Abstract
Tool wear rate (TWR) in EDM has a direct effect on machining accuracy and production costs. Many new electrode materials have been introduced to improve TWR, and electrodes sprayed with refractory alloys are said to be new research directions with its prospects as well. In this study, the research team compared TWR of coated and uncoated electrodes in EDM for Ti-6AL-4 V titanium alloy. The basic electrode material is aluminum, and the coating material on the electrode surface is AlCrNi. Process parameters including current (I), gap volt (Vg), pulse on time (TON) were surveyed via Taguchi method. The results showed that TON and I are strongly influencing the TWR of both electrodes. The TWR of Al electrode is approximately 24% larger than that of coated Al electrode.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Similar content being viewed by others
References
Kunieda, M., Lauwers, B., Rajurkar, K.P., Schumacher, B.: Advancing edm through fundamental insight into the process. CIRP Ann. 54(2), 64–87 (2005)
Abbas, N.M., Yusoff, N., Mahmod, R., et al.: Electrical discharge machining (edm): practices in malaysian industries and possible change towards green manufacturing. Procedia Eng. 41, 1684–1688 (2012)
Ho, K., Newman, S.: State of the art electrical discharge machining (edm). Int. J. Mach. Tools Manuf 43(13), 1287–1300 (2003)
Liu, Yu., Wang, W., Zhang, W., Ma, F., Yang, D., Sha, Z., Zhang, S.: Experimental study on electrode wear of diamond-nickel coated electrode in EDM small hole machining. Adv. Mater. Sci. Eng. 2019, 1–10 (2019)
Allen, P., Chen, X.: Process simulation of micro electro-discharge machining on molybdenum. J. Mater. Process. Technol. 186(1–3), 346–355 (2007)
Uhlmann, E., Rosiwal, S., Bayerlein, K., Röhner, M.: Influence of grain size on the wear behavior of CVD diamond coatings in micro-EDM. Int. J. Adv. Manuf. Technol. 47(9–12), 919–922 (2010)
Shirguppikar, S.S., Patil, M.S., Ganachari, V.S., Kolekar, T.V.: Experimental investigation of CNT coated tools for EDM processes. Mater. Today: Proc. 5(2), 7131–7140 (2018)
Tijo, D., Kumari, S., Masanta, M.: Ceramic-metal composite coating on steel using a powder compact tool electrode by the electro-discharge coating process. Silicon 10, 1625–1637 (2018)
Zhang, J.: Fabrication of TiN-Cu electrical discharge machining electrode by gel injection molding. Chin. J. Vacuum Sci. Technol. 39(2), 169–173 (2019). in Chinese
Khan, A.A.: Electrode wear and material removal rate during EDM of aluminum and mild steel using copper and brass electrodes. Int. J. Adv. Manuf. Technol. 39(5–6), 482–487 (2008)
Li, L., Wong, Y.S., Fuh, J.Y.H., Lu, L.: Effect of TiC in copper–tungsten electrodes on EDM performance. J. Mater. Process. Technol. 113(1–3), 563–567 (2001)
Shirguppikar, S.S., Patil, M.S., Mohit, R.: Experimental investigation of coated and uncoated tools used in electro discharge machining process for machining of TI-6AL-4V. Int. J. Mech. Eng. Technol. 10(8), 150–165 (2019)
Shirguppikar, S.S., Patil, M.S.: Experimental investigation of CNT coated tools for EDM processes. J. Mater. Today: Proc. 5(2), 7131–7140 (2018)
Nguyen, Huu Phan., Muthuramalingam, T., Vu, N.N., Tuan, N.Q.: Influence of micro size titanium powders mixed dielectric medium on surface quality measures in EDM process. Int. J. Adv. Manuf. Technol. 109(3–4), 797–807 (2020)
Geethapriyan, T., Kalaichelvan, K., Muthuramalingam, T., Rajadurai, A.: Performance analysis of process parameters on machining α-β titanium alloy in electrochemical micromachining process. Proc. Inst. Mech. Eng. Part B: J. Eng. Manuf. 232(9), 1577–1589 (2018)
Muthuramalingam, T., Ramamurthy, A., Moiduddin, K., Alkindi, M., Ramalingam, S., Alghamdi, O.: Enhancing the surface quality of micro titanium alloy specimen in WEDM process by adopting TGRA-based optimization. Materials 13(6), 1440 (2020)
Muthuramalingam, T.: Effect of diluted dielectric medium on spark energy in green EDM process using TGRA approach. J. Cleaner Prod. 238, 117894 (2019)
Huo, J., Liu, S., Wang, Y., Muthuramalingam, T., Pi, V.N.: Influence of process factors on surface measures on electrical discharge machined stainless steel using TOPSIS. Mater. Res. Express 6(8), 086507 (2019)
Muthuramalingam, T.: Measuring the influence of discharge energy on white layer thickness in electrical discharge machining process. Measurement 131, 694–700 (2019)
Muthuramalingam, T., Ramamurthy, A., Sridharan, K., Ashwin, S.: Analysis of surface performance measures on WEDM processed titanium alloy with coated electrodes. Mater. Res. Express 5(12), 126503 (2018)
Acknowledgements
The work described in this paper was supported by Thai Nguyen University of Technology.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2021 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Phan, N.H. et al. (2021). Tool Wear Rate Analysis of Uncoated and AlCrNi Coated Aluminum Electrode in EDM for Ti-6Al-4 V Titanium Alloy. In: Sattler, KU., Nguyen, D.C., Vu, N.P., Long, B.T., Puta, H. (eds) Advances in Engineering Research and Application. ICERA 2020. Lecture Notes in Networks and Systems, vol 178. Springer, Cham. https://doi.org/10.1007/978-3-030-64719-3_91
Download citation
DOI: https://doi.org/10.1007/978-3-030-64719-3_91
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-64718-6
Online ISBN: 978-3-030-64719-3
eBook Packages: EngineeringEngineering (R0)