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Open Access | Online First

Micro electro discharge milling of titanium super alloy: Analysis of material removal rate and surface roughness

Mohammad Yeakub ALIa,( ), Mohamed Abd RAHMANb, Muhamad Faizal Mohd KARINb, Mohd Saifuddin AMINDDINb, Seri Rahayu YA’AKUBa, Muataz Hazza Al HAZZAc, Abdul Md MAZIDd
Mechanical Engineering Programme Area, Universiti Teknologi Brunei, Gadong BE1410, Brunei Darussalam
Department of Manufacturing and Materials Engineering, International Islamic University Malaysia, Kuala Lumpur 50728, Malaysia
Mechanical Engineering Department, American University of Ras Al Khaimah, Ras Al Khaimah PO Box 10021, United Arab Emirates
School of Engineering and Technology, Central Queensland University Australia, Melbourne VIC3000, Australia

Peer review under responsibility of Editorial Committee of JAMST

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Abstract

This paper presents the machinability of titanium super alloy Ti-6Al-4V using micro electro discharge milling (Micro-ED Milling). Material removal rate (MRR), tool wear rate (TWR) and surface roughness were analysed using L18 orthogonal arrays of experiment. Based on analysis of variance (ANOVA) and signal-to-noise (S/N) ratio, empirical models have been developed. Optimum values of micro-ED milling parameters to achieve maximum MRR, minimum TWR and minimum surface roughness (Ra and Ry) were obtained. The optimum parameters were found to be 100 nF capacitance and 80 V gap voltage which leveraged 57.8 μg/s MRR and 0.96 μg/s TWR with 90% desirability. In addition, the optimum parameters for the minimum surface roughness were found to be 1 nF capacitance and 80 V gap voltage which produced 0.086 μm Ra and 0.63 μm Ry with 99% desirability. Experimental studies were conducted using optimum micro-ED milling parameters to validate the results. It was found that the predicted values were within 10% of the experimental values.

Keywords

Surface roughnessMaterial removal rateTitanium alloyTool wear rateMicro-EDM

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Journal of Advanced Manufacturing Science and Technology
Article number: 2025005
DOI: 10.51393/j.jamst.2025005
Cite this article:
ALI MY, RAHMAN MA, KARIN MFM, et al. Micro electro discharge milling of titanium super alloy: Analysis of material removal rate and surface roughness. Journal of Advanced Manufacturing Science and Technology, 2024, https://doi.org/10.51393/j.jamst.2025005

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Received: 09 May 2024
Revised: 17 June 2024
Accepted: 11 July 2024
Published: 24 July 2024
© 2025 JAMST

This is an Open Access article distributed under the terms of the Creative Commons Attribution License http://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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