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Machinability Analysis of Composite Electrode Produced by Spark Plasma Sintering Process during Electro-Discharge Machining of Titanium Alloy

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Abstract

The present experimental work aims at fabricating composite tool electrode made of copper, tungsten and boron carbide using spark plasma sintering process. Specifically, the study focuses on assessment of its performance during electro-discharge machining of titanium alloy. The machining parameters considered in this work are peak current, pulse duration and pulse cycle along with composition of tool electrode material (weight percentage of tungsten and boron carbide). In order to evaluate the performance of spark plasma sintered tool electrode, the machining characteristics considered are material removal rate, electrode wear rate, surface roughness, surface crack density, white layer thickness and micro-hardness of the machined surface. The energy dispersive x-ray spectrometry of the machined surface reveals that transfer of electrode elements onto the machined surface occurs with increase in the percentage of carbon and oxygen on it. X-ray diffraction of machined surface shows formation of metallic carbides (Al3B48C2, VC, TiC, W2B and W6C2.54) on it causing increase in micro-hardness of the machined surface and formation of recast layer or white layer.

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Abbreviations

MRR:

Material removal rate,

EWR:

Electrode wear rate,

EDM:

Electro-discharge machining,

SR:

Surface roughness,

SCD:

Surface crack density,

WLT:

White layer thickness.

MH:

Micro-hardness,

EDX:

Energy dispersive x-ray spectroscopy,

XRD:

X-ray diffraction,

SPS:

Spark plasma sintering,

PM:

Powder metallurgy

A:

Tool type

B:

Peak current in A

C:

Pulse duration in µs

D:

Pulse cycle in %

Fp :

Flushing pressure in MPa

V:

Voltage in V

Wi :

Initial weight of work piece in g

Wf :

Final weight of work piece (after machining) in g

ρw :

Density of work piece material in g/cm3

Wti :

Initial weight of electrode in g

Wtf :

Final weight of electrode (after machining) in g

ρt :

Density of electrode material in g/cm3

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Rourkela, Rourkela, 769008, India

    Anshuman Kumar Sahu & Siba Sankar Mahapatra

  2. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai, 600036, India

    Rahul Ravi & Srinivasa Rao Bakshi

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  1. Anshuman Kumar Sahu
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  4. Srinivasa Rao Bakshi
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Sahu, A.K., Mahapatra, S.S., Ravi, R. et al. Machinability Analysis of Composite Electrode Produced by Spark Plasma Sintering Process during Electro-Discharge Machining of Titanium Alloy. J. of Materi Eng and Perform 32, 1310–1332 (2023). https://doi.org/10.1007/s11665-022-07156-x

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