Multi-Objective Optimization of Process Parameters for Through-Hole Machining of Ti-6Al-4V Alloy by EDM

Abstract

Most of the work on EDM of Ti–6Al–4V alloy primarily attempted to increase the MRR for making a blind hole, where experiments were performed for a specific time period and effect of different parameters were evaluated. However along with the difficulties in machining of Ti–6Al–4V alloy, making a through hole on this alloy is another challenging task therefore, this work is aimed to make the through hole in Ti-6Al-4V work material with hollow copper tool by EDM process. the influence of various process parameters like flushing type (internal, external), discharge current, pulse on time and discharge voltage on the machining performance such as machining rate, taper in hole, overcut of hole, surface roughness and white layer thickness are studied and the optimal parametric setting for each response has been estimated. Since Multi response optimization accomplished with the help of grey relational analysis together with Taguchi approach. Additionally, an attempt to design and fabricate the rotating tool electrode in order to give a rotational motion to the tool for better performance during electro discharge machining of Ti-6Al-4V alloy.