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Experimental investigation on machining characteristics of titanium processed using electrolyte sonicated µ-ECDM
K V J Bhargav1, P S Balaji1, Ranjeet Kumar Sahu2
1Department of Mechanical Engineering, National Institute of Technology Rourkela, Rourkela, 769008, India.
Scientific Reports
|September 15, 2022
Summary
This study optimized micro-electrochemical discharge machining (µ-ECDM) for titanium using ultrasonication. The best parameters achieved high-quality microholes with minimal defects, advancing difficult-to-machine material processing.
Area of Science:
- Materials Science and Engineering
- Manufacturing Technology
- Surface Engineering
Background:
- Titanium's desirable properties drive demand in aerospace, chemical, and biomedical fields.
- Micromachining titanium presents significant challenges due to its material characteristics.
- Efficient and precise micro-fabrication techniques are crucial for advanced applications.
Purpose of the Study:
- To investigate the micromachining of commercially pure titanium using a novel electrolyte sonicated micro-electrochemical discharge machining (ES-µ-ECDM) system.
- To optimize process parameters for enhanced material removal rate, reduced overcut, and improved circularity of microholes.
- To determine the optimal operating conditions for achieving high-quality microholes with minimal surface defects.
Main Methods:
- Utilized a tailor-made electrolyte sonicated micro-electrochemical discharge machining (ES-µ-ECDM) system with a 36 kHz ultrasonication unit.
- Employed a Face-Centered Response Surface Methodology (FCC-RSM) based Design of Experiments (DOE) to study voltage (V), electrolyte concentration (wt%), and duty factor (DF).
- Applied the MOJAYA algorithm for multi-response optimization and the MADM (R-method) to identify the optimal process parameters.
Main Results:
- Achieved through-holes at specific parameter combinations (e.g., 80 V, 25 wt%, 60% DF and 80 V, 30 wt%, 50% DF).
- Ultrasonication enhanced electrolyte replenishment and debris removal, stabilizing the machining process.
- The optimal parameters (69 V, 30 wt%, 50% DF) yielded microholes with a circularity of 0.9615 and minimal surface defects.
Conclusions:
- The developed ES-µ-ECDM system effectively machines titanium microholes.
- Ultrasonication and optimized parameters significantly improve machining performance and quality.
- The study provides optimal conditions for precise micromachining of titanium, suitable for demanding industrial applications.
