Experimental Investigation and Optimization of Process Parameters in Ti – (6242) Alpha–Beta Alloy Using Electrical Discharge Machining

This investigation exposes electrical discharge machine (EDM) technique in expelling the metal with a conducted copper electrode from the Ti–6Al–2Sn–4Zr–2Mo alloy. The alloy Ti–6Al–2Sn–4Zr–2Mo has the highest resistance, high-temperature detection, high tensile strength, and high yield strength. Ti–6Al–2Sn–4Zr–2Mo alloy is commonly used for applications such as aerospace, medical equipment, automotive parts, and nuclear power plants. EDM provides easy machinability and excellent surface finishes. Machine parameters of primary noteworthiness, such as Discharge Current (I), Spark on time (μs), and Tool Diameter (mm), are considered using the Taguchi L27 orthogonal array. Metal removal rate (MRR), tool wear rate (TWR), and overcut (OC) perpendicularity are investigated with the help of mean effective plots. Multi response optimization to maximize the material removal rate (MRR) and minimize the tool wear rate (TWR) and over cut (OC) on the surface of the workpiece has been analyzed by Grey relational analysis (GRA). The result expresses that spark on time (Ton) contributes (6.22%) more on affecting the machining characteristics followed by electrode diameter (76.97%) and discharge current (16.97%). From the F-test, it is assumed that all the machining parameters have a significant influence on responses. Accordingly an optimum combination of machining parameters is also determined.