Experimental Investigations into the Effects of Microelectric-Discharge Milling Process Parameters on Processing Ti-6Al-4V

Microelectric-discharge milling is acquiring more importance in micromanufacturing because of its unique ability to produce three-dimensional microcavities with high aspect ratio in electrically conductive advanced materials regardless of its mechanical properties. The present study investigates the effects of major microelectric-discharge milling process variables [voltage (V), capacitance (C), electrode rotational speed (ERS), and feed rate (FR)] on Ti-6Al-4V. The output performance measures were identified as material removal rate (MRR) and tool wear rate (TWR) to assess the machinability of Ti-6Al-4V. Experiments were designed and carried out based on response surface methodology-Box-Behnken statistical design. The most influencing parameters for responses (MRR, TWR) were found to be capacitance and FR. At a capacitance of 0.4 mu F and FR of 18mm/min, maximum MRR of 0.9756mg/h, and TWR of 0.6342mg/h were observed. Similarly at 0.01 mu F and 6mm/min, minimum MRR of 0.2308mg/h, and TWR of 0.1259mg/h were obtained.