Journal
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
Volume 70, Issue 1-4, Pages 469-475Publisher
SPRINGER LONDON LTD
DOI: 10.1007/s00170-013-5274-5
Keywords
EDM; Ti-6Al-4V alloy; Material removal rate; Electrode wear rate; Surface roughness; Orthogonal experiment; Grey relational analysis
Funding
- Shaanxi Provincial Department of Education Fund [2013JK1014]
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Ti-6Al-4V is widely used in the aerospace, automobile, and biomedical fields, but is a difficult-to-machine material. Electrical discharge machining (EDM) is regarded as one of the most effective approaches tomachining Ti-6Al-4V alloy, since it is a non-contact electro-thermal machining method, and it is independent from the mechanical properties of the processed material. This paper aims to combine grey relational analysis and Taguchi methods to solve the problem of EDM parameters optimization. From the viewpoint of health and environment, tap water as working fluid has good working environment, since it does not release harmful gas. The process parameters include discharge current, gap voltage, lifting height, negative polarity and pulse duty factor. The electrode wear ratio (EWR), material removal rate (MRR) and surface roughness (SR) as objective parameters are chosen to evaluate the whole machining effects. Experiments were carried out based on Taguchi L9 orthogonal array and grey relational analysis, and then verified the results through a confirmation experiment. Compared the machining parameters A(1)B(1)C(3)D(2) with A(1)B(2)C(2)D(2), MRR increased from 1.28 mm(3)/min to 2.38 mm(3)/min, EWR decreased from 0.14 to 0.10 mm(3)/min and SR decreased from Ra 2.37 mu m to Ra 1.93 mu m. The process parameters sequenced in order of relative importance are: the ratio of pulse width to pulse interval, discharge current, lifting height and gap voltage. The results showed that using tap water machining Ti-6Al-4V material can obtain high MRR, decrease the machining cost and have no harmful to the operators and the environment.
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