OPTIMIZATION OF ROTARY ELECTRODE EDM PROCESS PARAMETERS DURING MACHINING OF Ti-6Al-4V ALLOY

This paper presents the experimental investigation to determine the parametric setting for the effective and efficient machining of Ti-6Al-4V alloy by Rotary Electric Discharge Machining process. The effect of process parameters i.e. peak current, duty cycle, and speed of Revolution has evaluated using response surface methodology. The metal removal rate and overcut have been measured for each experiment to study the effects of parameters on performance during machining. ANOVA results for material removal rate show that Peak current, Duty cycle, Speed of Revolution, interaction of Peak current and Speed of Revolution and interaction of duty cycle and Speed of Revolution are significant parameters. Results for overcut show that peak current and duty cycle are significant parameters, with peak current being the most significant factor. The multi-response optimal setting for maximizing material removal rate and minimizing overcut in machining of Ti-6Al-4V alloy gives satisfactory results.