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Numerical simulation of the effect of crater morphology for the prediction of surface roughness on electrical discharge textured Ti6Al4V

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Abstract

Extensive efforts (mathematical, numerical, and analytical) have been earlier tried to replicate the EDM process in its true nature. In the present work, the surface roughness (Ra) of the electrical discharge textured Ti6Al4V has got mathematically modeled. The parametric influence on the morphology of the developed craters got elucidated at distinct process conditions. The influential factors, viz. current (I, 2–10 A) and pulse on time (Ton, 100–300 μs), were varied to conduct a full factorial set of simulations and experimentations, keeping voltage (V, 30 V) as a constant. The I and V possessed dominant influence for material removal along the radial and axial directions (respectively), whereas the impact of Ton remained uniform in both the directions. Besides, two distinct considerations (based on the positioning of multi-overlapping craters) for prediction of Ra got proposed; the secondary craters superimposing with the primary along its circumference were found to fetch convincing results [with a maximum possible error (average) of 16%]. Simulation and experimentation results were compared using Ra data, crater morphological images, and radius to depth ratio (Rrd) plots. The outcomes were in close concordance with acceptable tolerances. The variation got attributed to the uncontrollable/disregarded factors (formation of recast layer and short circuit ensuing debris interference), prevalent in the case of in situ work environments.

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Acknowledgements

The authors extend their humble obligations to the Science and Engineering Research Board (SERB), Department of Science and Technology (DST), Government of India, for the research grant sanctioned for the project (Ref. No. ECR/2016/001929) through the aid of which this initiative was undertaken. The authors also thank Dr. Arun Tom Mathew, Associate Professor, Vellore Institute of Technology Vellore, Tamil Nadu, India for the support rendered in carrying out the simulations.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Mizoram, Aizawl, 796012, Mizoram, India

    Jibin T. Philip & Basil Kuriachen

  2. Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut, 673601, Kerala, India

    Jose Mathew

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  1. Jibin T. Philip
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Correspondence to Basil Kuriachen.

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Philip, J.T., Mathew, J. & Kuriachen, B. Numerical simulation of the effect of crater morphology for the prediction of surface roughness on electrical discharge textured Ti6Al4V. J Braz. Soc. Mech. Sci. Eng. 42, 248 (2020). https://doi.org/10.1007/s40430-020-02321-6

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  • DOI: https://doi.org/10.1007/s40430-020-02321-6

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