Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining
Electrical Discharge Machining (EDM) is a non-traditional cutting technology that is extensively utilized in contemporary industry, particularly for machining difficult-to-cut materials. EDM may be used to create complicated forms and geometries with great dimensional precision. Titanium alloys are...
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MDPI AG
2021-12-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/15/1/164 |
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| author | Panagiotis Karmiris-Obratański Emmanouil L. Papazoglou Beata Leszczyńska-Madej Krzysztof Zagórski Angelos P. Markopoulos |
| author_facet | Panagiotis Karmiris-Obratański Emmanouil L. Papazoglou Beata Leszczyńska-Madej Krzysztof Zagórski Angelos P. Markopoulos |
| author_sort | Panagiotis Karmiris-Obratański |
| collection | DOAJ |
| description | Electrical Discharge Machining (EDM) is a non-traditional cutting technology that is extensively utilized in contemporary industry, particularly for machining difficult-to-cut materials. EDM may be used to create complicated forms and geometries with great dimensional precision. Titanium alloys are widely used in high-end applications owing to their unique intrinsic characteristics. Nonetheless, they have low machinability. The current paper includes an experimental examination of EDM’s Ti-6Al-4V ELI (Extra Low Interstitials through controlled interstitial element levels) process utilizing a graphite electrode. The pulse-on current (I<sub>P</sub>) and pulse-on time (T<sub>on</sub>) were used as control parameters, and machining performance was measured in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The Surface Roughness (SR) was estimated based on the mean roughness (SRa) and maximum peak to valley height (SRz), while, the EDMed surfaces were also examined using optical and SEM microscopy and cross-sections to determine the Average White Layer Thickness (AWLT). Finally, for the indices above, Analysis of Variance (ANOVA) was conducted, whilst semi-empirical correlations for the MRR and TMRR were given using the Response Surface Method (RSM). The results show that the pulse-on time is the most significant parameter of the machining process that may increase the MRR up to 354%. Pulse-on current and pulse-on time are shown to have an impact on the surface integrity of the finished product. Furthermore, statistics, SEM, and EDX images on material removal efficiency and tool wear rate are offered to support the core causes of surface and sub-surface damage. The average microhardness of the White Layer (WL) is 1786 HV. |
| first_indexed | 2024-03-10T03:33:33Z |
| format | Article |
| id | doaj.art-2cc491cd145f42108a09665df12016a5 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T03:33:33Z |
| publishDate | 2021-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-2cc491cd145f42108a09665df12016a52023-11-23T11:49:05ZengMDPI AGMaterials1996-19442021-12-0115116410.3390/ma15010164Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge MachiningPanagiotis Karmiris-Obratański0Emmanouil L. Papazoglou1Beata Leszczyńska-Madej2Krzysztof Zagórski3Angelos P. Markopoulos4Department of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of Science and Technology, 30-059 Cracow, PolandLaboratory of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, 15780 Athens, GreeceDepartment of Materials Science and Non-Ferrous Metals Engineering, Faculty of Non-Ferrous Metals, AGH University of Science and Technology, 30-059 Cracow, PolandDepartment of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of Science and Technology, 30-059 Cracow, PolandLaboratory of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, 15780 Athens, GreeceElectrical Discharge Machining (EDM) is a non-traditional cutting technology that is extensively utilized in contemporary industry, particularly for machining difficult-to-cut materials. EDM may be used to create complicated forms and geometries with great dimensional precision. Titanium alloys are widely used in high-end applications owing to their unique intrinsic characteristics. Nonetheless, they have low machinability. The current paper includes an experimental examination of EDM’s Ti-6Al-4V ELI (Extra Low Interstitials through controlled interstitial element levels) process utilizing a graphite electrode. The pulse-on current (I<sub>P</sub>) and pulse-on time (T<sub>on</sub>) were used as control parameters, and machining performance was measured in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The Surface Roughness (SR) was estimated based on the mean roughness (SRa) and maximum peak to valley height (SRz), while, the EDMed surfaces were also examined using optical and SEM microscopy and cross-sections to determine the Average White Layer Thickness (AWLT). Finally, for the indices above, Analysis of Variance (ANOVA) was conducted, whilst semi-empirical correlations for the MRR and TMRR were given using the Response Surface Method (RSM). The results show that the pulse-on time is the most significant parameter of the machining process that may increase the MRR up to 354%. Pulse-on current and pulse-on time are shown to have an impact on the surface integrity of the finished product. Furthermore, statistics, SEM, and EDX images on material removal efficiency and tool wear rate are offered to support the core causes of surface and sub-surface damage. The average microhardness of the White Layer (WL) is 1786 HV.https://www.mdpi.com/1996-1944/15/1/164EDMwhite layermicrohardnessEDX mapsmicrostructure’ Titanium Grade 23Response Surface Method |
| spellingShingle | Panagiotis Karmiris-Obratański Emmanouil L. Papazoglou Beata Leszczyńska-Madej Krzysztof Zagórski Angelos P. Markopoulos Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining Materials EDM white layer microhardness EDX maps microstructure’ Titanium Grade 23 Response Surface Method |
| title | Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining |
| title_full | Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining |
| title_fullStr | Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining |
| title_full_unstemmed | Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining |
| title_short | Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining |
| title_sort | surface and subsurface quality of titanium grade 23 machined by electro discharge machining |
| topic | EDM white layer microhardness EDX maps microstructure’ Titanium Grade 23 Response Surface Method |
| url | https://www.mdpi.com/1996-1944/15/1/164 |
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