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<p>This study investigates the machinability of the Ti-6Al-2Sn-4Zr-2Mo alpha-beta alloy using wire electrical discharge machining (WEDM) with brass wire electrodes. The experimental framework employed Taguchi’s L27 orthogonal array to analyze the influence of critical parameters—pulse on time, pulse off time, wire feed, and wire tension—on material removal rate (MRR) and surface roughness (SR). The optimal conditions were identified as a pulse on time of 115&#xa0;µs, pulse off time of 30&#xa0;µs, wire feed of 6&#xa0;m/min, and wire tension of 15&#xa0;g, resulting in an MRR of 0.254&#xa0;mm<sup>3</sup>/min and SR of 2.342&#xa0;µm. Scanning electron microscopy (SEM) analysis revealed the formation of recast layers and deep craters, significantly affecting the surface morphology. Statistical tools such as ANOVA and regression analysis confirmed that pulse on time is the most significant parameter, with a high contribution to MRR and SR. The results indicate that WEDM is a viable method for precision machining of Ti-6242 alloys, achieving enhanced productivity and surface integrity. The significance of this study lies in its contribution to optimizing machining parameters for Ti-6242, addressing the challenges of machining this high-strength alloy. The results are benchmarked against state-of-the-art studies in a tabular format to contextualize the findings and highlight advancements in machining performance. </p>

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Surface Topographical Analysis and Empirical Assessment of Wire Electrical Discharge Machining on Ti-6242 Alpha-Beta Alloy

  • 期刊论文

  • 发表日期：

    2025年5月13日

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  • A. Perumal,
  • R. Prithivirajan,
  • S. Suresh Kumar,
  • P. R. Rajkumar

摘要

This study investigates the machinability of the Ti-6Al-2Sn-4Zr-2Mo alpha-beta alloy using wire electrical discharge machining (WEDM) with brass wire electrodes. The experimental framework employed Taguchi’s L27 orthogonal array to analyze the influence of critical parameters—pulse on time, pulse off time, wire feed, and wire tension—on material removal rate (MRR) and surface roughness (SR). The optimal conditions were identified as a pulse on time of 115 µs, pulse off time of 30 µs, wire feed of 6 m/min, and wire tension of 15 g, resulting in an MRR of 0.254 mm3/min and SR of 2.342 µm. Scanning electron microscopy (SEM) analysis revealed the formation of recast layers and deep craters, significantly affecting the surface morphology. Statistical tools such as ANOVA and regression analysis confirmed that pulse on time is the most significant parameter, with a high contribution to MRR and SR. The results indicate that WEDM is a viable method for precision machining of Ti-6242 alloys, achieving enhanced productivity and surface integrity. The significance of this study lies in its contribution to optimizing machining parameters for Ti-6242, addressing the challenges of machining this high-strength alloy. The results are benchmarked against state-of-the-art studies in a tabular format to contextualize the findings and highlight advancements in machining performance.