Statistical evaluation and performance analysis of edm wedm characteristics of hard ti 6al 2sn 4zr 2mo alloy

Abstract

Electrical Discharge Machining (EDM) and Wire Electrical Discharge Machining (WEDM) are capable of machining precision cutting and difficult-to-machine components of geometrically complex or hard materials such as heat-resistant steel, carbides, ceramics, heat-treated tool steels, composites, etc. These are commonly recycled in the dies and mould-making, aerospace, and nuclear industries. In these methods, optimum process parameters setting is crucial to achieving good surface finish on the tool as well as in the component factor. The parameters have to be optimized using various techniques to enhance quality. The hard Ti-6Al-2Sn-4Zr-2Mo alloy has been machined by the electrical discharge machining process and machining structures such as surface roughness, tool wear rate and material removal rate have been quantitatively analyzed to achieve peak performance in the current research. The experiments were conducted based on investigational design. The most essential factors were calculated from the mathematical analysis of the experimental results as voltage, pulse on time, and peak current. Besides that analysis Scanning Electron Microscope (SEM) was also used to describe the machined surface. The SEM analytical results specified the presence of craters on the machined surface, surface cracks, and particles and recast surface. Mathematical models relating the machining parameters to different machining parameters were established by Taguchi analysis, and the optimal setting of the process parameter was obtained using Minitab-17 software. The optimum process parameters were defined from the main effect plot as 80V,65and#956;s, 115 and#956;s, 4A for material removal rate, 60V, 65 and#956;s, 85 and#956;s 3 A, for tool wear rate and 60V, 35 and#956;s, 85 and#956;s, 3 A for surface roughness newline