr. P. Sudhakar Rao(2021). Analysis & Optimization of Parameters during EDM of Aluminium Metal Matrix Composite. Journal of University of Shanghai for Science and Technology.

DOI: 10.51201/Jusst12671

Google Scholar

[36] Mumtaz Rizwee, Dr. P Sudhakar Rao (2018). A Review On Electro Discharge Machining Of Metal Matrix Composite. International Journal of Technical Innovation in Modern Engineering & Science

Google Scholar

[37] Ashish Kumar, P.S. Rao(2019). Study of the optimization of process parameters in Electric discharge machining for different Alloy: A Review, IJRAR.

Google Scholar

[38] Mumtaz Rizwee, P. Sudhakar Rao, and Md Fuzail Ahmad (2021). Parametric Optimization of Electro Discharge Process during Machining of Aluminum/Boron Carbide/Graphite Composite, SAE International Journal of Materials and Manufacturing.

DOI: 10.4271/05-15-01-0007

Google Scholar

[39] Mumtaz Rizwee, P. Sudhakar Rao, and Mohd Yunus Khan(2022), Experimental Investigation and Optimization of EDM Parameters During Machining of Al/B4C/Gr MMC, 1 Chapter

DOI: 10.1201/9781003203681-9

Google Scholar