IMPROVEMENT OF SURFACE QUALITY OF Ti-6Al-4V ALLOY BY POWDER MIXED ELECTRICAL DISCHARGE MACHINING USING COPPER POWDER

Rafiqul Haque, Mukandar Sekh, Golam Kibria, Shamim Haidar

DOI Number
https://doi.org/10.22190/FUME201215042H
First page
063
Last page
079

Abstract


Electrical Discharge Machining (EDM) is one of the most popular non-conventional machining processes that are being used in many high precision manufacturing industries. To increase the EDM performance, a hybrid technique, namely, powder mixed electrical discharge machining (EDM) (PMEDM) is generally used for getting more precise requirements. In this study, an experimental investigation is carried out in order to explore the machining performance of the PMEDM process on Ti-6Al-4V alloy using copper (Cu) powder in the EDM oil dielectric. Taguchi’s L18 orthogonal array design has been utilized for design of experiments and the analysis of variance (ANOVA) has been performed with the help of Minitab-19 software. The optimal parametric setting of Cu powder mixed EDM has been found utilizing the Taguchi - Grey Relational Analysis (GRA) integrated approach and also validation of optimal parametric setting is done through experimentation. It is a novel approach for machining Ti-6Al-4V alloy by this PMEDM technique in which the surface quality has been improved significantly with the addition of suitable amount of Cu powder into the dielectric medium.

Keywords

PMEDM, Ti-6Al-4V Alloy, Cu Powder, Taguchi Analysis, Grey Relational Analysis (GRA), Surface Roughness (SR)

Full Text:

PDF

References


Jain, V.K., 2009, Advanced Machining Processes, Allied publishers, Delhi, India.

Jeswani, M.L., 1981, Effect of the addition of graphite powder to kerosene used as the dielectric fluid in electrical discharge machining, Wear, 70(2), pp. 133–139.

Mohri, N., Saito, N., Higash, M., 1991, A new process of finish machining on free surface by EDM methods, CIRP Annals, 40(1), pp. 207-210.

Chow, H.M., Yan, B.H., Huang, F.Y., Hung, J.C., 2000, Study of added powder in kerosene for the micro-slit machining of titanium alloy using electro-discharge machining, Journal of Materials Processing Technology, 101(1-3), pp. 95-103.

Kibria, G., Sarkar, B.R., Pradhan, B.B., Bhattacharyya, B., 2010, Comparative study of different dielectrics for micro-EDM performance during microhole machining of Ti-6Al-4V alloy, International Journal of Advanced Manufacturing Technology, 48, pp. 557–570.

Ojha, K., Garg, R.K., Sing, K.K., 2011, Effect of chromium powder suspended dielectric on surface roughness in PMEDM, Tribology-Materials, Surfaces & Interfaces, 5(4), pp. 165-171.

Garg, R.K., Ojha, K., 2012, Parametric Optimization of PMEDM Process with Chromium Powder Suspended Dielectric for Minimum Surface Roughness and Maximum MRR, Advanced Materials Research, 383-390, pp. 3202-3206.

Bhattacharya, A., Batish, A., Kumar, N., 2013, Surface characterization and material migration during surface modification of die steels with silicon, graphite and tungsten powder in EDM process, Journal of Mechanical Science and Technology, 27(1), pp. 133-140.

Unses, E., Cogun, C., 2015, Improvement of Electric Discharge Machining (EDM) Performance of Ti-6Al-4V Alloy with Added Graphite Powder to Dielectric, Strojniški vestnik - Journal of Mechanical Engineering, 61(6), pp. 409-418.

Long, B.T., Phan, N.H., Cuong, N., Jatti, V.S., 2016, Optimization of PMEDM process parameter for maximizing material removal rate by Taguchi’s method, International Journal of Advanced Manufacturing Technology, 87, pp. 1929-1939.

Sugunakar, S., Kumar, A., Markandeya, R., 2017, Effect of Powder Mixed Dielectric fluid on Surface Integrity by Electrical Discharge Machining of RENE 80, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), 14(3), pp. 43-50.

Ramesh, S., Jenarthanan, M.P., Bhuvanesh Kanna, A.S., 2018, Experimental investigation of powder-mixed electric discharge machining of AISI P20 steel using different powders and tool materials, Multidiscipline Modeling in Materials and Structures, 14(3), pp. 549-566.

Paul, B.K., Sahu, S.K., Jadam, T., Dutta, S., Dhupal, D., Mahapatra, S.S., 2018, Effects of Addition of Copper Powder in the Dielectric Media (EDM Oil) on Electro-Discharge Machining Performance of Inconel 718 Super Alloys, Materials Today: Proceedings, 5(9), pp. 17618-17626.

Lamichhane, Y., Singh, G., Bhui, A.S., Mukhiya, P., Kumar, P., Thapa, B., 2019, Surface modification of 316L SS with HAp nano-particles using PMEDM for enhanced Biocompatibility, Materials Today: Proceedings, 15, pp. 336-343.

Singh, K.J., 2019, Powder mixed electric discharge machining of high-speed steel T1 grade: Optimize through grey relational analysis, Multidiscipline Modeling in Materials and Structures, 15(4), pp. 699-713.

Hosni, N.A.J., Lajis, M.A., 2020, Experimental investigation and economic analysis of surfactant (Span-20) in powder mixed electrical discharge machining (PMEDM) of AISI D2 hardened steel, Machining Science and Technology, 24(3), pp. 398-424.

Rajavel, R., Selvarajan, L., Rajkumar, G., Raja, R., Rakshna, A., 2020, Investigation on machinability of Al 2024& 7.5% Si3N4 metal matrix composite with PMEDM using Taguchi based GRA, Materials Today: Proceedings, DOI: 10.1016/j.matpr.2020.03.234.

Xia, H., Kuneida, M., Nishiwaki, N., 1996, Removal amount difference between anode and cathode in EDM process, International Journal of Electrical Machining, 1, pp. 45–52.

Montgomery, D.C., 2013, Design and Analysis of Experiments, 8th Edition, Wiley, New York.

Tosun, N., Pihtili, H., 2010, Gray relational analysis of performance characteristics in MQL milling of 7075 Al alloy, International Journal of Advanced Manufacturing Technology, 43, pp. 509-515.

Kuo, Y., Yang, T., Huang, G.W., 2008, The use of grey relational analysis in solving multiple attribute decision-making problems, Computers & Industrial Engineering, 55(1), pp. 80–93.

Tosun, N., 2006, Determination of optimum parameters for multi-performance characteristics in drilling by using grey relational analysis, International Journal of Advanced Manufacturing Technology, 28, pp. 450–455.

Lin, J.L., Lin, C.L., 2002, The use of the orthogonal array with grey relational analysis to optimize the electrical discharge machining process with multiple performance characteristics, International Journal of Machine Tools & Manufacture, 42(2), pp. 237–244.

Singh, P.N., Raghukandan, K., Pai, B.C., 2004, Optimization by Grey relational analysis of EDM parameters on machining Al–10%SiCP composites, Journal of Materials Processing Technology, 155– 156, pp. 1658–1661.

Lin, Y.C., Lee, H.S., 2009, Optimization of machining parameters using magnetic-force-assisted EDM based on gray relational analysis, International Journal of Advanced Manufacturing Technology, 42, pp. 1052–1064.




DOI: https://doi.org/10.22190/FUME201215042H

Refbacks

  • There are currently no refbacks.


ISSN: 0354-2025 (Print)

ISSN: 2335-0164 (Online)

COBISS.SR-ID 98732551

ZDB-ID: 2766459-4