Performance evaluation of graphite and titanium oxide powder mixed dielectric for electric discharge machining of Ti–6Al–4V

Abstract Ti–6Al–4V is the most commonly used titanium alloy in aerospace, marine, and biomedical applications. Due to properties of poor machinability conventional machining, Electrical Discharge Machining (EDM) considered a prospective alternative for machining this strategic material. This study aims at enhancing performance powder mixed EDM (PMEDM) with application two different types powders, namely Graphite (Gr) Titanium Oxide (TiO 2 ) concentrations dielectric—kerosene. The effect these powers their relative quantities are studied terms metal removal rate (MRR), tool wear rate, Surface Roughness, surface integrity. performed using copper electrode kerosene as dielectric medium. A separate container submersible pump limit quantity keep suspension, respectively. Design experiments guided by Design-Expert software employed minimize number experimental runs develop empirical models response parameters variable parameters—peak current, type, concentration. Findings indicate that TiO has much higher on MRR compared graphite powder, maximum case recorded 41.01 mm 3 /min against 11.98 i.e., 3.42 times higher. Similarly, ratio 0.0704 0.1219 MRR, which 1.73 lower powder. same ratios minimum 0.0098, power 0.0282, again 2.88 In average roughness, Ra, far better since roughness attained 3.265 μm 9.936 highest lowest 2.228 2.411 TiO2 powders mechanism effects PMEDM texture also been observed SEM images influence concentration morphology.