ELECTRICAL DISCHARGE MACHINING OF TITANIUM ALLOY...

.

ELECTRICAL DISCHARGE MACHINING OF TITANIUM ALLOY USING

COPPER TUNGSTEN ELECTRODE WITH SiC POWDER SUSPENSION

DIELECTRIC FLUID

R I V A L

A thesis submitted in fulfilment of the

requirements for the award of the degree of

Master of Engineering (Mechanical)

Faculty of Mechanical Engineering

Universiti Teknologi Malaysia

AUGUST 2005

iii.

To my beloved family that were gone in Tsunami disaster 26 december 2004

M. Djamil Risma M.Y Rina Sari Ridayani M. Fauzi Alaudin Rizqa Maulidya Rusydina Fathnin

M. Faidzil Azlan

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ACKNOWLEDGEMENTS

In the name of Allah, the most Gracious and most Compassionate

I would like to thank Allah Almighty for blessing and giving me strength to

accomplish this thesis. A special thank to my supervisor, Assoc. Prof. Dr. Safian

Sharif who greatly helped me in every way I need to go through this study, Assoc.

Prof. Dr. Noordin Mohd. Yusof for being the co-supervisor and also for his

encouragements.

Many thank to all of the technicians in Production Laboratory, Machine Sop,

Metrology Laboratory and Material Laboratory, Faculty of Mechanical Engineering,

for their cooperation and assisting me in the various laboratory tasks. I am also

grateful to fellow researchers in the Production Laboratory for their advice and

support. I would like to express my sincere appreciation to all of my friends and

colleagues in Universiti Teknologi Malaysia for coloring my daily live and helped

me in one-way or another.

Deepest gratitude to my parents, M. Djamil and Risma, who give me a real

love, pray, support, and all they have. Together with my both sisters Rina Sari and

Ridayani with her family for supporting me. Also to my fiancee Bechty Zerullita for

her continuous encouragement and patience.

Finally, I am grateful to Universiti Teknologi Malaysia for financial support

during the period of this research work.

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ABSTRACT

Titanium alloys which are categorized as lightweight materials, posses

greater strength and toughness are usually known to create major challenges during

conventional and non-conventional machining. Electrical discharge machining

(EDM) which is very prominent amongst the non-conventional machining methods

is expected to be used quite extensively in machining titanium alloys due to the

favorable features and advantages that it can offer. This project was undertaken to

study the machining performance of EDM and powder mixed dielectric-electrical

discharge machining (PMD-EDM) on titanium alloy, Ti-6246 using copper tungsten

(CuW) electrode. Silicon carbide (SiC) powder at various concentration was mixed

in the dielectric to evaluate its effectiveness during the PMD-EDM process. The

effect of varying the machining parameters on the machining responses such as

material removal rate (MRR), electrode wear ratio (EWR), surface integrity and

overcut was investigated. The experimental plan for both processes were conducted

according to the design of experimental (DOE) and the results were statistically

evaluated using analysis of variance (ANOVA). Response surface methodology

(RSM) was employed in evaluating the machining performance of the PMD-EDM

process and mathematical models for MRR, EWR and machined surface roughness

(SR) were established. Result showed that current was the most significant parameter

that influenced the machining responses on both EDM and PMD-EDM of Ti-6246. It

was also found that PMD-EDM process produced less damaging effect on the

surface integrity of the machined surface as compared to EDM process.

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ABSTRAK

Aloi titanium yang dikategorikan sebagai bahan ringan yang mempunyai

kekuatan dan ketahanan yang tinggi dikenali kerana menimbulkan cabaran yang

besar semasa pemesinan konvensional ataupun pemesinan bukan konvensional.

Proses pemesinan nyahcas elektrik (EDM) yang agak dominan di antara proses

pemesinan bukan konvensional dijangkakan akan bertambah meluas penggunaannya

disebabkan sifat-sifat dan kelebihan yang dihasilkan keatas bendakerja. Projek ini

dilaksanakan untuk mengkaji prestasi proses EDM dan proses pencampuran serbuk

dalam dielektrik-pemesinan nyahcas elektrik (PMD-EDM) semasa memesin aloi

titanium, Ti-6246 menggunakan elektrod tungsten kuprum (CuW). Serbuk karbida

silikon (SiC) pada kepekatan yang berbagai dicampurkan ke dalam dielektrik untuk

menilai keberkesanannya semasa proses PMD-EDM. Kesan perubahan parameter

pemesinan ke atas tindak balas pemesinan seperti kadar pembuangan material

(MRR), nisbah kehausan elektrod (EWR), integriti permukaan dan ‘overcut’ telah

dikaji. Ujian pemesinan untuk kedua-dua proses telah dinilai secara statistik

menggunakan analisa variasi (ANOVA). Kaedah tindak balas permukaan (RSM)

telah digunakan untuk menilai prestasi proses PMD-EDM dan model matematik

untuk MRR, EWR, kekasaran permukaan (SR) telah dihasilkan. Keputusan

menunjukkan arus lektrik merupakan parameter yang paling signifikan yang

mempengaruhi tindak balas pemesinan untuk kedua-dua proses EDM dan PMD-

EDM ke atas Ti-6246. Juga didapati proses PMD-EDM telah menghasilkan kesan

yang tidak merosakkan ke atas integriti permukaan bendakerja berbanding dengan

proses EDM.

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CONTENTS

CHAPTER TITLE

DECLARATION

ACKNOWLEDGEMENTS

ABSTRACT

ABSTRAK

CONTENTS

LIST OF TABLES

LIST OF FIGURES

NOMENCLATURE

LIST OF APPENDICES

1 INTRODUCTION

1.1 Overview

1.2 Background of Research

1.3 Research Statement

1.4 Problem Statement

1.5 Objective

1.6 Scope

PAGE

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2 LITERATURE REVIEW

2.1 Introduction

2.2 Electric Discharge Machining (EDM)

2.2.1 Machining Parameter

2.2.2 Electrode

2.2.3 Flushing

2.2.4 Dielectric Fluid

2.2.5 Powder Mixed Dielectric Electric Discharge Machining

(PMD-EDM)

2.2.6 Machining Characteristics

2.3 Surface Integrity

2.3.1 Surface Topography (Surface Finish)

2.3.2 Surface Metallurgical Alteration

2.4 Titanium Alloys and Their Machinability

2.4.1 Introduction

2.4.2 Classification of Titanium Alloys

2.4.2.1 Commercially pure (CP) titanium (unalloyed)

2.4.2.2 Alpha and near-alpha alloys

2.4.2.3 Alpha-beta alloys

2.4.2.4 Beta alloys

2.4.3 EDM of Titanium Alloys

2.4.3.1 Machining Titanium Alloys with EDM

2.4.3.2 Electrode Materials

2.4.3.3 Surface Integrity in EDM of Titanium Alloys

2.5 Design of Experiment (DOE)

2.5.1 Two-level fractional factorial Design

2.5.2 Response surface methodology

2.5.3 Test of statistical significance

3 RESEARCH DESIGN

3.1 Introduction

3.2 Research Design Variables

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3.2.1 Response parameters

3.2.2 Machining parameters

3.2.3 Workpiece material

3.2.4 Electrode material

3.2.5 Powder material

3.2.6 Machine and Equipment

3.3 Analysis

3.3.1 Statistical analysis

3.3.2 Metal removal rate (MRR) measurement

3.3.3 Electrode wear rate (EWR) measurement

3.3.4 Surface roughness measurement

3.3.5 Measurement of hole diameter

3.3.6 Analysis of affected surface layer

3.4 Experimental Flowchart

4 RESULTS AND DISCUSSION

4.1 Introduction

4.2 Experimental Results

4.2.1 EDM of Ti-6246

4.2.2 PMD-EDM of Ti-6246

4.2.2.1 Optimization in PMD-EDM of Ti-6246

4.2.2.2 Confirmation Run

4.3 Discussion

4.3.1 EDM without SiC powder

4.3.2 EDM with SiC powder (PMD-EDM)

4.3.3 Comparison on selected machining characteristics in

EDM and PMD-EDM process

4.3.3.1 Overcut

4.3.3.2 Surface layer

4.4 Summary

5 CONCLUSIONS

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REFERENCES

APPENDICES

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LIST OF TABLES

TABLE NO. TITLE PAGE

3.1

3.2

3.3

3.4

3.5

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

4.12

4.13

4.14

4.15

4.16

Machining parameters

Chemical properties of Ti-6246 (wt%)

Mechanical properties of Ti-6246

Specification of electrode material

Physical and chemical properties of silicon carbide

Factors and levels for EDM of Ti-6246

Experimental plan for EDM of Ti-6246

Experimental results for EDM of Ti-6246

ANOVA table for MRR in EDM process

ANOVA table for EWR in EDM process

ANOVA table for SR (bottom) in EDM process

ANOVA table for SR (side) in EDM process

ANOVA table for overcut in EDM process

Summary of significant factors in EDM experiments

Factors and levels for PMD-EDM of Ti-6246

Experimental plan for PMD-EDM of Ti-6246

Experimental results for PMD-EDM of Ti-6246

ANOVA table for response surface quadratic model for

MRR in PMD-EDM process

ANOVA table after model reduction for MRR in PMD-

EDM process

ANOVA table after transformation for MRR in PMD-

EDM process

Final ANOVA table for EWR in PMD-EDM process

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4.17

4.18

4.19

4.20

4.21

4.22

4.23

4.24

4.25

4.26

Final ANOVA table for SR in PMD-EDM process

Summary of significant factors in PMD_EDM experiments

An example of the set goals for optimization in PMD-

EDM process

Possible solutions for optimization in PMD-EDM process

An example output from the point prediction in PMD-

EDM process

Analysis of confirmation experiments for MRR in PMD-

EDM process

Analysis of confirmation experiments for EWR in PMD-

EDM process

Analysis of confirmation experiments for SR in PMD-

EDM process

Amount of overcut

Selected Machining conditions for surface layer analysis

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LIST OF FIGURES

FIGURE NO. TITLE PAGE

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

Classification of EDM processes

Classification of major EDM research areas

Schematic diagram of EDM

Phases of electrical discharges

Schematic of PMD-EDM process

Effect of suspended Al powder on the sparking mechanism

Surface layers in EDMed workpiece

EDM surface layer for Bohler W300 ferritic steel

Microstructure of Ti-64 EDMed surface for different

dielectrics

Comparison of Ti-64 surface roughness for different

machining process

Objective of response surface methods

Microstructure of Ti-6246

Workpiece securely clamped to EDM table

Charmilles Roboform 100

Mitutoyo Formtracer CS-5000 surface roughness tester

Mitutoyo – Coordinate Measuring Machine (CMM)

Precisa Balance

Buehler automatic mounting machine

Grinder and Polisher

Optical microscope

Scanning electron microscope

Stirrer

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3.12 Flowchart outlining the analysis steps undertaken 51

3.13 Experimental flowchart 55

4.1 Normal probability plots of residuals for MRR in EDM

process 60

4.2 Residual vs predicted response for MRR in EDM process 61

4.3 Outlier T plot for MRR in EDM process 61

4.4 Interactions of main effect s plot for MRR in EDM process 62

4.5 Normal probability plots of residuals for EWR in EDM

process 64

4.6 Residual vs predicted response for EWR in EDM process 64

4.7 Outlier T plot for EWR in EDM process 65

4.8 Interactions plots for EWR in EDM process 66

4.9 Perturbation plot for EWR in EDM process 66

4.10 Influence of machining parameters on SR (bottom) in EDM

process (voltage=120V, current=16A, interval time=31.4 µs) 69

4.11 Influence of interaction of machining parameters on SR

(bottom) in EDM process (voltage=120V, pulse on time=31.4 µs,

and negative polarity) 69

4.12 Influence of interaction machining parameters on SR (side)

in EDM process (current=16A, pulse on time=31.4 µs and

negative polarity) 70

4.13 Influence of interaction machining parameters on overcut

in EDM process (current=16A, pulse on time=31.4 µs and

negative polarity) 71

4.14 Normal probability plots of residuals for MRR in

PMD-EDM process 79

4.15 Residuals vs predicted plots for MRR in PMD-EDM process 79

4.16 Outlier T plots for MRR in PMD-EDM process 80

4.17 Perturbation plots for MRR in PMD-EDM process 81

4.18 3D response surface for MRR in PMD-EDM process 81

4.19 One factor and interaction factor plot for EWR in

PMD-EDM process 85

4.20 Perturbation graph for SR in PMD-EDM process 85

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4.21 3D response surface for EWR in PMD-EDM process 86

4.22 3D response surface for SR in PMD-EDM process 86

4.23 Overlay plot 89

4.24 Surface layer for machining condition 3, (a) bottom hole

and (b) side hole 98





4.27 EDAX analysis of recast layer (point A) of the machined

surface; (a) condition 3, (b) condition 8 and (c) condition 16 102

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LIST OF ABBREVIATIONS AND SYMBOLS

ANOVA - Analysis of variance

CCD - Central composite design

CMM - Coordinate measuring machine

EDAX - Energy dispersive X-ray spectroscopy

EDM - Electro discharge machining

EWR - Electrode wear rate

EWW - Weight of electrode used

FCD - Face centre cube design

HAZ - Heat affective zone

Hcla - Centre line average value of the surface produced

HRC - Hardness Rockwell unit for steel (cone indenter)

HRB - Hardness Rockwell unit for soft steels (ball indenter)

MRR - Material/metal removal rate

PMD-EDM - Powder mixed dielectric electro discharge machining

RSM - Response surface methodology

SEM - Scanning electron microscopy

SR - Surface Roughness

tm - Machining times

USM - Ultra Sonic Machining

Wa - Weight of workpiece after machining

Wb - Weight of workpiece before machining

WRW - Weight of workpiece used

x1,x2, x3,….,xk - Input variables

α - Alpha phase

β - Beta phase

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y - Response

ε - Error

η - Expected response

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LIST OF APPENDICES

APPENDIX TITLE PAGE

A-1 Electrodes for EDM (Mahajan, 1981) 116

A-2 Selected powder from previous experiment 117

A-3 Results of EDM Ti-6246 118

A-4 Unmodified ANOVA table for EWR in EDM process 119

A-5 Results of PMD-EDM Ti-6246 120

B-1 Box-Cox Plot for EWR in EDM process 121

B-2 EDAX analysis of electrode material 122

B-3 Surface layer for machining condition 1 from Table 4.26 123












C-1 Proform program for hole making on EDM die sink machine 129

C-2 Sample of calculation for calculating various parameters 130

C-3 Flowchart outlining the steps undertaken in statistical analysis

of EDM 131

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C-4 Flowchart outlining the steps undertaken in statistical analysis

of PMD-EDM 132

C-5 Sample of calculation for converting empirical model from coded

to actual factors (MRR) 133

C-6 Sample of calculation for converting empirical model from coded

to actual factors (EWR) 134

CHAPTER 1

INTRODUCTION

1.1 Overview

The use of light, thin and compact mechanical elements has recently become

a global trend. The search for new, lightweight material with greater strength and

toughness has led to the development of new generation of materials, although their

properties may create major challenges during machining operations. Having greater

hardness and reinforcement strength, these materials are difficult to machine by the

traditional methods. Although these materials can be machined conventionally, sub

surface damages such as metallurgical alterations, work hardening, delamination and

microcracks and others can occur under certain circumstances which cause a

detrimental effect on the performance of the machined component. Since the cost of

using conventional machining is generally prohibitive, non-conventional machining

such as electric discharge machining (EDM) and laser machining probably amongst

the ideal technique in dealing with these materials, which includes titanium alloys.

Most titanium alloys and component design characteristics make them

expensive to be machined and historically, titanium has been perceived as a material

that is difficult to machine (Ezugwu and Wang, 1997; and Hong et al., 2001). Due to

titanium's growing acceptance in many industries, along with the experience gained

2

by progressive fabricators, a broad base of titanium machining knowledge is now

exist. It was reported that commercially pure grades of titanium [ASTM B, Grades

1,2,3,4] can be machined much easier than aircraft alloys [i.e. ASTM B, Grade 5 : Ti

6Al 4V] (ASM International, 1988).

Although titanium alloys is tough it can experienced sub-surface damaged

during machining operations. Damage appears in the form of microcracks, built up

edge, plastic deformation, heat affected zones and tensile residual stresses (Sharif,

1999; and Hong et al., 2001). In service, these can lead to degraded fatigue strength

and stress concentration.

Non-traditional machining of metal removal such as EDM expected to be

used extensively years to come, because it’s favorable results. It is particularly useful

for rapid removal of metal of free form surface or complex shaped parts, thin

sections, and from large areas down to shallow depths. This process has less

damaging effect on the mechanical properties of the metal.

1.2 Background of Research

EDM is a non-traditional process that is used to remove metal through the

action of an electrical discharge of short duration and high current intensity between

the tool (electrode) and the workpiece. There are no physical cutting forces between

the tool and the workpiece. This process is finding an increasing demand owing to its

ability to produce geometrical complex shapes as well as its ability to machine hard

materials that are extremely difficult to machine when using conventional process.

EDM has proved valuable especially in the machining of super tough, hard and

electrically conductive materials such as the new space age alloys (Lee and Li,

2001). Although EDM machining technology is widely used in mechanical

3

components manufacturing, its low efficiency and poor surface quality have been the

key problems restricting its development.

Numerous research studies (Wong et al., 1998, Tzeng and Lee, 2001, and

Zhao et al., 2002) showed that powder mixed dielectric electrical discharge

machining (PMD-EDM) process can distinctly improve the surface roughness,

material removal rate and decrease tool (electrode) wear. PMD-EDM employs

powder particles which are mixed in the dielectric fluid and it has a different

machining mechanism when compared to conventional EDM machining. Many

studies have applied this process in several kind of materials, but little work has been

carry out to study PMD-EDM on titanium alloys. In the previous study, the process

was carried using a copper electrode which was designed as a rotational diskette for

machining Ti 6Al 4V(Chow et al., 2000). In the same year, a combination of EDM-

USM (ultrasonic machining) for cutting Ti 6Al 4V was done by Lin et al. (2000).

One of the above methods were used hole making operations (EDM-USM).

From the above description it was found that comprehensive study on the

effect of machining conditions on Ti-6246 using EDM was not reported so far. New

machining data on EDM of Ti-6246 served a great significance and could be further

exploited especially for hole making operation. Further research on PMD-EDM

machining mechanism and its machining effect on this kind of material will ensure

better machining efficiency. This project is undertaken to study the effect of

machining conditions when PMD-EDM of Ti-6246 during the hole making

operation.

1.3 Research Statement

Electrical discharge machining of materials with added powder in dielectric

fluid will lead to improvement in machining characteristics.

4

1.4 Problem Statement

a. Does the performance of SiC powder in dielectric fluid deliver better results

in terms of surface integrity of titanium alloys (Ti-6246), mateial removal

rate and electrode wear rate.

b. Does PMD-EDM of Ti-6246 contribute to new machining characteristics.

1.5 Objective

a. To study the machinability of Ti 6246 using copper tungsten electrode during

the PMD-EDM process

b. To study the effect of machining parameter on the surface integrity

c. To establish mathematical models for some of the dependent variables by

using RSM in a specific range of parameter

d. To optimize the machining parameters in order to increase the PMD-EDM

performance

1.6 Scope

a. The material used in this study is Ti 6Al 2Sn 4Zr 6Mo (Ti-6246)

b. Charmilles Roboform 100 EDM die sinking machine was used for

experiment

c. Copper tungsten (CuW) was used as the electrode

d. Silicon carbide (SiC) powder of 130 nm grain size was used as the assisted

powder

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e. The machining responses that were investigated are material removal rate

(MRR), surface roughness (SR), electrode wear rate (EWR), dimensional

accuracy (hole diameter) and subsurface defect which include heat affective

zone (HAZ)

f. Experimental studies on EDM of Ti-6246 were carried out to determines the

significant parameters effecting five responses for PMD-EDM process

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PUBLICATIONS

S. Sharif, Rival and M.Y. Noordin (2005), “Electrical Discharge Drilling of Titanium

Alloy Ti-6246”, Proceedings of the National Conference on Advances in

Mechanical Engineering (NAME 2005) Volume II, May 18-20, Kuala Lumpur:

Faculty of Mechanical Engineering, UiTM, 423-430

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