Assessment Of Surface Integrity During Electrical Discharge Machining Of Titanium Grade 5 Alloys (Ti-6Al-4V)

Machining induced surface integrity is studied in the context of Electrical Discharge Machining (EDM) of Grade 5 Ti-alloy (Ti-6Al-4V). Experiments are conducted using copper electrode submerged in kerosene (as dielectric media). Different settings of peak discharge current, and pulse-on duration are utilized for conducting EDM experiments. Surface integrity of the EDMed specimen is assessed in purview of surface morphology, and topographical characteristics like surface roughness, surface crack density, white layer thickness, metallographic features, material migration, and micro-indentation hardness. Effects of peak current, and pulse-on duration are observed on influencing surface integrity of the end product. Additionally, data in regards of material removal efficiency, and tool wear rate are presented to support root causes behind surface and sub-surface damages.