Abstract:
Titanium and nickel-based alloys are materials of choice for many applications. Their
high strength and low density make them a suitable candidate for aerospace applications.
Besides these properties, these alloys exhibit remarkable corrosion resistance and biocompatibility. These properties make them suitable candidate for orthopedics implants.
Whereas the reactivity and heat resistance of these alloys renders them difficult to
machine. One of the known substitutes to the traditional cutting method is wire electrical
discharge machining which is commonly being used nowadays to process materials that
are tough to be machined on conventional machines being hard in nature, such as
aerospace alloys. Based on previous research involving the effect of input variables on
the output variables, this research aims to identify best machine setup for a quality
product. Starting with Peak current, Wire feed rate, Pulse on time and Pulse off time as
input parameters, and their effect on surface roughness and kerf width has been studied.
Influence of these process conditions of the wire electro-discharge machining on grains
distortion analyzed through SEM analysis results. Peak current and pulse on time are
significant factors for kerf width of Inconel 600, for the kerf width of titanium alloy peak
current and wire feed rate are found significant factors. For smoother surface, higher
feed rate and intermediate current values are preferable for Inconel 600, however for
titanium alloy high pulse off time and intermediate values of peak current are desirable
for smooth surface finish. More grain distortion was observed for samples with greater
surface roughness
