Investigations on the Surface Integrity of Ti6Al4V under Modified Dielectric(s)-Based Electric Discharge Machining Using Cryogenically Treated Electrodes

The surface integrity of machined components is considered to be an important part the quality matrix for high-performance applications in aviation industry. Therefore, close attention given made up hard-to-cut materials such as Ti6Al4V, which face processability challenges. In this regard, among non-conventional machining processes, electric discharge widely preferred cutting Ti6Al4V. study, potentiality cryogenic-treated tool electrodes (graphite and aluminum) with unmodified (kerosene) modified (kerosene Span 20, 60, 80) dielectrics are comprehensively investigated. A three-phased experimentation framework deployed based on following process parameters, i.e., surfactant type, concentration, electrode material, pulse ON:OFF time. Thorough statistical analyses performed full factorial design experiments, results characterized by physics. It found that mechanism highly dependent surfactants, especially their hydrophilic–lipophilic balance dielectric. desirability-based optimization show (with kerosene) produced relatively higher roughness values 7.5 µm 5.8 aluminum graphite electrodes, respectively. However, surfactant) resulted a lower degree workpiece. using S-60 resulting Ra 1.73 outperformed S-20, yielding 3.4 µm. minimum workpiece fewest defects at 25 g/L 50:25 µSec time, cryogenically treated electrode.