Robust setting of Ti-6Al-4V machining using WEDM (Low Energy with Electrolysis Free Circuit Off )

Abstract

Titanium alloys such as Ti-6Al-4V are increasingly used in aerospace and automotive industries, and also used as medical implant material in wide variety of applications. Wire-electro discharge machining (WEDM) is an important non-traditional machining process, widely used for machining a variety of difficult-to-machine materials including titanium alloys with intricate shape but Ti-6Al-4V always needs some new setup parameters of cutting because the differentials occur among material properties. The investigated machining parameters were pulse-ON Time, pulse-OFF Time, intensity/peak current and wire speed affecting the material removal rate (MRR) and surface roughness (Ra). The experimental settings of machining parameters were determined by using Classical DOE with 20 runs have been layout. The statistically significant of machining parameters on the material removal rate (MRR) and surface roughness (Ra) are determined by using analysis of variance (ANOVA). Result from ANOVA by using Design Expert 7 (DX7) software shows that pulse-ON Time is significant factor for both material removal rate (MRR) and surface roughness (Ra) of WEDM Ti-6Al-4V. Then, based on interaction between factors robust setting of Ti-6Al-4V machining using WEDM (Low Energy with EF Circuit Off) has been produced.