A Study of Dimensional Accuracy on Die Sinking Electrical Discharge Machining of Ti-6AL-4V

Objectives: In this work, an investigation of dimensional accuracy (DA) on the die sinking electrical discharge machining (EDM) of Ti-6AL-4V titanium alloy with positive polarity of copper-tungsten (Cu-W) electrode has been carried out. Methods/Analysis: Pulse on time (ON), pulse off time OFF), peak current (IP) and servo voltage (SV) were selected as the cutting parameters. The experiments have been conducted upon the two levels of full factorial design with added four center points Design of Experiments (DOE). A mathematical model is developed to associate the effects of these four cutting parameters with DA of the work piece. Multiple linear regression modelling technique was performed in the mathematical modelling process. Furthermore, Analysis of Variance (ANOVA) technique was performed to determine the significance of the cutting parameters. Findings: Based on the results, ON, IP and SV were found to be the significant cutting parameters contributes to the DA. This finding also indicates the model developed is observed to be in good simultaneous with the experimental results.