Experimental study on micro EDM-drilling of Ti6Al4V using helical electrode |
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Authors: | Soraya Plaza,Jose A. Sanchez,Endika Perez,Ruben Gil,Borja Izquierdo,Naiara Ortega,Iñ igo Pombo |
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Affiliation: | 1. Faculty of Engineering of Bilbao, University of the Basque Country, Alameda de Urquijo s/n, 48013 Bilbao, Spain;2. Faculty of Technical Engineering of Bilbao, University of the Basque Country, Paseo Rafael Moreno “Pitxitxi” 3, 48013 Bilbao, Spain |
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Abstract: | There is a growing interest in the machining of micro-holes with high aspect-ratio in difficult-to-machine alloys for the aerospace industry. Processes based on electro discharge machining (EDM) and developed for the manufacture of both micro-electrode and micro-hole are actually used, but most of them involve micro-EDM machines. In this work, the influence of EDM parameters on material removal rate, electrode wear, machining time and micro-hole quality when machining Ti6Al4V is studied. Due to an inefficient removal of debris when increasing hole depth, a new strategy based on the use of helical-shaped electrodes has been proposed. The influence of helix angle and flute depth with respect to process performance has been addressed. Main results include 37% reduction in machining times (hole diameter 800 μm) when using electrode helix angle of 45° and flute-depth of 50 μm, and an additional 19% with flute-depth of 150 μm. Holes of 661 μm diameter and as much as 6.81 mm depth, which yields in aspect ratio of 10:1, have successfully been machined in Ti6Al4V. |
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Keywords: | EDM, electro discharge machining WEDG, wire electro discharge grinding ISEDM, inverse slab electro discharge milling R1, R2, R3, R4, R5, EDM regimes studied MRR (mm3/min), material removal rate I (A), current intensity U0 (V), open-circuit voltage ton (μs), pulse on-time toff (μs), pulse off-time tback (μs), backwards time Vgap (V), reference servo voltage W (%), electrode wear lw (mm), length worn-out electrode hdepth (mm), depth actually drilled in the hole Ra (μm), average roughness |
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