Investigation on the effect of dielectrics during micro-electro-discharge machining of Ti-6Al-4V

• Published in: International journal of advanced manufacturing technology Vol. 95; no. 1-4; pp. 861 - 874
• Main Authors: Tiwary, A. P., Pradhan, B. B., Bhattacharyya, B.
• Format: Journal Article
• Language: English
• Published: London Springer London 01.03.2018; Springer Nature B.V
• Subjects: Aerospace industry; Automotive engines; Automotive parts; Biocompatibility; CAE) and Design; Chemical industry; Computer-Aided Engineering (CAD; Deionization; Dielectrics; Discharge; Engine components; Engineering; Industrial and Production Engineering; Material removal rate (machining); Mechanical Engineering; Media Management; Medical electronics; Medical instruments; Organic chemistry; Original Article; Process parameters; Surgical implants; Titanium base alloys; Tool wear; Wear rate; Micro-holes; Dielectric; Ti-6Al-4V; Micro-EDM; Cu powder mixed deionized water
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-017-1231-z

Machining of micro-holes using micro-electro-discharge machining (micro-EDM) is an important field of micro-manufacturing technique. Micro-holes are essential features in optical devices, medical instruments, and automobile engine parts. Micro-EDM has been considered as the best non-traditional machining technique for generating micro-holes on high strength temperature resistant, and difficult to machine advanced materials such as Ti-6Al-4V. Ti-6Al-4V is a widely used material in aerospace and chemical industries. However, machining of micro-holes on Ti-6Al-4V using micro-EDM process is not fully explored. In this study, emphasis has been made to experimentally investigate the influence of various types of dielectrics, such as DEF-92 (EDM oil), pure deionized water, and Cu powder mixed deionized water on micro-EDM process response parameters, such as material removal rate (MRR), tool wear rate (TWR), overcut (OC), and taper during micro-hole machining of Ti-6Al-4V. It is observed that Cu powder mixed deionized water significantly improves the machining performance of the micro-EDM process. Furthermore, the machined profile and topography of the micro-hole obtained with Cu powder mixed deionized water is found to be better as compared to those machined with EDM oil or pure deionized water.