Sustainable EDM Technique for High-Performance Titanium Alloys: The Case of Ti-5553

Abstract

TIMETAL 5553 is a robust near- β titanium alloy engineered to enhance manufacturability while offering exceptional combinations of mechanical properties, including significant hardenability. The nominal, chemical composition of TIMETAL 5553 consists of Ti-5wt. % Al-5wt. % Mo-5wt. % V-3wt. % Cr. To improve machining performance during the electro-discharge machining of Ti-5553 using a copper tool electrode, this study aims to determine the ideal configuration of process parameters, such as peak discharge current, gap voltage, pulse-on duration, and flushing pressure. Ti-5553 has been machined using an electro discharge machine as part of an experiment. A 4-parameter, 3-level L 9 orthogonal array serves as the foundation for this experiment. This is accomplished by altering the flushing pressure, pulse-on time, voltage, and current. The goal of changing this parameter is to minimize Surface Roughness (Ra), increase Material Removal Rate (MRR), and decrease Tool Wear Rate (TWR/EWR). The multi-responses have been transformed into a single-domain framework using desirability function analysis (DFA). For process optimization, the Taguchi method which is frequently considered an integrated optimization methodology has been used herein. A Surftest SV-2100 M4 tester has been used to measure surface roughness to assess surface abnormalities on the EDMed Ti-5553. Furthermore, the impact of critical process variables on material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) was examined. The findings showed that a rise in peak current causes MRR to rise proportionately. To describe the relationship between MRR and important input parameters, such as flushing pressure (Fp), peak current (Ip), open-circuit voltage (V), and pulse-on time (Ton), a second-order regression model was created. By offering insightful information about the separate and combined effects of process variables on MRR, TWR and Ra, this model makes it easier to optimize machining conditions.