Characterization of arcing parameters in presence of graphite powder concentration in EDM of Ti-6Al-4V

Abstract

Abstract Irrespective of the toughness, strength & hardness of any conductive material, Electric Discharge Machining (EDM) is a proven machining method. Selection of most favorable process parameters for machining is desirable to avoid excessive tool wear, damaged surfaces, and unwanted roughness. For this, the main reason could be the arcing while machining. Arcing results from successive electric discharges occurring at the interface of both the electrodes. Also, presence of powder concentration makes it more susceptible to occurring. This paper emphasizes identifying the combination of parameters that lead to arcing in the machining of titanium alloy Ti-6Al-4V using copper C100 electrode on Die Sinking EDM. Graphite powder concentration of 0%, 5% and 10% in SEO-45 EDM oil is used for the investigation. To identify arcing parameters, Taguchi parameter Design approach is used. Three stage process parameters are selected for finishing, intermediate and roughing stages to study arcing. Scanning electron microscopic (SEM) images of the machined surface tells that less surface crack density (SCD) has been formed on the machined surface. Discharge current, duty cycle and graphite powder concentration are the variables and effect of arcing on Material removal rate, Electrode wear rate and Surface roughness of Ti-6Al-4V is analyzed.