Analysis of Recast Layer, Wear Rate and Taper Angle in Micro-electrical Discharge Machining Over Ti–6Al–4V

  • S. RajamanickamEmail author
  • J. Prasanna
Conference paper
Part of the Lecture Notes in Mechanical Engineering book series (LNME)


In this paper, micro-electrical discharge machining of thin titanium alloy foil sheet (Ti–6Al–4V) is performed using 100-µm tungsten rod to study the output parameters such as recast layer thickness at entry and exit surfaces, material removal rate, linear wear rate and taper angle. The electrical input parameters considered in this research work are, namely, pulse on-time, current, pulse off-time and voltage. Further, SEM analysis reported is highly useful in calculating the output parameters originality for all input parameters combinations and additional value to the experimental observations. Grey relational analysis is employed to find the optimum machining parameter among the various combinations of electrical input parameters in micro-electrical discharge machining. The smaller hole is highly useful in fabrication of micro-products.


Ti–6Al–4V Electric discharge machining Regression analysis 



The authors wish to thank the persons from College of Engineering, Anna University, Chennai, Tamil Nadu, India, for their contribution and Vel Tech High Tech Dr. Rangarajan Dr. Sakunthala Engineering College, Chennai, Tamil Nadu, India, for their support and strong motivation.


  1. 1.
    Egashira, K., Morita, Y., Hattori, Y.: Electrical discharge machining of submicron holes using ultrasmall-diameter electrodes. Precis. Eng. 34, 139–144 (2010)CrossRefGoogle Scholar
  2. 2.
    Fonda, P., Wang, Z., Yamazaki, K., Akutsu, Y.: A fundamental study on Ti–6Al–4V’s thermal and electrical properties and their relation to EDM productivity. J. Mater. Process. Technol. 202, 583–589 (2008)CrossRefGoogle Scholar
  3. 3.
    Ho, K.H., Newman, S.T.: State of the art electrical discharge machining (EDM). Int. J. Mach. Tools Manuf. 43, 1287–1300 (2003)CrossRefGoogle Scholar
  4. 4.
    Marafona, J., Chousal, J.A.G.: A finite element model of EDM based on the Joule effect. Int. J. Mach. Tools Manuf. 46, 595–602 (2006)CrossRefGoogle Scholar
  5. 5.
    Kibria, G., Sarkar, B.R., Pradhan, B.B., Bhattacharyya, B.: Comparative study of different dielectrics for micro-EDM performance during microhole machining of Ti–6Al–4V alloy. Int. J. Adv. Manuf. Technol. 48, 557–570 (2010)CrossRefGoogle Scholar
  6. 6.
    Shabgard, M., Khosrozadeh, B.: Investigation of carbon nanotube added dielectric on the surface characteristics and machining performance of Ti–6Al–4V alloy in EDM. J. Manuf. Processes 25, 212–219 (2017)CrossRefGoogle Scholar
  7. 7.
    Jahan, M.P., Wong, Y.S., Rahman, M.: A study on the quality micro-hole machining of tungsten carbide by micro-EDM process using transistor and RC-type pulse generator. J. Mater. Process. Technol. 209, 1706–1716 (2009)CrossRefGoogle Scholar
  8. 8.
    Masuzawa, T.: State of the art of micromachining. Ann. ClRP 49, 473–488 (2000)CrossRefGoogle Scholar
  9. 9.
    Mishra, B.P., Routara, B.C.: An experimental investigation and optimisation of performance characteristics in EDM of EN-24 alloy steel using Taguchi Method and Grey Relational Analysis. Mater. Today: Proc. 4, 7438–7447 (2017)CrossRefGoogle Scholar
  10. 10.
    Rajyalakshmi, G., Venkata Ramaiah, P.: Multiple process parameter optimization of wire electrical discharge machining on Inconel 825 using Taguchi grey relational analysis. Int. J. Adv. Manuf. Technol. 1–14 (2013)Google Scholar
  11. 11.
    Tosun, N.: Determination of optimum parameters for multi-performance characteristics in drilling by using grey relational analysis. Int. J. Adv. Manuf. Technol. 28, 450–455 (2006)MathSciNetCrossRefGoogle Scholar
  12. 12.
    Lin, C.L., Lin, J.L., Ko, T.C.: Optimisation of the EDM process based on the orthogonal array with fuzzy logic and grey relational analysis method. Int. J. Adv. Manuf. Technol. 19, 271–277 (2002)CrossRefGoogle Scholar
  13. 13.
    Narender Singh, P., Raghukandan, K., Pai, B.C.: Optimization by grey relational analysis of EDM parameters on machining Al–10%SiCP composites. J. Mater. Process. Technol. 155–156, 1658–1661 (2004)CrossRefGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringVel Tech High Tech Dr. Rangarajan Dr. Sakunthala Engineering CollegeAvadi, ChennaiIndia
  2. 2.College of EngineeringGuindy, ChennaiIndia

Personalised recommendations