Investigation on performance characteristics of micro-EDM dressing for the fabrication of micro-rod(s) on Ti-6Al-7Nb biomedical material. Issue 3 (4th May 2021)

• Record Type: Journal Article
• Authors: Shah, Md Shamim; Saha, Probir
• Is Part Of: Machining science and technology. Volume 25:Issue 3(2021)
• Page Start: 398
• Page End: 421
• Publication Date: 2021-05-04
• Subjects: Micro-EDM dressing -- offline responses -- pulse-discriminating system -- real-time responses -- Ti-6Al-7Nb; Machining -- Periodicals; 671.3505
• DOI: 10.1080/10910344.2020.1815050
• Languages: English
• ISSNs: 1091-0344

Abstract

Abstract: The performance characteristics of micro-EDM dressing were investigated based on some real-time and offline responses for the fabrication of micro-rod(s) on a novel Ti-6Al-7Nb biomedical material. These characteristics evaluated along the micro-rod length at three different discharge energy settings were analyzed by monitoring the discharge gap condition captured through an in house developed pulse-discriminating system (PD). The experimental results show that the normal pulse was more (∼90%) in the low energy setting ( E 1 ). In contrast, arcing was more (∼28%) in the high energy setting ( E 3 ). Pulse frequency was found more (∼60 N c / s ) in E 1 . However, due to an increase in the 'idle' time, it significantly decreased (∼25 N c / s ) along the machining length. Material removal rate, however, was found more (∼5.7 × 10 3, µm 3 /s) in E 3 . The specific energy was found very high (∼9 MJ/mm 3 ) in E 1 since the process spent additional energy to remove the re-solidified molten metal. The tool wear ratio was, on the other hand, found very high (∼2.1) in E 1 due to prolonged exposure to discharges and experiencing higher total discharge energy by the work-tool interface. E 3 was found more suitable for fabricating dimensionally accurate micro-rod(s) on this material because of less tool wear.