EDM of Ti-6Al-4V: Electrode and polarity selection for minimum tool wear rate and overcut

Titanium and its alloys especially Ti-6Al-4V are being widely used numerous application areas. In addition to have iconic properties, Ti-6Al-4V is considered as challenging material in machining perspective that is why it has captured global research focus. In this research, electric discharge machining of Ti-6Al-4V has been carried out by employing four different types of electrode materials (graphite, aluminum, copper, and brass) assigned with two alternate polarities (positive and negative). Selection of the most appropriate tool material and electrode polarity is the important aspect needed to be explored for this alloy. In addition to polarity, discharge current, and pulse time ratio have been considered as process variables owing to have their direct influence in electric discharge machining. Taguchi L9 array has been employed for each of the four electrodes with positive polarity and similarly L9 with negative polarity. Thus, a total number of 72 experiments have been conducted. Tool wear rate and overcut (OC) around the machined surfaces are the response characteristics to be investigated in order to achieve minimum amounts of both of these two responses. Selection of the most suitable tool with common tool polarity has been carried out meeting the decision criteria of minimum tool wear and minimum OC.