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Experimental investigation of surface integrity after wire electro-discharge machining of Ti–6Al–4V

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Abstract

This article presents the relationship of machining parameters containing pulse-on time (Ton), pulse-off time (Toff), peak current (IP) and servo voltage (SV) on surface integrity characteristics, including white layer thickness (WLT), heat-affected zone (HAZ) and surface crack density (SCD) and also on material removal rate (MRR), after wire electric discharge machining of Ti–6Al–4V. Taguchi’s method was utilized to design the experiments, and response surface methodology (RSM) was employed for developing the empirical models. Results indicated that Ton and IP played a significant role on surface integrity characteristics. In addition, the microstructure of selected machined samples was analysed using a field emission scanning electron microscope (FESEM) and energy-dispersive X-ray (EDX) analysis. Accuracy of models was examined using residual analysis and confirmation runs. Finally, multi-response optimization of process parameters was obtained using desirability approach. Results can be used to improve the quality of the machined workpiece significantly to fulfil the requirements of the various industries. The novelty of this research is mainly investigation and multi-response optimization of all the surface integrity characteristics at the same time.

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Abbreviations

T on :

Pulse-on time

T off :

Pulse-off time

IP:

Peak current

SV:

Servo voltage

WLT:

White layer thickness

HAZ:

Heat-affected zone

SCD:

Surface crack density

MRR:

Material removal rate

RSM:

Response surface methodology

FESEM:

Field emission scanning electron microscope

EDX:

Energy-dispersive X-ray

WEDM:

Wire electrical discharge machining

ANOVA:

Analysis of variance

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Authors and Affiliations

  1. Department of Mechanics, Isfahan University of Technology, Isfahan, 84156-83111, Iran

    Danial Ghodsiyeh & Saleh Akbarzadeh

  2. Department of Materials, Manufacturing and Industrial Engineering, Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, Skudai, Malaysia

    Sudin Izman

  3. Department of Mechanics and Aerospace, Politecnico di Torino, 10129, Turin, Italy

    Mona Moradi

Authors
  1. Danial Ghodsiyeh
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  2. Saleh Akbarzadeh
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  3. Sudin Izman
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  4. Mona Moradi
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Correspondence to Danial Ghodsiyeh.

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Ghodsiyeh, D., Akbarzadeh, S., Izman, S. et al. Experimental investigation of surface integrity after wire electro-discharge machining of Ti–6Al–4V. Sādhanā 44, 196 (2019). https://doi.org/10.1007/s12046-019-1184-z

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  • DOI: https://doi.org/10.1007/s12046-019-1184-z

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