Experimental modelling and optimisation of process parameters of hole drilling by electrical discharge machining of aerospace titanium alloy

摘要

Advancement of new materials and machining technology has changed the domain and ranges both of aerospace vehicles, still a few problems of conventional as well as non-conventional machining processes is unresolved such as low material removal rate (MRR), frequent tool wear and poor surface finish, etc. In this experimental study, a new process in electrical discharge machining (EDM), termed as electrical discharge drilling (EDD is used to make the hole in titanium alloy (Ti-6Al-4V) and also used altogether a new approach of hybrid of methodologies for modelling as well as optimisation of the hole made for MRR, average surface roughness (R_a) and average circularity (C_a). The used methodology comprises of Taguchi methodology (TM) with response surface methodology (RSM) for modelling and RSM coupled with principal component analysis-based (PCA) grey relational analysis (GRA) for optimisation. The obtained results indicate that applied hybrid approaches in present study of EDD process are reasonable and substantiates with facts of improvement in MRR by 30.80%, R_a by 24.81% and C_a by 26.09%.