Multi response optimization of PMEDM of Ti6Al4V using Al2O3 and SiC powder added de-ionized water as dielectric medium using grey relational analysis

In the present work, surface characteristics of powder mixed electro-discharge machining (PMEDM) process are investigated using alumina and carborundum abrasive powder added dielectric fluid for titanium alloy Ti6Al4V. Deionized water is utilized as dielectric to accomplish an environmentally safe machining climate, and limit the emanation of harmful substances. Pulse ON/OFF time (T ON /T OFF ), discharge current (I P ), and powder concentration (PC) are selected as process variables to reconnoiter characteristics of performance like surface finish, rate of material removal, and tool wear. The multi-response optimization has been performed using grey relational analysis (GRA) to establish the optimal parametric combination of process variables that gives the finest surface quality and minutest tool wear. The investigation results divulge that discharge current (I P ) and powder concentration (PC) have the most significant effect on material removal rate (MRR), tool wear rate (TWR), and surface finish. The surface characteristics were evaluated by scanning electron microscope for the optimal parameters combination. The minutest value of surface roughness and tool wear rate is achieved at I P : 06 amps, T ON : 05 µS, T OFF : 96 µS, and PC: 0.50 g/L. The optimized set of parameters would help process engineers to attain improved machining performance of PMEDM, economically along with desired surface characteristics. Article Highlights Feasibility analysis of using abrasive powder mixed De-Ionized water as Dielectric for machining of hard-to-cut alloy. Significance of powder material type/properties and their concentration on surface integrity have been established. Grey Relational Analysis is practiced to investigate the optimum parameters that deliver the best surface finish with lower rate of a tool wear.