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. 2024 May 24;15(6):692.
doi: 10.3390/mi15060692.

Improving Micro-EDM Machining Efficiency for Titanium Alloy Fabrication with Advanced Coated Electrodes

Hoang-Vuong Pham  1 , Huu-Phan Nguyen  2 , Shirguppikar Shailesh  3 , Duc-Toan Nguyen  4 , Ngoc-Tam Bui  5
Affiliations

Improving Micro-EDM Machining Efficiency for Titanium Alloy Fabrication with Advanced Coated Electrodes

Hoang-Vuong Pham et al. Micromachines (Basel). .

Abstract

Enhancing the operational efficacy of electrical discharge machining (EDM) is crucial for achieving optimal results in various engineering materials. This study introduces an innovative solution-the use of coated electrodes-representing a significant advancement over current limitations. The choice of coating material is critical for micro-EDM performance, necessitating a thorough investigation of its impact. This research explores the application of different coating materials (AlCrN, TiN, and Carbon) on WC electrodes in micro-EDM processes specifically designed for Ti-6Al-4V. A comprehensive assessment was conducted, focusing on key quality indicators such as depth of cut (Z), tool wear rate (TWR), overcut (OVC), and post-machining surface quality. Through rigorous experimental methods, the study demonstrates substantial improvements in these quality parameters with coated electrodes. The results show significant enhancements, including increased Z, reduced TWR and OVC, and improved surface quality. This evidence underscores the effectiveness of coated electrodes in enhancing micro-EDM performance, marking a notable advancement in the precision and quality of Ti-6Al-4V machining processes. Among the evaluated coatings, AlCrN-coated electrodes exhibited the greatest increase in Z, the most significant reduction in TWR, and the best OVC performance compared to other coatings and the uncoated counterpart.

Keywords: Micro-EDM; Ti-6Al-4V; coated electrode; efficacy; surface quality.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
(a) Schematic representation of a thin film-coated tool electrode and (b) development of thin film coating of tin material on micro tool electrode.
Figure 2
Figure 2
EDAX of Thin Film Coating. (a) Titanium Nitride. (b) Aluminum Chromium Nitride. (c) Carbon.
Figure 2
Figure 2
EDAX of Thin Film Coating. (a) Titanium Nitride. (b) Aluminum Chromium Nitride. (c) Carbon.
Figure 3
Figure 3
Hyper 10 Micro-EDM machine.
Figure 4
Figure 4
Influence of coating material on Z coordinate. (a) V = 120; C = 100 pF and RPM = 200 rpm. (b) V = 140; C = 1000 pF and RPM = 400 rpm. (c) V = 160; C = 10,000 pF and RPM = 600 rpm.
Figure 5
Figure 5
Influence of coating material on TWR. (a) V = 120; C = 100 pF and RPM = 200 rpm. (b) V = 140; C = 1000 pF and RPM = 400 rpm. (c) V = 160; C = 10,000 pF and RPM = 600 rpm.
Figure 5
Figure 5
Influence of coating material on TWR. (a) V = 120; C = 100 pF and RPM = 200 rpm. (b) V = 140; C = 1000 pF and RPM = 400 rpm. (c) V = 160; C = 10,000 pF and RPM = 600 rpm.
Figure 6
Figure 6
Influence of coating material on Overcut (OVC). (a) V = 120; C = 100 pF and RPM = 200 rpm. (b) V = 140; C = 1000 pF and RPM = 400 rpm. (c) V = 160; C = 10,000 pF and RPM = 600 rpm.
Figure 7
Figure 7
Machining dimensions in micro-EDM.
Figure 7
Figure 7
Machining dimensions in micro-EDM.
Figure 8
Figure 8
SEM imagery of the machined surface in micro-EDM.
Figure 8
Figure 8
SEM imagery of the machined surface in micro-EDM.
Figure 9
Figure 9
Topography of the machined Surface after micro-EDM (V = 120; C = 100 pF and RPM = 200 rpm).
Figure 9
Figure 9
Topography of the machined Surface after micro-EDM (V = 120; C = 100 pF and RPM = 200 rpm).
Figure 10
Figure 10
EDX analysis of the machined surface after micro-EDM. (V = 120; C = 100 pF and RPM = 200 rpm).
See this image and copyright information in PMC

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