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Experimentation and Analysis into Micro-Hole Machining of Ti-6Al-4V by Micro-EDM Using Boron Carbide Powder Mixed De-Ionized Water

In micro-electrical discharge machining (micro-EDM), dielectric plays a significant role during the machining process as different types of dielectrics encounters different chemical compositions, cooling rates and dielectric strengths. Therefore, while employing these different dielectrics, dissimilar process responses are accounted when machining in EDM at micron level. The present paper investigates micro-EDM characteristics such as material removal rate (MRR), tool wear rate (TWR), overcut (OC), taperness and machining time (MT) during micro-machining of through holes on Ti-6Al-4V superalloy employing de-ionized water based dielectric other than conventional hydro-carbon oil i.e. kerosene. The paper also includes the comparative study of the micro-EDM machining characteristics employing boron carbide (B4C) powder as additive in de-ionized water dielectric at different discharge energies. The results show that MRR and taper of micro-hole are better and TWR is less employing B4C additive in the dielectric than pure one, i.e. the productivity is improved and same micro-tool can be used for machining an array of micro-holes. Surface topography and recast layer formed during micro-hole machining by micro-EDM has also been investigated based on optical and SEM micrographs. Energy dispersive spectroscopy (EDS) analysis of machined surface as well as tool electrode surface has been done and the results show that there is significant amount of infusion of tungsten element onto the machined surface. A significant amount of carbon element is found onto the tool electrode surface.