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Ti6Al4V Alaşımının Elektro Erozyon ile İşlemesinde Elektrolitik Cu ve CuBe Takım Elektrotlarının Performansının Karşılaştırılması

Year 2021, Volume: 8 Issue: 3, 1455 - 1461, 30.09.2021
https://doi.org/10.31202/ecjse.946472

Abstract

Elektro erozyonla işlemede en önemli maliyet unsuru takım elektrodunun (elektrodun) üretimidir. Bakır, bakır alaşımları ve grafit en yaygın kullanılan elektrot malzemeleridir. Yüksek iş parçası işleme hızlı (MRR), düşük takım aşınma hızlı (TWR), düşük üretim ve malzeme maliyetli uygun elektrot malzemesinin seçilmesi, EDM ile işleme maliyetlerini düşürmenin anahtarıdır. Bu çalışmada, Ti6Al4V alaşımının işlenmesinde CuBe takım elektrotlarının EDM performansı, farklı bekleme süresi (ts) ve akım boşalımı (I) ayarları için elektrolitik Cu (E-Cu) elektrotlara kıyasla deneysel olarak incelenmiştir. CuBe elektrotlarla işlemede MRR'de bir artış, TWR'de ve relatif aşınmada (RW = TWR / MRR) bir azalma gözlenmiştir. Bununla birlikte, CuBe alaşımının yüksek hammadde maliyeti, bu elektrotların endüstriyel uygulamalarda yaygın olarak kullanılmasında önemli bir dezavantajdır. Elektrodun üretim maliyetini ve ömrünü etkileyen EDM uygulamaları için yeni bir performans indeks formülasyonu tanıtıldı. Sonuçlarımıza göre CuBe, orta akım ayarlarında elektrot malzemesi olarak avantajlı bir şekilde kullanılabilir. Ancak düşük ve yüksek akım ayarlarında E-Cu'nun hammadde maliyetinin düşük olması onu daha avantajlı hale getirmektedir.

References

  • Referans1 Asokan, T., Sudhakar, R. S., De Costa, P., Electrical discharge drilling of titanium alloys for aerospace applications, Proceedings of the 19th AIMTDR Conference, 2000: 161-165.
  • Referans2 Zhang, W. J., Reddy, B.V., Deevi, S.C., Physical properties of TiAl-base alloys, Scripta Materialia, 2001, 45(6): 645-651.
  • Referans3 Harcubaa, P. L. Bacakovab, J. Straskya, M. Bacakovab, K. Novotnab, M. Janeceka. Surface treatment by electric discharge machining of Ti–6Al–4V alloy for potential application in orthopedics, Journal of The Mechanical Behavior of Biomedical Materials, 2012, 7: 96–105.
  • Referans4 Amorim F. L. and Weingaertner W. L., Die-sinking electrical discharge machining of a high-strength copper-based alloy for injection molds, J. of the Braz. Soc. of Mech. Sci., 2004, 26:137–144.
  • Referans5 Kuhn, A., Altenberger, I., Kaufler, A., Ölzl, H. H., Fünfer. M., Properties of high-performance alloys for electromechanical connectors, copper alloys-early applications and current performance, In Tech., 2018, 3: 51–68.
  • Referans6 Yaman K. and Çoğun C., An experimental work on using conductive powder-filled polymer composite cast material as tool electrode in EDM, The Int. Journal of Advanced Manufacturing Technology, 2014, 73: 535–543.
  • Referans7 Regmi M. and Gupta A., Performance of copper electrode for machining en-19 and nickel-plated en-19 alloy steel by EDM, International Journal of Industrial and Manufacturing Systems Engineering, 2017, 2: 1-6.
  • Referans8 Kumari, S., Dattaand, S., Massanta, M., Nandi G., Pal. P. K., Electro-discharge machining of Inconel 825 superalloy: Effects of tool material and dielectric flushing, Silicon, 2018, 10: 2080–2099.
  • Referans9 Ablyaz, T. R., Shlykov, E. S., Muratov, K. R., Mahajan, A., Singh, G., Devgan, S., Sidhu. S. S., Surface characterization and tribological performance analysis of electric discharge machined duplex stainless steel, MPDI, Micromachines, 2020, 11:1-14.
  • Referans10 Hasçalık, A., and Çaydaş, U., Electrical discharge machining of titanium alloy (Ti-6Al-4V), Appl. Surf. Sci., 2007, 253: 9007–9016.
  • Referans11 Shabgard, M., Khosrozadeh, B., Investigation of carbon nanotube added dielectric on the surface characteristics and machining performance of Ti–6Al–4V alloy in EDM process, J. Manuf. Process. 2017, 25: 212–219. Referans12 Li, L., Feng, L., Bai, X., Li, Z. Y., Surface characteristics of Ti–6Al–4V alloy by EDM with Cu–SiC composite electrode, Applied Surface Science, 2016, 388: 546-550.
  • Referans13 Li, J. Z., Shen, F.H., Yu, Z.Y., Natsu, W., Influence of microstructure of alloy on the machining performance of micro EDM, Surface & Coatings Technology, 2013, 228: 460-465.
  • Referans14 Strasky, J. and Janeceketc, M., Electric discharge machining of Ti-6Al-4V alloy for biomedical use WDS'11, Proc. of Contri, 2011, 3: 127-131.
  • Referans15 Verma, V., Sahu, R., Process parameter optimization of die-sinking EDM on Titanium grade – V alloy (Ti6Al4V) using full factorial design approach, Materials Today: Proceedings, 2017, 4: 1893-1899.
  • Referans16 Ünses, E. and Çoğun, C., Improvement of Electric Discharge Machining (EDM) Performance of Ti-6Al-4V Alloy with Added Graphite Powder to Dielectric. Journal of Mechanical Engineering, 2015, 61(6): 409-418.
  • Referans17 Koua, Z. and Han, F., On sustainable manufacturing titanium alloy by high-speed EDM milling with moving electric arcs while using water-based dielectric, Journal of Cleaner Production, Published, 2018, 189: 78-87.
  • Referans18 Hashmi, S., Comprehensive materials processing. Newnes., 2014, 542-545
  • Referans19 Kıbrıa, G. and Bhattacharyya, B., Microelectrical discharge machining of Ti-6Al-4V: Implementation of innovative machining strategies. In: Microfabrication and Precision Engineering. Woodhead Publishing, 2017, 99-142.

The Comparison of Performance of Electrolytic Cu and CuBe Tool Electrodes in Electric Discharge Machining of Ti6Al4V Alloy

Year 2021, Volume: 8 Issue: 3, 1455 - 1461, 30.09.2021
https://doi.org/10.31202/ecjse.946472

Abstract

The most crucial cost element of Electric Discharge Machining (EDM) is the production of tool electrode (shortly electrode). Copper, its alloys, and graphite are the most commonly used electrode materials. Selecting the proper electrode material with low production and material cost, high workpiece material removal rate (MRR) and low tool electrode wear rate (TWR) is key to reducing machining costs with EDM. In this study, the EDM performance of CuBe tool electrodes in the machining of Ti6Al4V alloy was experimentally investigated in comparison to electrolytic Cu (E-Cu) electrodes for different pulse time (ts) and discharge current (I) settings. An increase in MRR and a decrease in TWR and relative wear (RW=TWR/MRR) were observed in machining with CuBe electrodes. However, the high raw material cost of CuBe alloy is an essential drawback in widely using these electrodes in industrial applications. A new performance index formulation is introduced for EDM applications that factor in the production cost of the electrode and its life (i.e., RW). According to our results, the CuBe could be used advantageously as the electrode material at medium current settings. However, at low and high current settings, the low raw material cost of E-Cu makes it more favorable.

References

  • Referans1 Asokan, T., Sudhakar, R. S., De Costa, P., Electrical discharge drilling of titanium alloys for aerospace applications, Proceedings of the 19th AIMTDR Conference, 2000: 161-165.
  • Referans2 Zhang, W. J., Reddy, B.V., Deevi, S.C., Physical properties of TiAl-base alloys, Scripta Materialia, 2001, 45(6): 645-651.
  • Referans3 Harcubaa, P. L. Bacakovab, J. Straskya, M. Bacakovab, K. Novotnab, M. Janeceka. Surface treatment by electric discharge machining of Ti–6Al–4V alloy for potential application in orthopedics, Journal of The Mechanical Behavior of Biomedical Materials, 2012, 7: 96–105.
  • Referans4 Amorim F. L. and Weingaertner W. L., Die-sinking electrical discharge machining of a high-strength copper-based alloy for injection molds, J. of the Braz. Soc. of Mech. Sci., 2004, 26:137–144.
  • Referans5 Kuhn, A., Altenberger, I., Kaufler, A., Ölzl, H. H., Fünfer. M., Properties of high-performance alloys for electromechanical connectors, copper alloys-early applications and current performance, In Tech., 2018, 3: 51–68.
  • Referans6 Yaman K. and Çoğun C., An experimental work on using conductive powder-filled polymer composite cast material as tool electrode in EDM, The Int. Journal of Advanced Manufacturing Technology, 2014, 73: 535–543.
  • Referans7 Regmi M. and Gupta A., Performance of copper electrode for machining en-19 and nickel-plated en-19 alloy steel by EDM, International Journal of Industrial and Manufacturing Systems Engineering, 2017, 2: 1-6.
  • Referans8 Kumari, S., Dattaand, S., Massanta, M., Nandi G., Pal. P. K., Electro-discharge machining of Inconel 825 superalloy: Effects of tool material and dielectric flushing, Silicon, 2018, 10: 2080–2099.
  • Referans9 Ablyaz, T. R., Shlykov, E. S., Muratov, K. R., Mahajan, A., Singh, G., Devgan, S., Sidhu. S. S., Surface characterization and tribological performance analysis of electric discharge machined duplex stainless steel, MPDI, Micromachines, 2020, 11:1-14.
  • Referans10 Hasçalık, A., and Çaydaş, U., Electrical discharge machining of titanium alloy (Ti-6Al-4V), Appl. Surf. Sci., 2007, 253: 9007–9016.
  • Referans11 Shabgard, M., Khosrozadeh, B., Investigation of carbon nanotube added dielectric on the surface characteristics and machining performance of Ti–6Al–4V alloy in EDM process, J. Manuf. Process. 2017, 25: 212–219. Referans12 Li, L., Feng, L., Bai, X., Li, Z. Y., Surface characteristics of Ti–6Al–4V alloy by EDM with Cu–SiC composite electrode, Applied Surface Science, 2016, 388: 546-550.
  • Referans13 Li, J. Z., Shen, F.H., Yu, Z.Y., Natsu, W., Influence of microstructure of alloy on the machining performance of micro EDM, Surface & Coatings Technology, 2013, 228: 460-465.
  • Referans14 Strasky, J. and Janeceketc, M., Electric discharge machining of Ti-6Al-4V alloy for biomedical use WDS'11, Proc. of Contri, 2011, 3: 127-131.
  • Referans15 Verma, V., Sahu, R., Process parameter optimization of die-sinking EDM on Titanium grade – V alloy (Ti6Al4V) using full factorial design approach, Materials Today: Proceedings, 2017, 4: 1893-1899.
  • Referans16 Ünses, E. and Çoğun, C., Improvement of Electric Discharge Machining (EDM) Performance of Ti-6Al-4V Alloy with Added Graphite Powder to Dielectric. Journal of Mechanical Engineering, 2015, 61(6): 409-418.
  • Referans17 Koua, Z. and Han, F., On sustainable manufacturing titanium alloy by high-speed EDM milling with moving electric arcs while using water-based dielectric, Journal of Cleaner Production, Published, 2018, 189: 78-87.
  • Referans18 Hashmi, S., Comprehensive materials processing. Newnes., 2014, 542-545
  • Referans19 Kıbrıa, G. and Bhattacharyya, B., Microelectrical discharge machining of Ti-6Al-4V: Implementation of innovative machining strategies. In: Microfabrication and Precision Engineering. Woodhead Publishing, 2017, 99-142.
There are 18 citations in total.

Details

Primary Language Turkish
Subjects Engineering
Journal Section Makaleler
Authors

Levent Urtekin 0000-0002-6212-344X

Fatih Bozkurt 0000-0001-9897-1558

Hacı Özerkan 0000-0002-7214-9985

Can Çoğun 0000-0001-5045-2767

İbrahim Uslan 0000-0003-1486-4865

Publication Date September 30, 2021
Submission Date June 1, 2021
Acceptance Date July 29, 2021
Published in Issue Year 2021 Volume: 8 Issue: 3

Cite

IEEE L. Urtekin, F. Bozkurt, H. Özerkan, C. Çoğun, and İ. Uslan, “Ti6Al4V Alaşımının Elektro Erozyon ile İşlemesinde Elektrolitik Cu ve CuBe Takım Elektrotlarının Performansının Karşılaştırılması”, El-Cezeri Journal of Science and Engineering, vol. 8, no. 3, pp. 1455–1461, 2021, doi: 10.31202/ecjse.946472.
Creative Commons License El-Cezeri is licensed to the public under a Creative Commons Attribution 4.0 license.
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