Investigation on the impact of sub-zero treated electrodes in EDM

ABSTRACT

Owing to the challenges faced during conventional machining of Titanium (Ti) alloys due to their low thermal conductivity and high chemical reaction, non-conventional machining techniques are used. Electrical Discharge Machining (EDM) is a promising solution that can precisely machine hard materials into intricate geometries but faces lower material removal rate, higher tool wear rate, and poor surface quality. In this research work, the effect of sub-zero treatments on EDM electrodes was investigated, and experimental investigations were conducted to identify the impact of sub-zero treated electrodes during EDM of Ti-6Al-4V under different discharge energy regimes. Peak Current, Pulse-On-Time and Gap Voltage were varied in 3 levels to evaluate the effect on MRR and TWR. A comprehensive study on EDMed surfaces has been assessed using the morphological and metallurgical observations from SEM micrographs, EDAX and XRD patterns. Sub-zero treated electrodes outperformed the Untreated (UT) electrodes regarding erosion rates and surface quality.

KEYWORDS:

• Cold
• cryogenics
• electrode
• EDM
• MRR
• TWR

Acknowledgments

We are grateful to the Department of Science and Technology (DST), Government of India, and the Centre for Precision Measurements and Nanomechanical Testing, Department of Mechanical Engineering, National Institute of Technology Calicut for providing the facility purchased through the ‘Fund for Improvement of Science and Technology’ scheme (FIST—No. SR/FST/ETI-388/2015) during the research work.

We are thankful for the support provided by ISRO Sponsored Cryo Lab in AJCE, Kerala.

Disclosure statement

No potential conflict of interest was reported by the author(s).