Abstract
Titanium alloy (Ti-6Al-4 V) is widely used in a number of fields such as medical, aeronautical, and nuclear fields. Since the surface finish should be enhanced as much possible in efficient way, the micro EDM process can be used for machining such materials. The process mechanism can be enhanced by utilizing the coated electrode in the process. In the present study, an effort was made to investigate the effects of process parameters on drilling titanium alloy with aluminum chromium nitride (AlCrNi)-coated aluminum electrode in micro EDM process. An optimization approach was also implemented using Taguchi-DEAR approach. From the experimental interpretation, the conclusions were made as follows. The AlCrNi-coated aluminum electrode can enhance the machinability of micro EDM process. The optimal combination of voltage (140 V), capacitance (10000pF), and spindle rotation (200 rpm) could provide better quality measures among the chosen variables. The moderate voltage and capacitance can remove the material effectively with lower overcut, since the electrical conductivity can effectively enhance the conductivity of the plasma energy column. The coated electrode can create the tiny craters with uniform energy distribution.
Similar content being viewed by others
Availability of data and materials
There is no need to mention the availability of data and materials in the present study.
References
Liew PJ, Yap CY, Wang J, Zhou T, Yan J (2020) Surface modification and functionalization by electrical discharge coating: a comprehensive review. Int J Extrem Manuf 2:012004. https://doi.org/10.1088/2631-7990/ab7332
Mao X, Almeida S, Mo J, Ding S (2022) The state of the art of electrical discharge drilling: a review. Int J Adv Manuf Technol 121:2947–2969. https://doi.org/10.1007/s00170-022-09549-7
Zhang W, Wang M, Zhang Y (2022) Study on debris evacuation of EDM small hole processing on titanium alloy. Int J Adv Manuf Technol 121:2335–2341. https://doi.org/10.1007/s00170-022-09487-4
Perveen A, Jahan MP (2021) Experimental and statistical investigation into micro-EDM of Hastelloy-X using PVD diamond-coated and AlTiN-coated tungsten carbide electrodes. Int J Manuf Res 16:52–81. https://doi.org/10.1504/IJMR.2021.10028782
Wang P, Yu D, Li M (2022) A study on ultrasonic-assisted micro-EDM of titanium alloy. Int J Adv Manuf Technol 121:2815–2829. https://doi.org/10.1007/s00170-022-09355-1
George J, Chandan R, Manu R, Mathew J (2021) Experimental investigation of silicon powder mixed EDM using graphene and CNT nano particle coated electrodes. SILICON 13:3835–3851. https://doi.org/10.1007/s12633-020-00658-0
Liu S, Thangaraj M, Moiduddin K, Al-Ahmari AM (2022) Influence of adaptive gap control mechanism and tool electrodes on machining titanium (Ti-6Al-4V) alloy in EDM process. Materials 15:513. https://doi.org/10.3390/ma15020513
Liu S, Geethapriyan T, Thangaraj M, Shanmugam R, Ramoni M (2022) Influence of heat-treated Cu-Be electrode on machining accuracy in ECMM with Monel 400 alloy. Arch Civ Mech Eng 22:154. https://doi.org/10.1007/s43452-022-00478-6
Phan NH, Muthuramalingam T, Vu NN, Tuan NQ (2020) Influence of micro size titanium powder-mixed dielectric medium on surface quality measures in EDM process. Int J Adv Manuf Technol 109:797–807. https://doi.org/10.1007/s00170-020-05698-9
Thangaraj M, Ramamurthy A, Moiduddin K, Alkindi M, Ramalingam S, Alghamdi O (2020) Enhancing the surface quality of micro titanium alloy specimen in WEDM process by adopting TGRA-based optimization. Materials 13:1440. https://doi.org/10.3390/ma13061440
Shanmugam R, Ramoni M, Thangamani G, Thangaraj M (2021) Influence of additive manufactured stainless steel tool electrode on machinability of beta titanium alloy. Metals 11:778. https://doi.org/10.3390/met11050778
Phan NH, Dong PV, Mthuramalingam T, Thien NV, Dung HT, Hung TQ, Duc NV, Ly NT (2021) Experimental investigation of uncoated electrode and PVD AlCrNi coating on surface roughness in electrical discharge machining of Ti-6Al-4V. Int J Eng, Transactions A: Basics 34:928–934. https://doi.org/10.5829/ije.2021.34.04a.19
Ablyaz TR, Shlykov ES, Kremlev SS (2017) Copper-coated electrodes for electrical discharge machining of 38X2H2MA steel. Russ Engin Res 37:910–911. https://doi.org/10.3103/S1068798X17100033
Danade UA, Londhe SD, Metkar RM (2019) Machining performance of 3D-printed ABS electrode coated with copper in EDM. Rapid Prototyp J 25:1224–1231. https://doi.org/10.1108/RPJ-11-2018-0297
Mandal P, Mondal SC (2021) Performance analysis of copper-based MWCNT composite coated 316L SS tool in electro discharge machining. Mach Sci Technol 25:422–437. https://doi.org/10.1080/10910344.2020.1855652
Huo J, Liu S, Wang Y, Thangaraj M, Pi VN (2019) Influence of process factors on surface measures on electrical discharge machined stainless steel using TOPSIS. Mater Res Express 6:086507. https://doi.org/10.1088/2053-1591/ab1ae0
Muthuramalingam T, Mohan B (2014) Performance analysis of iso current pulse generator on machining characteristics in EDM process. Arch Civ Mech Eng 14:383–390. https://doi.org/10.1016/j.acme.2013.10.003
Ablyaz T, Muratov K, Preetkanwal SB, Sarabjeet SS (2019) Experimental investigation of wear resistance of copper coated electrode-tool during electrical discharge machining. IOP Conf Ser: Mater Sci Eng 510:012001. https://doi.org/10.1088/1757-899X/510/1/012001
Uhlmann E, Rosiwal S, Bayerlein K, Röhner M (2010) Influence of grain size on the wear behavior of CVD diamond coatings in micro-EDM. Int J Adv Manuf Technol 7:919–922. https://doi.org/10.1007/s00170-009-2131-7
Yuangang W, Fuling Z, Jin W (2009) Wear-resist electrodes for micro-EDM. Chinese J Aeronaut 22:339–342. https://doi.org/10.1016/S1000-9361(08)60108-9
Muthuramalingam T (2019) Measuring the influence of discharge energy on white layer thickness in electrical discharge machining process. Measurement 131:694–700. https://doi.org/10.1016/j.measurement.2018.09.038
Muthuramalingam T (2019) Effect of diluted dielectric medium on spark energy in green EDM process using TGRA approach. J Clean Prod 238:117894. https://doi.org/10.1016/j.jclepro.2019.117894
Ponappa K, Sasikumar KSK, Sambathkumar M, Udhayakumar M (2019) Multi-objective optimization of EDM process parameters for machining of hybrid aluminum metal matrix composites (AL7075/TiC/B4C) using genetic algorithm. Surf Rev Lett 26:1950071. https://doi.org/10.1142/S0218625X19500719
Kolli M, Prasad AVSR, Naresh DS (2021) Multi-objective optimization of AAJM process parameters for cutting of B4C/Gr particles reinforced Al 7075 composites using RSM-TOPSIS approach. SN Appl Sci 3:711. https://doi.org/10.1007/s42452-021-04699-x
Nayak I, Rana J (2021) Multi-response optimization in wire electrical discharge machining (WEDM) of D2 steel using utility approach. Manuf Rev 8:16. https://doi.org/10.1051/mfreview/2021014
Muthuramalingam T, Ramamurthy A, Moiduddin K, Alkindi M, Ramalingam S, Alghamdi O (2020) Enhancing the surface quality of micro titanium alloy specimen in WEDM process by adopting TGRA-based optimization. Materials 13:1440. https://doi.org/10.3390/ma13061440
Phan NH, Dong PV, Dung HT, Thien NV, Muthuramalingam T, Shirguppikar S, Tam NC, Ly NT (2021) Multi-object optimization of EDM by Taguchi-DEAR method using AlCrNi coated electrode. Int J Adv Manuf Technol 116:1429–1435. https://doi.org/10.1007/s00170-021-07032-3
Nguyen PH, Banh TL, Mashood KA, Tran DQ, Pham VD, Muthuramalingam T, Nguyen VD, Nguyen DT (2020) Application of TGRA-based optimisation for machinability of high-chromium tool steel in the EDM process. Arab J Sci Eng 45:5555–5562. https://doi.org/10.1007/s13369-020-04456-z
Maddu J, Karrolla B, Vuppala S, Shaik RU (2021) Formation and optimization of electrical discharge coatings using conventional electrodes. Energies 14:5691. https://doi.org/10.3390/en14185691
Author information
Authors and Affiliations
Contributions
Phan Nguyen Huu: optimization and surface morphology; T. Muthuramalingam: optimization; Pham Van Dong: optimization; Nguyen Van Thien: experiments; Hoang Tien Dung: experiments; Shailesh Shirguppikar: experiments.
Corresponding authors
Ethics declarations
Ethical approval
There is no ethical approval needed in the present study.
Consent to participate
There is no consent to participate needed in the present study.
Consent for publication
There is no consent to publish needed in the present study.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Huu, P.N., Muthuramalingam T., Van, D.P. et al. Multi-objects optimization in µ-EDM using AlCrNi-coated tungsten carbide electrode for Ti-6AL-4 V. Int J Adv Manuf Technol 122, 2267–2276 (2022). https://doi.org/10.1007/s00170-022-10022-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-022-10022-8