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An Experimental Investigation of the Erosion Phenomenon in µED-Milling of Titanium and Its Parametric Optimization Using Desirability Analysis

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Abstract

The study investigates the erosion phenomenon of the micro-electrical discharge milling (µED-milling) while fabricating microslots on titanium grade 2 alloy. Control parameters such as voltage, capacitance and depth of cut (DOC) are varied during experimentation. Material removal rate (MRR), tool wear rate (TWR) and electrode wear ratio (EWR) are the response measures evaluated to visualize the effect of variation of control parameters. An in-depth analysis of the erosion mechanism is done by characterizing the optical microscopy images of the machined cavities and the worn-out tools. Empirical models of MRR, TWR and EWR as functions of the control parameters are formulated by regression analysis. Thereafter, desirability analysis is applied to simultaneously optimize all the responses by assigning equal weightage and importance. Maximum composite desirability of 0.646 is attained at 104 pF, 110 V and 1000 µm. The analysis of variance test revealed that capacitance and voltage are more significant to all the responses than the DOC. A good correlation between the experimental and predicted values is achieved from residual analysis, which signifies the adequacy of the regression models. From the confirmation test, the highest error of 7.77% is observed between the experimental and predicted values of TWR, which justifies the desirability approach in simultaneous optimization of all the responses.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Saveetha Engineering College, Chennai, Tamil Nadu, 602105, India

    Siddhartha Kar

  2. Department of Mechanical Engineering, National Institute of Technology Silchar, Silchar, Assam, 788010, India

    Promod Kumar Patowari

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  1. Siddhartha Kar
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Correspondence to Siddhartha Kar.

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Kar, S., Patowari, P.K. An Experimental Investigation of the Erosion Phenomenon in µED-Milling of Titanium and Its Parametric Optimization Using Desirability Analysis. Arab J Sci Eng 47, 8847–8861 (2022). https://doi.org/10.1007/s13369-021-06387-9

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  • DOI: https://doi.org/10.1007/s13369-021-06387-9

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