MACHINING CHARACTERISTICS OF TITANIUM WITH ROTARY ELECTRODISCHARGE MACHINING

Where force suction Rushing is not feasible, alternative methods to clear the debris effectively from the gap between the electrodes in electro-discharge machining (EDM) have been attempted, e.g. the application of a magnetic held, special planetary motion of the tool electrode or low frequency vibration of the electrode. The orbital motion of the electrode helps in improving the machining rate. It also improves, to some extent, form and dimensional accuracy in the machining process. This paper presents the experimental investigation of EDM of titanium alloy with a copper-tungsten electrode in respect of metal removal rate, electrode wear, surface roughness by varying currents and electrode rotations. An effort has also been made to compare these results with those of stationary electrodes. Experiments were statistically designed, and a mathematical model of the process has been developed. It is found that rotating the electrode improves the metal removal rate due to improved flushing action and sparking efficiency. However, this results in high surface roughness. The electrode wear rate also increases with increasing speed. However, the wear ratio is not significantly affected.