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<p>The micro electrochemical discharge machining (µECDM) process is mostly applied for the machining of insulated materials such as composites, glass, and ceramics, which are increasingly being used in defense, aerospace, biomedical fields, etc. Titanium-based alloys are widely used in aerospace, but machining them at high rates with good surface quality and dimensional accuracy is challenging. Additionally, there are a few reports on machining conductive materials, particularly titanium alloys, using hybrid µECDM techniques, indicating a need for further investigation. In the course of the present study, the machining of titanium alloy has been performed using the µECDM and its hybrid variant, i.e., ultrasonic-assisted ECDM (µUECDM) and powder-mixed ECDM (µPECDM) processes. The performance was analyzed in terms of varied electrical parameters, such as applied voltage, duty factor (DF), and electrolyte concentration (EC). The µUECDM produces micro holes with higher dimensional accuracy as compared to the other two processes under discussion. In contrast, the µPECDM was found to have superior quality of the machined surface (Ra 0.27&#xa0;µm, recast layer thickness 2.98&#xa0;µm, and surface crack density 0.016&#xa0;µm/µm<sup>2</sup>) and higher material removal rate (MRR), i.e., 1.8&#xa0;mg/min, as compared to the µUECDM and the µECDM. All these processes were also examined by using a single-pulse current graph, which indicated that µPECDM and µUECDM generated multiple sparks. Finally, the efficacy of these hybrid processes on the machining performance was analyzed using the debris particles, obtained during the machining operations. The agglomeration of DPs is significantly controlled by ultrasonication of the process.</p>

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Hybrid µECDM techniques for machining titanium alloys: a comparative analysis of ultrasonic-assisted and powder-mixed processes

  • 期刊论文

  • 发表日期：

    2025年5月10日

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  • Nitesh Kumar,
  • Harish Bishwakarma,
  • Niladri Mandal,
  • Alok Kumar Das

摘要

The micro electrochemical discharge machining (µECDM) process is mostly applied for the machining of insulated materials such as composites, glass, and ceramics, which are increasingly being used in defense, aerospace, biomedical fields, etc. Titanium-based alloys are widely used in aerospace, but machining them at high rates with good surface quality and dimensional accuracy is challenging. Additionally, there are a few reports on machining conductive materials, particularly titanium alloys, using hybrid µECDM techniques, indicating a need for further investigation. In the course of the present study, the machining of titanium alloy has been performed using the µECDM and its hybrid variant, i.e., ultrasonic-assisted ECDM (µUECDM) and powder-mixed ECDM (µPECDM) processes. The performance was analyzed in terms of varied electrical parameters, such as applied voltage, duty factor (DF), and electrolyte concentration (EC). The µUECDM produces micro holes with higher dimensional accuracy as compared to the other two processes under discussion. In contrast, the µPECDM was found to have superior quality of the machined surface (Ra 0.27 µm, recast layer thickness 2.98 µm, and surface crack density 0.016 µm/µm2) and higher material removal rate (MRR), i.e., 1.8 mg/min, as compared to the µUECDM and the µECDM. All these processes were also examined by using a single-pulse current graph, which indicated that µPECDM and µUECDM generated multiple sparks. Finally, the efficacy of these hybrid processes on the machining performance was analyzed using the debris particles, obtained during the machining operations. The agglomeration of DPs is significantly controlled by ultrasonication of the process.