On application of tool mimic approach for fabrication of functional surfaces using EDM process

Textured functional surfaces have various applications in surface modification, bioengineering, lubrication, and hydrodynamics. Present work introduces a new two-step, a cost-effective manufacturing process that successfully produces speckles texture over the surface of Ti-6Al-4V alloy materials. The first step covers the chemical machining of the copper tool material using a low-cost masking process that creates an array of electrodes. In the second step, the fabricated tool is then utilized to machine the Ti-6Al-4V alloy using spark discharges from the electric discharge machining process. A nondestructive method to calculate the height of the features has been provided in the form of a mathematical model. Confirmatory experimental values for the radius of the single electrode formed over the tool surface were found to be 0.435 mu m, whereas the optimized value was 0.475 mu m. Less than 10% error has been obtained between experimental and calculated values. The mechanics of chemical action over the tool surface has been explained with an analytical expression developed for the concept of inertial velocity, and adequacy of the model is confirmed by the SEM (scanning electron microscopy) and EDS (energy-dispersive X-ray spectroscopy) analysis. The surface obtained after the texturing process is hydrophilic, with contact angles being 49.6 for textured and 74.1, confirmed by the wettability test. Further, it was observed that the percentage error between the mask radius and the final textured circular pattern was about 5.4%. [GRAPHICS]