An Experimental Study on Processing TC4 with Nano Particle Surfactant Mixed Micro EDM

Area of Science:

• Materials Science
• Manufacturing Engineering
• Surface Engineering

Background:

• Micro electrical discharge machining (micro EDM) is a non-contact method for removing conductive materials using high temperatures.
• It is particularly suitable for machining titanium and its alloys, outperforming traditional methods.
• Improving micro EDM efficiency and surface quality remains a key challenge.

Purpose of the Study:

• To investigate the impact of nanoparticle surfactants on micro EDM performance for titanium alloys.
• To evaluate the effectiveness of adding TiO2, Al2O3, and ZrO2 nanoparticles to the dielectric fluid.
• To optimize micro EDM parameters for enhanced machining outcomes.

Main Methods:

• Micro electrical discharge machining experiments were conducted on titanium alloy.
• Different nanoparticle surfactants (TiO2, Al2O3, ZrO2) were added to the dielectric fluid.
• Machining parameters, including open-circuit voltage, were varied to assess their effects.

Main Results:

• Titanium alloy micro EDM with TiO2 dielectric showed the highest material removal rate at 100 V open-circuit voltage.
• Dielectric fluids mixed with nanoparticle surfactants resulted in lower tool wear rates.
• The taper ratio improved with nanoparticle surfactant addition compared to deionized water.
• Surface roughness (Ra) was reduced by up to 50% using TiO2 dielectric fluid.

Conclusions:

• Adding nanoparticle surfactants to the dielectric fluid enhances micro EDM performance for titanium alloys.
• TiO2, Al2O3, and ZrO2 show varying degrees of improvement in material removal and surface finish.
• The micro EDM method with nano particle surfactant mixed dielectric offers a promising approach for superior machining of titanium alloys.