Skip to main content
SpringerLink
Log in

Analysis of high aspect ratio small holes in rapid electrical discharge machining of superalloys using Taguchi and TOPSIS

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

The main aim of this paper is to perform high aspect ratio small holes using rapid electrical discharge machining (rapid-EDM) of superalloys, namely Ti–6Al–4V and Inconel 718 with the tool materials like brass tubes and copper tubes. For employing the above-said materials, the performance characteristics such as material removal rate (MRR), tool wear rate (TWR) and overcut (OC) have been studied. In these investigations, DOE-Taguchi’s L9 orthogonal array has been utilized to build an experimental layout with the machining parameters such as current, on-time, off-time and capacitance. From the analysis, it is confirmed that there was a 40% increase in MRR, 282% decrease in TWR and 56% decrease in OC for rapid-EDM of Ti–6Al–4V material using the brass tubes than the copper tubes. Further, it is also validated that there is a 61% increase in MRR, 6% drop of TWR and 33% increase in OC for rapid-EDM of Inconel 718 material using brass tubes than the copper tubes. So, this comparative study has concluded that the machining of Ti–6Al–4V using brass tube has produced a maximum of MRR and minimum of TWR and OC. In Taguchi analysis, the individual effect of machining parameters on MRR, TWR and OC was studied. In addition, optimum combinations of machining parameters for MRR, TWR and OC were also discussed. Furthermore, multi-objective optimization was executed using TOPSIS to find good combination of machining parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

References

  1. Gamage JR, DeSilva KMA, Chantzis D, Antar M (2017) Sustainable machining: process energy optimisation of wire electrodischarge machining of Inconel and Titanium superalloys. J Clean Prod 164:642–651

    Article  Google Scholar 

  2. Naveed A, Kashif I, Khaja M, Rafaqat A, Naif AS (2018) Machinability of titanium alloy through electric discharge machining. Mater Manuf Processes. https://doi.org/10.1080/10426914.2018.1532092

    Article  Google Scholar 

  3. Maximilian H, Philip K, Andreas K, Alexander S (2018) Anomalous influence of polarity in sink EDM of titanium alloys. CIRP Ann 67(1):221–224

    Article  Google Scholar 

  4. Li L, Li ZY, Wei XT, Cheng X (2015) Machining characteristics of Inconel 718 by sinking-EDM and Wire-Edm. Mater Manuf Process 30(8):968–973

    Article  Google Scholar 

  5. Pervaiz S, Rashid A, Deiab I, Nicolescu M (2014) Influence of tool materials on machinability of titanium-and nickel-based alloys: a review. Mater Manuf Process 29(3):219–252

    Article  Google Scholar 

  6. Feng W, Chu X, Hong Y, Zhang L (2018) Studies on the surface of high-performance alloys machined by micro-EDM. Mater Manuf Process 33(6):615–625

    Article  Google Scholar 

  7. Jabbaripour B, Sadeghi MH, Faridvand S, Shabgard MR (2012) Investigating the effects of edm parameters on surface integrity, MRR and TWR in machining of Ti–6Al–4V. Mach Sci Technol 16(3):419–444

    Article  Google Scholar 

  8. Yilmaz O, Bozdana AT, Okka MA (2014) An intelligent and automated system for electrical discharge drilling of aerospace alloys: Inconel 718 and Ti–6Al–4V. Int J Adv Manuf Technol. 74(9–12):1323–1336

    Article  Google Scholar 

  9. Rajamanickam S, Prasanna J (2018) TOPSIS on high aspect ratio electric discharge machining (EDM) of Ti–6Al–4V using 300 μm brass rotary tube electrodes. Mater Today Proc 5(9):18489–18501. https://doi.org/10.1016/j.matpr.2018.06.191

    Article  Google Scholar 

  10. Tiwary AP, Pradhan BB, Bhattacharyya B (2015) Study on the influence of micro-EDM process parameters during machining of Ti–6Al–4V superalloy. Int J Adv Manuf Technol 76(1–4):151–160

    Article  Google Scholar 

  11. Ay M, Çaydaş U, Hasçalık A (2013) Optimization of micro-EDM drilling of Inconel 718 superalloy. Int J Adv Manuf Technol 66(5–8):1015–1023

    Article  Google Scholar 

  12. Bassoli E, Denti L, Gatto A, Iuliano L (2016) Influence of electrode size and geometry in electro-discharge drilling of Inconel 718. Int J Adv Manuf Technol 86(5–8):2329–2337

    Article  Google Scholar 

  13. Fang N, Wu Q (2009) A comparative study of the cutting forces in high speed machining of Ti–6Al–4V and Inconel 718 with a round cutting edge tool. J Mater Proc Technol 209:4385–4389

    Article  Google Scholar 

  14. Vincent N, Kumar AB (2016) Experimental investigations into EDM behaviours of En41b using copper and brass rotary tubular electrode. Procedia Technol 25:877–884

    Article  Google Scholar 

  15. Kamal K, Sandeep KR, Singh VP, Anu B (2018) Experimental study on diametric expansion and taper rate in EDM drilling for high aspect ratio micro holes in high strength materials. Mater Today Proc 5(2):7363–7372. https://doi.org/10.1016/j.matpr.2017.11.406

    Article  Google Scholar 

  16. Prasanna J, Karunamoorthy L, Venkat Raman M, Prashanth Sai, Raj Chordia D (2014) Optimization of process parameters of small hole dry drilling in Ti–6Al–4V using Taguchi and grey relational analysis. Measurement 48:346–354

    Article  Google Scholar 

  17. Sagar US, Pravin SJ (2018) Optimization of micro EDM drilling process parameters for titanium alloy by rotating electrode. Procedia Manuf 20:119–126

    Article  Google Scholar 

  18. Chandrasekhara Sastry C, Hariharan P, Pradeep Kumar M (2019) Experimental investigation of dry, wet and cryogenic boring of A A7075 alloy. Mater Manuf 34(7):814–831. https://doi.org/10.1080/10426914.2019.1605174

    Article  Google Scholar 

  19. Peng C, Du H, Liao TW (2017) A research on the cutting database system based on machining features and TOPSIS. Robot Comput Integr Manuf 43:96–104

    Article  Google Scholar 

  20. Tripathy S, Tripathy DK (2016) Muti-attribute optimization of machining process parameters in powder mixed electro- discharge machining using TOPSIS and grey relational analysis. Eng Sci Technol Int J 19:62–70. https://doi.org/10.1016/j.jestch.2015.07.010

    Article  Google Scholar 

  21. Tiwari M, Mausam K, Sharma K, Singh RP (2014) Investigate the optimal combination of process parameters by using a grey relational analysis. Procedia Mater Sci 5:1736–1744

    Article  Google Scholar 

  22. Mausam K, Singh PK, Sharma K, Gupta RC (2016) Investigation of process parameter of edm using genetic algorithm (GA) approach for carbon fiber based two phase epoxy composites. Mater Today Proc 3:4102–4108. https://doi.org/10.1016/j.matpr.2016.11.081

    Article  Google Scholar 

  23. Sharma P, Singh S, Mishra DR (2014) Electrical discharge machining of AISI 329 stainless steel using copper and brass rotary tubular electrode. Procedia Mater Sci 5:1771–1780

    Article  Google Scholar 

  24. Durso G, Ravasio C (2017) Material-technology index to evaluate micro-EDM drilling process. J Manuf Proc 26:13–21

    Article  Google Scholar 

  25. Li Y, Hou W, Xu J, Yu H (2016) An investigation on drilling micro holes in different process using micro-EDM. In: Proceedings IEEE: international conference on mechatronics and automation, pp 1283–1288

Download references

Acknowledgements

Authors would like to express sincere gratitude to SEM Laboratory, Mechatronics Laboratory and Metallurgical Laboratory of Anna University, Chennai. Authors also wish to express sincere thanks to omega inspection and analytical laboratory for chemical compositions test, density test and hardness test.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, College of Engineering Guindy, Anna University, Chennai, 600 025, India

    S. Rajamanickam & J. Prasanna

  2. Department of Mechanical Engineering, Veltech Hightech Dr.Rangarajan Dr.Sakunthala Engineering College, Avadi, Chennai, 600 062, India

    S. Rajamanickam

  3. Department of Mechanical Engineering, Indian Institute of Information Technology, Design and Manufacturing, Kurnool, Andhra Pradesh, India

    C. Chandrasekhara Sastry

Authors
  1. S. Rajamanickam
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. Prasanna
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. C. Chandrasekhara Sastry
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to S. Rajamanickam.

Additional information

Technical Editor: Lincoln Cardoso Brandao.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rajamanickam, S., Prasanna, J. & Chandrasekhara Sastry, C. Analysis of high aspect ratio small holes in rapid electrical discharge machining of superalloys using Taguchi and TOPSIS. J Braz. Soc. Mech. Sci. Eng. 42, 99 (2020). https://doi.org/10.1007/s40430-020-2180-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-020-2180-2

Keywords

Search

Navigation