Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy
Titanium alloys are considered one of the materials required in industries. They can be used in various fields due to their high strength and corrosion resistance, but titanium alloys are considered difficult to machine using traditional methods. EDM is used to machine a workpiece using electrical d...
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| Format: | Article |
| Language: | English |
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Sciendo
2025-06-01
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| Series: | Management Systems in Production Engineering |
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| Online Access: | https://doi.org/10.2478/mspe-2025-0019 |
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| author | Enzi Abass Abdulameer Ahmed Ghazi Hassoon Omar Hashim Hamieh Abdallah |
| author_facet | Enzi Abass Abdulameer Ahmed Ghazi Hassoon Omar Hashim Hamieh Abdallah |
| author_sort | Enzi Abass |
| collection | DOAJ |
| description | Titanium alloys are considered one of the materials required in industries. They can be used in various fields due to their high strength and corrosion resistance, but titanium alloys are considered difficult to machine using traditional methods. EDM is used to machine a workpiece using electrical discharges to cut hard materials that are challenging to cut with traditional methods. Therefore, this paper focuses on the machine of a high-strength material-titanium alloy Ti-6Al-4V and studies the influence of cutting process variables on the metal removal rate, tool wear rate, and surface roughness of the samples. The samples matrix form is created depending on the design of experiments method. Pulse-on time, discharge current, and gap process variables with three levels create mathematical models to predict the responses without conducting practical experiments. The results proved that machining variables impacted the responses, which were proven through results data analysis and the interaction plots. Also, the maximum error between experimental and predicted values using the mathematical model was 0.022 (mg/min) for the MRR, 1.719 (mg/min) for the TWR, and 0.334 (μm) for the Ra. |
| format | Article |
| id | doaj-art-5fb052f096a84c7abd25c80d9ebbbb43 |
| institution | DOAJ |
| issn | 2450-5781 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Sciendo |
| record_format | Article |
| series | Management Systems in Production Engineering |
| spelling | doaj-art-5fb052f096a84c7abd25c80d9ebbbb432025-08-20T03:11:11ZengSciendoManagement Systems in Production Engineering2450-57812025-06-0133220221110.2478/mspe-2025-0019Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium AlloyEnzi Abass0Abdulameer Ahmed Ghazi1Hassoon Omar Hashim2Hamieh Abdallah3University of Technology-IraqUniversity of Technology-IraqUniversity of Technology-IraqFord Motor CompanyTitanium alloys are considered one of the materials required in industries. They can be used in various fields due to their high strength and corrosion resistance, but titanium alloys are considered difficult to machine using traditional methods. EDM is used to machine a workpiece using electrical discharges to cut hard materials that are challenging to cut with traditional methods. Therefore, this paper focuses on the machine of a high-strength material-titanium alloy Ti-6Al-4V and studies the influence of cutting process variables on the metal removal rate, tool wear rate, and surface roughness of the samples. The samples matrix form is created depending on the design of experiments method. Pulse-on time, discharge current, and gap process variables with three levels create mathematical models to predict the responses without conducting practical experiments. The results proved that machining variables impacted the responses, which were proven through results data analysis and the interaction plots. Also, the maximum error between experimental and predicted values using the mathematical model was 0.022 (mg/min) for the MRR, 1.719 (mg/min) for the TWR, and 0.334 (μm) for the Ra.https://doi.org/10.2478/mspe-2025-0019electrical discharge machiningmachining parameterstitanium alloy ti-6al-4vresponse surface methodologydata analysis |
| spellingShingle | Enzi Abass Abdulameer Ahmed Ghazi Hassoon Omar Hashim Hamieh Abdallah Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy Management Systems in Production Engineering electrical discharge machining machining parameters titanium alloy ti-6al-4v response surface methodology data analysis |
| title | Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy |
| title_full | Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy |
| title_fullStr | Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy |
| title_full_unstemmed | Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy |
| title_short | Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy |
| title_sort | experimental investigation of manufacturing variables effect on electrical discharge machining of titanium alloy |
| topic | electrical discharge machining machining parameters titanium alloy ti-6al-4v response surface methodology data analysis |
| url | https://doi.org/10.2478/mspe-2025-0019 |
| work_keys_str_mv | AT enziabass experimentalinvestigationofmanufacturingvariableseffectonelectricaldischargemachiningoftitaniumalloy AT abdulameerahmedghazi experimentalinvestigationofmanufacturingvariableseffectonelectricaldischargemachiningoftitaniumalloy AT hassoonomarhashim experimentalinvestigationofmanufacturingvariableseffectonelectricaldischargemachiningoftitaniumalloy AT hamiehabdallah experimentalinvestigationofmanufacturingvariableseffectonelectricaldischargemachiningoftitaniumalloy |