Performance Measurement and Discharge Data Based Analysis of Ultrasonic Assisted μEDM for Ti6Al4V

Unconventional machining of difficult-to-cut conductive materials with high accuracy, low heat-affected zone formation, and the ability to cut intricate geometries entitles micro-electrical discharge machining (& mu;EDM) as the most versatile technology in micromachining. Ultrasonic vibration assistance further enhances the material-removing ability of the & mu;EDM process while imparting several other benefits. The present work proposes a comparative study between the unassisted and ultrasonic vibration assisted & mu;EDM to the tool electrode for machining microslots on Ti6Al4V material using an in-house developed tool holder. The characteristics of the discharge waveforms were captured using a data acquisition system at high sampling rates. The pulse discrimination system is used to perform an in-depth study of the discharge pulses. & mu;EDM milling experiments were performed to machine microslots at varying input voltages, capacitances, and feed rates. The ultrasonic vibrations proved beneficial in addressing the primary issue associated with the & mu;EDM process, i.e., the material removal rate (MRR) with a maximum of 35% increment. Applying ultrasonic vibrations reduced the recast layer and tool wear rate (TWR) and increased the surface finish.