Response Surface Modeling of Material Removal and Tool Wear Rate in Powder Mixed Electrical Discharge Machining of CoCrMo Alloy

Abstract

Electric discharge machining (EDM) is commonly used in implant manufacturing due to the challenge of machining materials that are widely employed in these applications. The study applies response surface methodology to model the impact of powder concentration and machining parameters in powder mixed EDM of CoCrMo alloys, a prevalent material for implantation. AISI 316L stainless steel was selected as the electrode material, while Ti6V4Al was chosen as the additive powder based on their biocompatibility properties. An experimental design was created using a Taguchi L16 array, which involved selecting 4 levels for each parameter of additive ratio, discharge current, pulse on time, and pulse off time. Regression models were developed for material removal rate (MRR) add tool wear rate (TWR) with satisfactory coefficients of determinations (0.87). Effect of the process parameters on MRR and TWR were analysed by means of 3D response surface plots. As a result of the modeling, it was revealed that discharge current, puls on time positively affected MRR, powder concentrations and puls off time negatively affected it. On the other hand, all of the considered process parameters have increasing effect on TWR.

Keywords

• Electric Discharge Machining
• CoCrMo
• Powder Mixed EDM
• MRR
• TWR

CoCrMo Alaşımının Toz Katkılı Elektrik Deşarj ile İşlenmesinde Malzeme Kaldırma ve Takım Aşınma Hızının Cevap Yüzeyi Modellemesi

Öz

Elektro Erozyonla İşleme (EDM), özellikle diğer talaşlı imalat yöntemleri ile işlenmesi zor malzemeler kullanıldığından implant üretiminde yaygın olarak kullanılan bir yöntemdir, Bu çalışma, toz katkılı EDM yönteminde, implantasyon için yaygın olarak kullanılan CoCrMo alaşımlarının işlenmesinde toz konsantrasyonu ve işleme parametrelerinin etkisini modellemek için yanıt yüzey metodolojisini kullanulmıştır. Biyouyumluluk özellikleri dikkate alınarak lektrot malzemesi olarak AISI 316L paslanmaz çelik, katkı tozu olarak Ti6V4Al tercih edilmiştir. Katkı oranı, deşarj akımı, vurum süresi ve bekleme süresi bağımsız değişkenler olarak belirlenmiştir. Her bir parametre için 4 seviyesi ile Taguchi L16 dizisi kullanarak deney tasarımı oluşturulmuştur. Yanıt yüzey yöntemi, malzeme kaldırma hızı ve takım aşınma hızı için deneysel verilere dayalı regresyon modelleri oluşturmak için kullanılmıştır.

Anahtar Kelimeler

• Elektro Erozyonla İşleme
• CoCrMo
• Toz Katkılı EDM
• MRR
• TWR
• RSM

Kaynakça

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