Electrical discharge machining of Ti6Al4V with a bundled electrode |
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| Authors: | Lin Gu Lei LiWansheng Zhao KP Rajurkar |
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| Affiliation: | a State Key Laboratory of Mechanical Systems and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, China
b Center for Nontraditional Manufacturing Research, University of Nebraska-Lincoln, USA |
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| Abstract: | The aim of this study is to investigate an efficient Ti6Al4V electrical discharge machining (EDM) process with a bundled die-sinking electrode. The feasibility of machining Ti6Al4V with a bundled electrode was studied and its effect on EDM performance was compared experimentally using a solid die-sinking electrode. The simulation results explain the high performance of the EDM process with a bundled electrode by through the use of multi-hole inner flushing to efficiently remove molten material from the inter-electrode gap and through the improved ability to apply a higher peak current. A 3-factor, 3-level experimental design was used to study the relationships between 2 machining performance parameters (material removal rate: MRR, tool wear ratio: TWR) and 3 machining parameters (fluid flow rate, peak current and pulse duration). The main effects and influences of the 2-factor interactions of these parameters on the performances of the EDM process with the bundled electrode are discussed. |
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| Keywords: | EDM Bundled electrode Ti6Al4V Multi-hole inner flushing Computational fluid dynamics |
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