Experimental modelling and optimisation of process parameters of hole drilling by electrical discharge machining of aerospace titanium alloy

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

Download Full-text

Study of high-efficiency electrical discharge machining-induced ablation machining of titanium alloy TC4 using a multi-function electrode

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-014-5654-5 ◽

2014 ◽

Vol 72 (1-4) ◽

pp. 377-385 ◽

Cited By ~ 4

Author(s):

Xu An’yang ◽

Liu Zhidong ◽

Li Wenpei ◽

Tian Zongjun ◽

Qiu Mingbo

Keyword(s):

Titanium Alloy ◽

Electrical Discharge ◽

High Efficiency ◽

Electrical Discharge Machining

Download Full-text

Experimental Determination of Parameters to Avoid Arcing in Electrical Discharge Machining of Titanium Diboride Particulate Reinforced Ferrous Matrix Composite

Volume 3: Design and Manufacturing, Parts A and B ◽

10.1115/imece2010-39886 ◽

2010 ◽

Cited By ~ 1

Author(s):

Akash B. Pandey ◽

Prakash K. Brahmankar ◽

Harsh S. Purohit

Keyword(s):

Matrix Composite ◽

Process Parameters ◽

Titanium Diboride ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Short Circuit ◽

Fatigue Properties ◽

Wear Rates ◽

Tib2 Particles ◽

Particulate Reinforced

Titanium diboride (TiB2) particles are most popular reinforcement along with tungsten carbide for ferrous matrices for developing composites with high specific modulus, improved wear resistance and hardness while providing good fatigue properties as well. The hardness of such composites poses a problem in conventional machining in terms of very fast wear rates of tools and very high cutting forces. Non-conventional processes like electrical discharge machining (EDM) are very popular for machining of conductive composites like TiB2 reinforced ferrous matrix composites. However, there are a large number of process parameters for EDM which need to be selected and controlled carefully for satisfactory machining performance. Parameter settings which lead to arcing are specifically investigated and avoided as this phenomenon leads to uncontrolled machining through short circuit conditions and large energy discharges. In this paper, an experimental approach to determine the parameter settings which will lead to arcing during EDM machining of TiB2 particulate reinforced ferrous matrix composite is discussed. Values of major EDM process parameters are selected in roughing, intermediate and finishing domains. Experimental trials using L27 design of experiment are conducted and parameter combinations leading to arcing are recorded and the zone of parameters that can lead to arcing is identified.

Download Full-text