Titanium and nickel alloys are the most popular high-strength temperature-resistant (HSTR) alloys which have different applications for their outstanding material properties. The process of electrochemical milling (EC milling) is similar to conventional electrochemical machining where the material is removed by simple geometric tool following a predefined path in a layer-by-layer fashion and has great application in machining of any HSTR alloys. With the indigenously developed setup, the present research work investigates the influence of process parameters, like feed rate and milling layer depth, on various performance criteria, such as, overcut, machining depth, perpendicularity and radius of curvature of the side wall, by EC milling process on Ti6Al4V. It was observed that EC milling with NaCl(1 M) + NaNO3(1 M) mixed electrolyte generates different complex and three-dimensional features on Ti6Al4V with desired accuracy. Internal flushing with tool rotation improves the accuracy of the machined profile due to better removal of sludge from the machining zone.
EC milling Feed rate Milling layer depth Tool rotation Internal flushing Mixed electrolyte 3D complex features
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The authors acknowledge special thanks to AR&DB, DRDO, New Delhi, for the financial assistantship.
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