An Analysis of Machining on Titanium Alloy (TI6AL4V) with WEDM

International Research Journal of Engineering and Technology (IRJET)

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Volume: 04 Issue: 06 | June -2017

p-ISSN: 2395-0072

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AN ANALYSIS OF MACHINING ON TITANIUM ALLOY(TI6AL4V) WITH WEDM Atul Kumar Dixit, Sandeep Kumar Gupta, Shweta Pandey Mechanical Eng. Department Rungta College of Engineering & Technology Chhattisgarh Assistant Professor, Mechanical Eng .Department Rungta College of Engineering & Technology Chhattisgarh Electrical Eng. Department Rungta College of Engineering & Technology Chhattisgarh ---------------------------------------------------------------------***---------------------------------------------------------------------

Abstract - There Is A Quick Development Of High Quality

Temperature Safe (HSTR) Composites, For Example, NitraCompound, Waspa-Combination, Titanium-Amalgam, Inconal, Die-Cast Steel And So Forth. Since, The Properties of These Composite Materials Are High In Hardness, Sturdiness, And Effect Quality And Temperature Safe, In This Manner, The Machining Of These Materials By Moderate Strategies Is Truly Confounded. The Flighty Machining Procedures Are Most Superb Coordinated To Machine Such Amalgams. This Displays, A Far Reaching Study Of Different Research Works Tending To The Machining Of HSTR Combinations Through Wire Electric Release Machining. Being An Exceptionally Complex Machining Process And Having A Substantial Number Of Control Parameters Which Influence The Essential Reaction Parameters Like MRR, Surface Harshness, Geometry And So On, Numerous Calculation Devices Have Been Executed To Enhance The Procedure, And Master Frameworks Are Created For Future Forecasts. Therefore, The Present Review Is An Endeavor To Give Future Bearings And An Extensive Refresh Information On Wedm Of Hstr Composites Key Words: Titanium Alloys,Wedm,Literature Review 1. INTRODUCTION WEDM is a vital machining process which is utilized to machine complex geometric shapes where high exactness and awesome surface complete is required. In view of its higher procedure capacity and efficiency, WEDM can without much of a stretch machine complex parts and accuracy segments which are hard to be machined by customary machining process. In this operation, the material expulsion happens from the electrically conductive material by start of fast and dreary start release between the crevice of the work and instrument cathode associated in an electrical circuit.

There is no relative contact between the apparatus and the work piece. The cathode is drenched in a fluid dielectric medium. These electric releases soften and vaporize minute measures of work Material, Which Are Then Shot Out And Flushed Away By The Dielectric. WEDM Finds Broad Use In Regions, For Example, Apparatus And Kick The Bucket Making, Vehicle, Aviation, Atomic, Shuttles, Marine Car, GasTurbine Motor, Military Ballistic, PC And Gadgets Businesses, And So On. Titanium Amalgams Then Again Are Propelled Materials Which Discover Use In The Multi-Disciplinary Š 2017, IRJET

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Defensive Layer, Atomic, Compound Vessels, Games And Medicinal Applications.

Having Properties ,For Example, High Hardness, Sturdiness, Affect Quality And Temperature Safe, The Machining Of High Quality Compounds By Traditional Strategies Is Troublesome And Tedious. Among The Non-Regular Machining Forms, WEDM Is A Well-Suited Procedure To Machine Such Amalgams.

1.1 PRINCIPAL OF WIRE EDM The Spark Theory On A Wire EDM Is Essentially The Same As That Of The Vertical EDM Handle. In Wire EDM, The Conductive Materials Are Machined With A Progression Of Electrical Releases (Starts) That Are Created Between A Precisely Situated Moving Wire (The Terminal) And The Work Piece. High Recurrence Beats Of Exchanging Or Direct Current Is Released From The Wire To The Work Piece With A Little Start Hole Through And Protected Dielectric Liquid (Water). Many Flashes Can Be Seen At One Time. This Is On The Grounds That Genuine Releases Can Happen More Than One Hundred Thousand Times Each Second, With release sparkles enduring in the scope of 1/1,000,000 of a moment or less. The volume of metal evacuated amid this short time of start release relies on upon the coveted cutting pace and the surface wrap up required. The wire terminal is typically a spool of metal, copper or metal and zinc wire from 0.01to 0.014" thick.

Fig -1: schematic diagram of wedm process 1.2 TITANIUM Titanium Is A Solid And Light Metal And More Grounded Than Normal, Low-Carbon Steels, Yet It Is 45% Lighter. In Addition, Titanium Is Twice As Solid As Powerless Aluminum Compounds However Just 60% Heavier. Titanium And Its Composites Are Poor Warm Conductors That Outcomes In ISO 9001:2008 Certified Journal

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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395 -0056

Volume: 04 Issue: 06 | June -2017

p-ISSN: 2395-0072

www.irjet.net

The Ponder Scattering Of Warm In The Meantime As Machining Titanium And The Larger Part Of Warmth Is Exceptional On The Toot Face And Front Line. The Alloying Inclination Or Compound Reactivity Of Titanium Amalgams With The Cutting Device Material Is Solid At Instrument Operation Temperatures. This Causes Rankling, Welding, And Spreading, Along With Quick Wear Or Cutting Apparatus Disappointment. Titanium Compounds Indicate Warm Plastic Unpredictability That Prompts Just A Single Of Its Kind Uniqueness Of Chip Development Amid Machining. The Shear Strains In The Chip Are Not Steady; Rather, They Are Constrained To A Little Range In A Thin Band That Structures Indented Chips. The Contact Length Between The Chip And The Apparatus Is To A Great Degree (Short Of What 33% The Contact Length Of Steel With A Similar Nourish Rate And Profundity Of Cut). This Infers The High Cutting Temperature And The High Anxiety Are At The Same Time Thought Close To The Front Line (Inside 0.5 Mm). Indented Chips Create Variances In The Cutting Power And This Circumstance Is More Advanced When Α–Β Composites Are Machined. The Constrain Of Vibration, With The High temperature, applies a small scale exhaustion stacking on the cutting device, which is accepted to be not entirely responsible for strict flank wears. titanium is not effectively eroded via ocean water, and in this manner is utilized as a part of propeller shafts, fixing and different parts of pontoons that are presented to ocean water.

The machining of titanium and its composites is normally cumbersome because of different characteristic properties. it is exceptionally synthetically quick and it tends to patch to the cutting apparatus amid machining which prompts early disappointment of the instruments.

2. LITERATURE REVIEW Literature Review Is A Very Concrete Part Of Any Research Paper And Review Paper. That Section Alloy Us To Calculate And See The Future Scope Of That Project, & Permit Us To Get Some More Knowledge (Both Theoretically And Practically).

Basil Et Al [4] Did A Number Of Trial Experiments To Calculate The Machine Performance Of Grade-5 Titanium Alloy In Wedm . Experimental Design Was Adopted In This Work To Determine The Best Machining Parameter And Its Optimum Condition And The Role Of Each Parameter On The Performance Of Machining Characteristics. Although Eighteen Experiment Data Were Taken And Put Into The Optimization Software Analysis Have Been Done And Mathematical Empirical Formula Have Got Which Is Show The Predicted Response Parameter.

Atul Kumar And Dr D.K. Singh [12] Have Done Project On Variation Of Cutting Performance With Pulse On Time, Pulse Off Time, Open Voltage, Feed Rate Override, Wire Feed, Servo Voltage, Wire Tension And Flushing Pressure Were Experiment Investigated In Wire Electric Discharge Machining Processes. Brass Wire With 0.25 Mm Diameter And Skd 61 Alloys Steel With 10 Mm Thickness Took As Tool And Work Materials. The Display Parameter Is Mrr And Surface Roughness. That Project Has Been Competed By © 2017, IRJET

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Using Taguchi’s L18 (2*1×3*7) Orthogonal Array Under Variable Conditions Of Parameters. Finally On The Basis Of Output We Can Say Or Concluded That The Mrr Is Directly Perposionally Increase To Pulse On Time And Inversely Decrease With Pulse Off Time And Open Voltage. The Effect Of Feed Rate Overdrive, Wire Feed, Servo Voltage, Wire Tension And Flushing Pressure On Mrr Is Not Very Important. Other Side In The Case Of Surface Roughness Its Value Continuously Decrease With Increase Of Pulse Off Time Open Voltage And Wire Feed and increases with increase in feed rate override and servo voltage. weightage of other parameter will not be considered because it has no significant to analysis.

Hsieh Et Al [6] Have Been Found Wedm Characteristics Of Tinix (X=Zr And Cr) Ternary Shape Memory Alloys. They Analyzed Surface Roughness(Ra) Of Machined Tinix Alloys Increased With Increase Pulse Time. They Did Number Of Test On Specimen And On The Basis Of Experiment They Have Concluded Hardness Of Each Work Piece Was Reported Between 875 And 807 Hv For Tinizr And Tinicr Alloys Respectively. kuriakose et al [7] performed project on ti6al4v with robofil 310, 5-axis cnc wedm as experiment machine. the main important process parameters or Controllable Factore Of The Wire Electric Discharge Machine(Wedm) Are Time Between Two Pulses(Ton Or Toff), Pulse Duration, Servo Voltage, Servo Speed Variation, Wire Speed, Wire Tension And Die-Electric Fluid Pressure(Deionized Water Pressure).After That One Optimization Software Package Is Used Taguchi's L18 (Orthogonal Array). The Machining Operation Have Done Was With Zinc Coated And Uncoated Brass Wire Of 0.25mm Diameter. Taguchi's And Anova Both Methods Have Been Using To Find Out The Parameter Who Is Responsible To Influence Of Process. For Better Surface Quality The Coated Wires Were Preferred Over Than The Place Of Uncoated Wires. The Time Between Two Pulses Is The Most Important And The Most Sensitive Parameter That Affect The Creation Of Layer Consisting Of Mixture. gokler et al [8] is performed his experiment on sodic mark xi a500 edw wedm as machine tool and 1040, 2379 and 2378 steel as work piece different materials are used in here to see how cutting is varying and offset parameters on surface roughness in wedm process. from the experimental data they concluded off set parameter is not effecting surface roughness of material and exactly same result to cutting parameter .when the thickness will vary like increase then feed rate will decrease. Hewidy Et Al [9] Did Their Work On Wedm By Using Inconel 601 And Calculate Surface Roughness By Using Response Surface Methodology (Rsm).After It They Gave Summery Of When Peak Current Increase Surface Roughness Will Be Increased & Other Case When Duty Factor And Wire Tension Increase Surface Roughness Will Decrease. Mahapatra And Patnaik [10] Compare The Parameter Of Coated Brass Wire Electrode And Non Coated Brass Wire Electrode On wedm machining performance basis on their work they have concluded ISO 9001:2008 Certified Journal

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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395 -0056

Volume: 04 Issue: 06 | June -2017

p-ISSN: 2395-0072

www.irjet.net

coated brass wire electrode is better to non coated brass wire electrode it can perform very effectively in higher speed and show very good surface finish compare to non coated wire electrode .

3. CONCLUSIONS After The Far Reaching Investigation Of Writing, It Has Been Watched That There Exists A Plenty Of Space For Research Under Wedm Some Of Which Are As Per The Following: Lacking Work Has Been Done On Wedm Of pure titanium gread-5 . the pure titanium is generally utilized for heat exchangers sea, reactor vessels and water piping. the machinability of titanium for wedm wishes to be considered. since, recast layer is a standard event in edm that cause a few issues. different materials dissolve and re-harden on the base materials, offering ascend to surface covering in which the properties are not quite the same as those of the first material. small exertion has been accounted for regarding the matter of the plausibility of utilizing a bizarre machining procedure, for example, wedm for machining of titanium. there is a genuine require for streamlining of process parameters utilizing wedm. there exists space for research of the hybridization procedure in this field. another region of research can be a few novel materials in the vein of metal grid composite.

REFERENCES [1] Ho, K. H., Newman, S. T., Rahimifard, S., & Allen, R. D. (2004). State Of The Art In Wire Electrical Discharge Machining (Wedm). International Journal Of Machine Tools And Manufacture, 44(12), 1247-1259.

[2] Rahman, M., Wang, Z. G., & Wong, Y. S. (2006). A Review On High-Speed Machining Of Titanium Alloys. Jsme Int. J, 49(1), 11-20.

[3] Ezugwu, E. O., & Wang, Z. M. (1997). Titanium Alloys And Their Machinability—A Review. Journal Of Materials Processing Technology, 68(3), 262-274.

[4] Basil, K., Paul, D. J., & Issac, D. J. M. (2013). Spark Gap Optimization Of Wedm Process On Ti6al4v. International Journal Of Engineering Science And Innovative Technology (Ijesit), 2(1), 364-369.

[5] Sarkar, S., Mitra, S., & Bhattacharyya, B. (2006).Parametric Optimisation Of Wire Electrical Discharge Machining Of Titanium Alloy Through An ArtificialNeural Network Model. The International journal of advanced manufacturing technology, 27(5-6), 501-508.

[6] hsieh, s. f., chen, s. l., lin, h. c., lin, m. h., & chiou, s. y.

(2009. the machining characteristics and shape recovery ability of ti–ni–x (x= zr, cr) ternary shape memory alloys using the wire electro-discharge machining. international journal of machine tools and manufacture, 49(6), 509-514.

[7] Kuriakose, S., & Shunmugam, M. S. (2004). Characteristics Of Wire-Electro Discharge Machined Ti6al4v Surface.

Materials Letters, 58(17), 2231-2237. © 2017, IRJET

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[8] Gökler, M. I., & Ozanözgü, A. M. (2000). Experimental Investigation Of Effects Of Cutting Parameters On Surface Roughness In The Wedm Process. International Journal Of Machine Tools And Manufacture, 40(13), 1831-1848.

[9] Hewidy, M. S., El-Taweel, T. A., & El-Safty, M. F. (2005).

Modelling The Machining Parameters Of Wire Electrical Discharge Machining Of Inconel 601 Using rsm. journal of materials processing technology, 169(2), 328-336.

[10] mahapatra, s. s., & patnaik, a. (2006). parametric optimization of wire electrical discharge machining (wedm) process using taguchi method. journal of the brazilian society of mechanical sciences and engineering, 28(4), 422429.

[11] ghodsiyeh, d., golshan, a., hosseininezhad, n., hashemzadeh, m., & ghodsiyeh, s. (2012). optimizing finishing process in wedming of titanium alloy (ti6al4v) by zinc coated brass wire based on response surface methodology. indian journal of science and technology, 5(10), 3365-3377.

[12] atul kumar and dr. d. k. singh, 2012. “performance analysis of wire electricdischarge machining (w-edm).” international journal of engineering research& technology (ijert) vol. 1 issue 4, june – 2012, issn: 2278-0181 BIOGRAPHIES Atul Kumar Dixit Mechanical Eng Department Rungta College Of Engineering& Technology Bhilai Chhattisgarh490023.

Sandeep Kumar Gupta Assistant Professor Mechanical Eng.Department Rungta College Of Engineering& Technology Bhilai Chhattisgarh490023.

Shweta Pandey Electricl Eng. Department Rungta College Of Engineering& Technology Bhilai Chhattisgarh490023.

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