WEDM Performance of Ti-6Al-4V: Emphasis on Multi-Cut Strategy, Effects of Electrode Wire

Abstract

Abstract In the present work, machinability of Ti-6Al-4V was studied during Wire Electrical Discharge Machining (WEDM) in consideration with multi-cut strategy. Multi-cut strategy includes one main/rough cut followed by a number of finish/trim cut. Machining performance was assessed in purview of Kerf width, Material Removal Rate (MRR), phenomena of wire wear, and finally, surface integrity of the end product. Apart from surface morphology, topographical studies were made which included surface roughness, surface crack density, white layer thickness, element transfer, metallographic features. Performance of electrode wire (uncoated brass and zinc coated brass wire) in relation to different modes of cut was compared in the context of WEDM of Ti-6Al-4V.