Vibration assisted electro-discharge machining of Ti6Al4V alloy using conical shaped tool
In recent years, the world of material science has observed a wide range of applications of Titanium alloys; especially Ti6Al4V, a grade-V alpha-beta titanium alloy; in biomedical instruments, automobile engineering, aerospace engineering, marine engineering, etc. Shaping this material by conventional machining processes is very difficult because of some of its properties, like high strength, high chemical affinity, etc. That’s why non-conventional machining processes, like electro-discharge machining (EDM), have been applied to shape the material. Past researches revealed that in EDM, both the quality of machining and machining rate deteriorate due to accumulation of debris in the machining zone. The present research has been focused to achieve better machining rate and machining quality by incorporating conical tool and vibration in the workpiece. The effects of, both vibration of workpiece and shape of the tool on material removal rate (MRR) and Diametric Over-cut (DOC), have been studied through a planned set of experiments. The result shows that MRR almost doubled using vibration assisted EDM. However, the DOC also increased due to vibration. On the other hand, the use of the conical tool resulted in increased MRR and a reduced DOC. The paper also includes analysis of the effects of peak-current and pulse-ontime on MRR and DOC.