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<p>In this experimental study, the factors were the dielectric fluid type (<i>F</i><sub>t</sub>), powder type (<i>P</i><sub>t</sub>), and powder concentration (<i>C</i><sub>p</sub>), and the machining parameters were the applied voltage (<i>V</i>), capacitance (pf), pulse-on time (<i>T</i><sub>on</sub>), and pulse-off time (<i>T</i><sub>off</sub>). The output parameters were the material removal rate (MRR) and tool wear rate (TWR). Six types of oils and three types of metal powders along with their respective particle concentrations were chosen for current experiment. Castor, Karanja, Kusum, hydraulic, synthetic, and mineral oils were mixed with aluminum oxide (Al<sub>2</sub>O<sub>3</sub>), nickel (Ni), and chromium (Cr) powder at 6, 8, and 10&#xa0;g/L, respectively, employing an overhead stirrer to investigate and compare the conditions under which the green oil powder mixed mixture and the conventional oil powder mixed mixture yielded a higher MRR and lower TWR during the micro-EDM process of titanium alloy (Ti–6Al–4&#xa0;V) using a 0.8&#xa0;mm tungsten carbide (WC) tool in positive polarity with fixed machining parameters (240&#xa0;V, 100 pf, <i>T</i><sub>on</sub>: 20&#xa0;µs, and <i>T</i><sub>off</sub>: 5&#xa0;µs). All powders used in this experiment are 32-micron (450 mesh) in size. The Taguchi L<sub>27</sub> orthogonal array (O.A.) and grey relational analysis (GRA) were used to design and optimize the input process parameters for both responses. Furthermore, scanning electron microscopy (SEM), optical microscopy, and EDS analyses were performed to examine the surface morphology, characteristics of the WC tool, and elemental composition of the work material. It was observed that machining with Karanja oil in a 6&#xa0;g/L Cr powder mixture showed a higher MRR and minimal TWR. Additionally, machining with synthetic oil in 8&#xa0;g/L Ni powder mixture showed higher MRR and minimal TWR than Karanja oil with 6&#xa0;g/L Cr powder mixture. The TWR is minimal in synthetic oil compared to machining with Karanja oils. In addition, machining with synthetic oils results in smoother surfaces than machining with Karanja oils.</p>

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Experimental investigation on machinability of Ti–6Al–4 V using powder mixed EDM process

  • 期刊论文

  • 发表日期：

    2025年9月13日

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  • Manas Ranjan Pal,
  • Kishore Debnath,
  • Santosh Kumar Sahu

摘要

In this experimental study, the factors were the dielectric fluid type (Ft), powder type (Pt), and powder concentration (Cp), and the machining parameters were the applied voltage (V), capacitance (pf), pulse-on time (Ton), and pulse-off time (Toff). The output parameters were the material removal rate (MRR) and tool wear rate (TWR). Six types of oils and three types of metal powders along with their respective particle concentrations were chosen for current experiment. Castor, Karanja, Kusum, hydraulic, synthetic, and mineral oils were mixed with aluminum oxide (Al2O3), nickel (Ni), and chromium (Cr) powder at 6, 8, and 10 g/L, respectively, employing an overhead stirrer to investigate and compare the conditions under which the green oil powder mixed mixture and the conventional oil powder mixed mixture yielded a higher MRR and lower TWR during the micro-EDM process of titanium alloy (Ti–6Al–4 V) using a 0.8 mm tungsten carbide (WC) tool in positive polarity with fixed machining parameters (240 V, 100 pf, Ton: 20 µs, and Toff: 5 µs). All powders used in this experiment are 32-micron (450 mesh) in size. The Taguchi L27 orthogonal array (O.A.) and grey relational analysis (GRA) were used to design and optimize the input process parameters for both responses. Furthermore, scanning electron microscopy (SEM), optical microscopy, and EDS analyses were performed to examine the surface morphology, characteristics of the WC tool, and elemental composition of the work material. It was observed that machining with Karanja oil in a 6 g/L Cr powder mixture showed a higher MRR and minimal TWR. Additionally, machining with synthetic oil in 8 g/L Ni powder mixture showed higher MRR and minimal TWR than Karanja oil with 6 g/L Cr powder mixture. The TWR is minimal in synthetic oil compared to machining with Karanja oils. In addition, machining with synthetic oils results in smoother surfaces than machining with Karanja oils.