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An Investigation to Achieve Good Surface Integrity in Wire Electrical Discharge Machining of Ti-6242 Super Alloy

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Abstract

The aim of this study is to investigate the effect of cutting parameters such as pulse-on time (Ton), servo-voltage (U), feed rate (S) and flushing pressure (P) on surface roughness (Ra) when machining Ti-6242 super alloy by WEDM process. The cutting was performed using a brass tool electrode and deionized water as a dielectric fluid. To optimize cutting parameters for surface roughness improvement, Taguchi’s signal‐to‐noise ratio (S/N) approach was applied using L9 (3^4) orthogonal array and Lower-The-Better (LTB) criteria. Substantially, the findings from current investigation suggest the application of the values 0.9 µs, 100 V, 29 mm/min, and 60 bar for the cutting parameters Ton, U, S and p, respectively, for producing a good surface finish quality. Electron microscope scanning (SEM) observations have been performed on machined surface for a wide range of cutting parameters to characterize wire EDMed surface of Ti-6242. SEM micrographs indicated that white layer and machining-induced damage characteristics are highly dependent on cutting parameters. For high servo-voltage, decreasing the pulse-on time Ton and feed rate S leads to a strong decrease in the overall machining-induced surface damage. Furthermore, for high levels of servo-voltage and feed rate, it was observed that pulse-on time could play a role in controlling the density of surface microcracks. In fact, the use of low cutting pulse-on time combined with high servo-voltage and feed rate was found to inhibit surface microcracks formation, giving the material surface better resistance to cracking than with high pulse on-time.

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Data Availability

The datasets generated during and/or analyzed during the current study are available from the corresponding author on reasonable request.

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Authors and Affiliations

  1. School of Mechanical and Manufacturing Engineering, ISAE-SUPMECA Institute of Mechanics of Paris, Saint-Ouen, France

    Sonia Ezeddini, Mohamed Boujelbene & Emin Bayraktar

  2. College of Engineering, University of Hail, Hail, Kingdom of Saudi Arabia

    Wajdi Rajhi & Mohamed Boujelbene

  3. Laboratoire de Mécanique, Matériaux et Procédés LR99ES05, Ecole Nationale Supérieure d’Ingénieurs de Tunis, Université de Tunis, 5 Avenue Taha Hussein, Montfleury, 1008, Tunis, Tunisia

    Wajdi Rajhi

  4. University of Tunis El Manar, ENIT, École Nationale d’Ingénieurs de Tunis, Tunis, Tunisia

    Sahbi Ben Salem

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Correspondence to Wajdi Rajhi.

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Ezeddini, S., Rajhi, W., Boujelbene, M. et al. An Investigation to Achieve Good Surface Integrity in Wire Electrical Discharge Machining of Ti-6242 Super Alloy. J. of Materi Eng and Perform 33, 4523–4537 (2024). https://doi.org/10.1007/s11665-023-08270-0

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