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Electrical discharge machining of Al-TiB2 with a low-frequency vibrating tool

  • M. Prabu EMAIL logo , G. Ramadoss , P. Narendersingh , T.V. Christy and V. Vedhagiri Eswaran
Published/Copyright: October 2, 2013
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Science and Engineering of Composite Materials
From the journal Science and Engineering of Composite Materials Volume 21 Issue 3

Abstract

Aluminum-based composite reinforced materials produced in situ with titanium boride (TiB2) particulates have higher potential for advanced structural applications where high specific strength modulus as well as superior temperature resistance is imperative. In the present work, aluminum alloy-titanium boride composites were developed using a new combination of in situ techniques. Electrical discharge machining studies were conducted on aluminum alloy-TiB2 composite workpieces using a brass electrode. From the results, it is clear that the material removal rate and surface cracks of the workpiece increase with an increase in current and decreases with increase in the composition of titanium boride.

Keywords: aluminum-TiB2; composites; electrical discharge machining; machining of aluminum-based composite

1 Introduction

Titanium diboride (TiB2) is a refractory compound that exhibits outstanding features such as high melting point (3225°C) and high hardness value (86HRA or 960HV) [1]. The exothermic nature of the reaction of TiB2 with aluminum provides a conductive condition for producing the A1-TiB2 composite using an in situ method. A review of the literature reveals that only a few works have been reported on Al-TiB2. The unavailability of potential processing routes to overcome the poor wettability and high melting temperature for TiB2 could have accounted for this [2]. The 60% improvement in tensile and yield strength accompanied by 18% increase in “modulus”, but 56% of loss of ductility from the aluminum matrix with the addition of copper, improved the tensile and yield strengths by a factor of 2.5–2.8. However, whisker modulus remains the same as that of the unmodified matrix [2].

Al2O3 and Al3Ti particulates are formed by an in situ process and distributed in the Al matrix by heat-treating pellets obtained by cold-pressing a powder mixture of TiO2 (rutile type)+Al in a furnace. The synthesized products (Al2O3+TiB2)-Al are porous and free of agglomeration by sintering. They could serve as excellent “master alloys” for subsequent dilution in aluminum melt and processing of Al matrix composites reinforced with Al2 O3 and TiB2 particulates. The two-step process provides a novel, low-cost route for preparing this type of useful composites [3]. TiB2, with characteristics of high melting point (3225°C), low density (4.5 g/cm3), high electrical conductivity (22×106 Ω cm), good thermal conductivity (96 W/m/K), high hardness (25 GPa), and considerable chemical stability, is one of the candidates for high-temperature structural and wear applications [4].

TiB2 is attractive for a wide range of technological applications including cathodes for salt-bath electrolysis in Al production, electrodes for electrical discharge machining (EDM), cutting tools for wear-resistant parts and armor equipments, etc. [5]. Al 6061 is widely used in numerous applications including transport and construction, where superior mechanical properties such as tensile strength, hardness, and its superior corrosion resistance make it a suitable candidate material for marine structural applications [5]. The TiB2 particulates in Al 6061 matrix are manufactured through an in situ process involving the salt-metal reaction of 61N titanium-containing K2TiF6 and boron-containing KBF4 salts in the presence of molten Al 6061 alloy. The reaction scheme used to form the composites is given by Eqs. (1) and (2) [6].

(1)3K2TiF6+22Al+6KBF4 = 2Al3Ti+3AlB2+9AlB2+9KAlF4+K3AlF6+heat (1)
(2)3Al3Ti+3AlB2 = 12Al+TiB2 (2)

The manufactured Al-TiB2 composites exhibit higher values of hardness (88.6), tensile strength, and Young’s modulus compared to the base alloy. EDM is an extremely well-known machining process among newly developed nontraditional machining techniques. The merit of EDM techniques is most apparent in machining metal matrix composites (MMCs), which have the highest hardness in reinforcement. The EDM process does not involve mechanical energy; thus, the hardness, strength, or toughness of the workpiece does not affect the material removal rate (MRR) [7]. In the EDM process, the material erosion mechanism primarily makes use of electrical energy and turns it into thermal energy through a series of discrete electrical discharges occurring between the electrode and the workpiece immersed in a dielectric fluid; the thermal energy generates a channel of plasma between the cathode and the anode at a temperature in the range of 8000–12,000°C or as high as 20,000°C, initializing a substantial amount of heating and melting of material at the surface of each pole. When the pulsating direct current supply occurring at the rate of approximately 20,000–30,000 Hz is turned off, the plasma channel breaks down. This causes a sudden reduction in the temperature, allowing the circulating dielectric fluid such as kerosene (dielectric constant ε of 1.8) to improve the plasma channel and flush the molten material from the pole surfaces in the form of microscopic debris.

This process of melting and evaporating material from the workpiece surface is in contrast to the conventional machining processes, as chips are not mechanically produced. The volume of material removed per discharge is typically in the range of 10-6–10-4 mm3, and the MRR is usually improved fully here after 400 mm3/min depending on the specific application. Because the shaped electrode defines the area in which the spark erosion will occur, the accuracy of the part produced after EDM is fairly high [8].

In EDM, the machined surface is made up of three distinct layers consisting of a white layer, a recast layer, and a heat-affected zone. The unaffected parent metal provided a review on the metallurgy of the machined surface, which is dependent on the solidification behavior of molten metal after the discharge cessation and subsequent phase transformation. The thickness of the recast layer formed on the workpiece surface and the level of thermal damage suffered by the electrode can be determined by analyzing the growth of the plasma during sparking [9]. As the white layer is the topmost layer exposed to the environment, it exerts a great influence on the surface properties of the workpiece.

Several authors discovered the presence of microcracks and high tensile residual stresses on the machined surface caused by the high temperature gradient [10]. The adverse effect of discharge energy also provides some insights on the fatigue strength of the workpiece, which propagates from the multiple surface imperfections within the recast layer [11]. In addition, the machined surface has relatively high microhardness, which can be obtained by the emigration of carbon from the oil dielectrics to the workpiece surface, forming iron carbides in the white layer [12]. The concentration of carbides, both as surface layer on the workpiece and as fine powder debris, is dependent on the frequency and polarity of the applied current together with other processing parameters such as pulse shape, gap spacing, and dielectric temperature [13]. However, Thomson [14] argued that the pulse duration and type of electrode material under a paraffin dielectric has little effect on the amount of carbon contamination. He also suggested that the number and size of microcracks increase with pulse duration when machining with copper electrode. However, to the authors’ knowledge, only very few works have been reported on EDM of Al-TiB2 composites. Hence, an attempt has been made to investigate the effects of EDM of Al-TiB2 composites in this work.

2 Experimental procedure

2.1 Composite fabrication

Al 6061 alloy in as-cast condition was used in this study, and 12 wt% TiB2 particulates in Al 6061 matrix (henceforth referred to as Al 6061/TiB2/12p) was manufactured through an in situ process involving the salt-metal reaction between titanium-containing K2TiF6 and the boron-containing KBF4 salts in the presence of molten Al 6061 alloy. During the in situ reaction process, the elements Ti and B are introduced from the above-mentioned two salts into the molten aluminum to react within it. The samples were prepared from the cast composite plate for carrying out EDM. The experimental test setup is shown in Figure 1A.

Figure 1 (A) Experimental setup. (B) Machined workpiece.
Figure 1

(A) Experimental setup. (B) Machined workpiece.

2.2 EDM experiments

An experimental setup was developed and tests were conducted in an electrical discharge machine to study the various machining parameters of the EDM process. The tool electrode material used is brass; the values of pulse current, pulse-on time, pulse-off time, flushing pressure, and vibration of tool are shown in Table 1. Applying these parameters, the test was conducted on 32 combinations with and without tool vibrations.

Table 1

EDM parameters.

MaterialAl-TiB2
ElectrodeBrass
DielectricKerosene
Current (A)4, 6, 8, 10, 12
Pulse-on duration (μs)200, 400, 600, 800, 1000
Pulse-off duration (μs)20, 40, 60, 80, 100
Flushing pressure (kg/cm2)0.4, 0.6, 0.8, 1.0, 1.2
Tool vibration (Hz)0, 10, 20, 30, 40

The experiments were conducted on a SPARKONIX Die sinking electrical discharge machine (Sparkonix India Private Limited, Pune, Maharashtra, India). The material removed was measured using an electronic balance setup, and MRR is expressed as the ratio of the difference in the weight of the workpiece before and after the machining to the machining time and is expressed in Eqs. (3) and (4). The machined workpiece and the brass tool used are shown in Figures 1B and 2B, respectively, for clarity.

Figure 2 (A) Vibration setup in the experiment with tool and workpiece. (B) Brass tool.
Figure 2

(A) Vibration setup in the experiment with tool and workpiece. (B) Brass tool.

(3)MRR = (Wwb-Wwa)/t (3)

where Wwb and Wwa are the weights of the workpiece before and after the machining, respectively, and t is the machining time [15].

The tool wear rate (TWR) is also expressed as the ratio of the difference in the weight of the tool before and after the machining to the machining time. The tool and workpiece were weighed before and after machining in order to find the TWR and MRR. The accuracy of the weighing balance (Shimadzu Corporation, BL-220 H) is ±0.001 g.

(4)TWR = (Wtb-Wta)/t (4)

where Wtb and Wta are the weight of the tool before and after the machining, respectively.

3 Results and discussion

3.1 Developing mathematical models

In this section, a mathematical model was developed using SPSS software to predict the behavior of MRR and TWR of EDM drilling. The response function can be expressed by Eq. (5):

(5)MRR = f(C, ON, OFF, F, V) (5)

where C is current, ON is the pulse-on time, OFF is the pulse off time, F is the flushing pressure, and V is the tool vibration frequency.

The selected model includes the effect of main factors and is a segment of a power series polynomial expression. After determining the significant coefficient, the final regression model was developed and is given below. Also, various combinations of input parameters and their corresponding MRR and TWR are depicted in Table 2. These data were used from the mathematical model using curve fitting analogy.

Table 2

Parametric investigations of MRR and TWR.

Sample no.Current (A)On time (μs)Off time (μs)Pressure (kg/cm2)MRR (g/min)TWR (g/min)
1123253310.0480.065
281000550.80.0550.375
38550550.80.03760.187
48100550.80.0150.04
58550550.80.0390.135
6127753310.080.505
715550550.80.0830.391
812325780.60.0460.037
912775780.60.0750.355
105325780.60.0160.012
115325330.60.0170.017
125775330.60.02830.118
1357753310.0280.112
145775780.60.0270.058
1553253310.0180.012
168550550.80.040.13
1753257810.0160.013
188550551.20.0390.13
1912325330.60.0490.077
20127757810.0760.408
2157757810.0260.119
2212775330.60.0740.501
238550550.40.040.168
2485501000.80.0370.044
258550100.80.0490.297
26123257810.0450.038
271550550.80.010.004

MRR = 0.00015×(C)1.1564(ON)0.5543×(OFF)0.0821×(P)0.0287TWR = 2.8863×10-7(C)1.5641×(ON)1.8036×(OFF)0.4123×(P)0.0644

3.2 Effects of off time and pressure on MRR

Figure 3 depicts the surface plot representation of MRR against off time and pressure. From the figure, it is clear that the MRR attains a peak value if off time and pressure values are approximately in the mid terms in their respective ranges. A parabolic trend could be observed in MRR.

Figure 3 Surface plot of MRR vs. pressure, off time.
Figure 3

Surface plot of MRR vs. pressure, off time.

The MRR process is composed of melting and evaporation caused by the change in thermal energy in the discharge channel of processes and greatly depends on the pulse-off time and melting point of TiB2 particles, resulting in formation of a parabolic curve. The flow of dielectric blocks the formation of ionized bridges and reduces the MRR. The increase in flushing pressure clears the material particles and also reduces the TWR.

3.3 Effects of on time and pressure on MRR

From Figure 4, it can be observed that the pulse-on time and flushing pressure affect the MRR. The MRR is directly proportional to the amount of energy applied during this on time as increase in pulse-on time increases MRR values. These factors result in higher thermal loading on both electrodes (tool and workpiece) followed by a higher amount of material being removed. The flushing pressure has a considerable effect on the MRR. The dielectric fluid is forced at low velocity into this spark gap; hence, short circuiting becomes less pronounced as a result of the accumulated particles. This would help to improve the significance of the working efficiency and leads to an increase in MRR.

Figure 4 Surface plot of MRR vs. pressure, on time.
Figure 4

Surface plot of MRR vs. pressure, on time.

Increase in flushing pressure also improves the machining process in the form of cleaning the ceramic particles to be removed, and from that stage the material tries to settle down in the conductive path to continue the formation of ionized bridges.

3.4 Effects of on/off time on MRR

Figure 5 represents the surface plot of MRR against on and off time. From the experimental investigations, it is clear that MRR is directly proportional to the on time. However, an arc formation is evidenced in MRR as off time varies and reaches peak value at the mid segment. This is due to the melting point of TiB2 particles. Also, metal removal rate increases with increasing pulse-on time initially; after an optimum value is reached no visible improvement in the MRR is noticed.

Figure 5 Surface plot of MRR vs. off time, on time.
Figure 5

Surface plot of MRR vs. off time, on time.

3.5 Effects of pressure and current on MRR

This study of EDM parameters using full fractional design reveals a relationship between MRR and current and flushing pressure, i.e., increasing the input current automatically leads to increase in MRR. The effect of flushing pressure on the MRR has been evaluated in the transcend investigation and is shown in Figure 6. Increase in the flushing pressure improves the machining processes by clearing TiB2 particles removed from the material, thereby setting the conductive point to continue the formation of ionized bridges. However, the flushing pressure reaches very high values (1 kg/cm2). The flow of dielectric blocks the formation of ionized bridges and reduces the MRR. Metal removal rate is found to be increased with increasing values of discharge current. Increased rate of material removal from the workpiece and the tool electrode is attributed to the higher thermal loading as a result of higher discharge current value.

Figure 6 Surface plot of MRR vs. pressure, current.
Figure 6

Surface plot of MRR vs. pressure, current.

3.6 Effects of off time and current on MRR

Experimental results revealed that MRR could be increased gradually. Figure 7 shows the comparison of MRR with pulse-off time and current. Increase in the current and time leads to increase in MRR. This results in higher thermal loading on both electrodes due to material being removed; the process depends on pulse-off time and the melting point of TiB2 particles. The surface curve forms a semicircle shape. Also, MRR decreases as the percent of titanium boride particles in the composite increases due to the shielding effect of titanium boride particles in the composite.

Figure 7 Surface plot of MRR vs. off time, current.
Figure 7

Surface plot of MRR vs. off time, current.

The variation of MRR with pulse current and pulse-off time is discussed here. The MRR as a function of discharge current and pulse duration is presented in Figure 7. They result in higher thermal loading on both electrode materials being removed. With increase in off time, the MRR is parabolic in shape with increasing slope, and at a certain optimum level the MRR shows a decreasing fashion. The slope decreases with increasing pulse duration.

3.7 Effects of on time and current on MRR

From Figure 8, it can be concluded that MRR increases proportionally with increase in on time and current values. However, higher rate of change is evidenced with change in on time. This effect is due to the fact that the spark discharge energy is increased to solicit the action of melting, fabrication, and advancing large impulsive force in the spark gap, thereby increasing MRR. Higher current and on time results in a higher thermal loading on both the cathode and the anode, followed by a higher amount of material being ejected. Longer pulse duration causes higher rate of removal of material from the workpiece.

Figure 8 Surface plot of MRR vs. on time, current.
Figure 8

Surface plot of MRR vs. on time, current.

3.8 Crack formation in different process parameters

Figures 9 and 10 represent the SEM images of crater and crack formation, respectively. This study of EDM parameters using a half-fractional design reveals an interesting phenomenon, namely, there is no linear relationship between surface crack density and pulse energy.

Figure 9 Crater formation on the electrical discharge machined workpiece.
Figure 9

Crater formation on the electrical discharge machined workpiece.

Figure 10 Crack formation on the electrical discharge machined workpiece.
Figure 10

Crack formation on the electrical discharge machined workpiece.

Also, it has been found that crack formation is caused by the stress induced by the EDM process. If induced stress exceeds the maximum tensile strength of the material, cracking occurs. In this study, the relationship between EDM parameters and induced stress indicates that the parameter that has the greatest influence on induced stress is the pulse-on duration. If the pulse-on duration remains constant, the induced stress will increase, but with increased pulse current, the increase in induced stress is quite small.

However, cracks exist in the recast layer, which exhibits surface roughness caused by an uneven fusing structure, globules of debris, shallow craters, and pockmarks. Scanning electron microscopy (SEM) results show that the effect of increased pulse-on time is not only due to the increased surface roughness but also to increasing crack density. Moreover, there is no obvious correlation between pulse current and the resulting surface roughness and surface crack density.

As the pulse-on duration is increased, it leads to a greater degree of crack formation. Although the pulse current is increased, there is no significant increase in the induced stress, and in turn this increases the MRR significantly. Cracks are not readily formed within the white layer due to its ability to rapidly dissipate heat. Various researchers have also indicated that cracks were most likely to be evident in the recast layer of thickness between 20 and 50 μm. Although a thick layer has the tendency to crack more easily, the area occupied by the thick layer is less. Despite the small surface, crack density is witnessed for large pulse currents. It is also evident that crack formulation is larger for a small current; hence, only a small amount of stress is released.

3.9 X-ray diffraction analysis

An X-ray diffraction (XRD) pattern of the composite presented is depicted in Figure 11. From the figure, it can be clearly noted that the composite is mainly composed of aluminum and TiB2. In addition, traces of TiAl3, TiB, and TiSi2 are also seen. The presence of TiSi2 is mainly due to the use of the graphite clay crucible and silicon contamination from the clay [14]. Because the two salts K2TiF6 and KBF4 are stoichiometrically mixed to form TiB2, it remains to be the main intermetallic component formed by the reaction. This is also confirmed by the XRD analysis.

Figure 11 XRD pattern of the composite.
Figure 11

XRD pattern of the composite.

4 Conclusion

Al-TiB2 composites can be machined by EDM with kerosene as a dielectric fluid and using a half-fractional design arranged by pulse current and pulse-on duration. On this basis the following observations are made:

  1. This work evaluates the feasibility of machining Al-TiB2 MMCs with dielectric fluid.

  2. The feasibility of EDM with a low-frequency stationary tool was evaluated.

  3. MRR was found to be higher for larger current.

  4. TWR slightly increases by increasing the current.

  5. Increase in MRR was found by increasing the pulse-on time.

  6. Flushing pressure of the dielectric fluid has a considerable effect on MRR and TWR. When the flushing pressure is increased, the MRR and TWR are decreased.

  7. Results also indicate that MRR is increased and TWR is decreased when using suspended pure kerosene.

  8. Al-TiB2 composites can be machined using EDM, and by selecting the optimum level for the EDM parameters, namely, current, pulse-on time, pulse-off time, and flushing pressure, the effectiveness of MRR will be greatly enhanced.

  9. MRR and TWR are influenced by discharge current.

  10. Flushing pressure plays an important role in continuing the process and improving the MRR at higher discharge current and pulse duration level.

  11. Reduced metal removal rate is evidenced with increased titanium boride content in the composite material.

  12. Surface crack formation is related to the EDM parameters. Increased pulse-on duration will increase both the average thickness of the white layer and the induced stress. These two conditions tend to promote crack formation. When the pulse current is increased, the increase in MRR causes a high deviation in thickness of the white layer.

Corresponding author: M. Prabu, Department of Mechanical Engineering, Sengunthar Engineering College, Tiruchengode, 637205, Tamil Nadu, India, e-mail:

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Received: 2013-1-28
Accepted: 2013-8-25
Published Online: 2013-10-2
Published in Print: 2014-6-1

©2014 by Walter de Gruyter Berlin Boston

This article is distributed under the terms of the Creative Commons Attribution Non-Commercial License, which permits unrestricted non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited.

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https://doi.org/10.1515/secm-2013-0023
Keywords for this article
aluminum-TiB2; composites; electrical discharge machining; machining of aluminum-based composite
Creative Commons
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Articles in the same Issue

  1. Frontmatter
  2. Original articles
  3. Microstructures and physical properties of laser amorphous reinforced composite coatings
  4. The thermal resistance, flame retardance, and smoke control mechanism of nano MH/GF/NBR composite material
  5. The effect of sodium hydroxide treatment and fiber length on the tensile property of coir fiber-reinforced epoxy composites
  6. Evaluation of morphological characteristics and mechanical performance of Rockforce mineral fiber- and glass fiber-reinforced polyamide-6 composites
  7. Synthesis of superabsorbent resin with the properties of temperature tolerant, salt tolerant, and water absorbency deferred
  8. A study on tribological characterization of Al-Cu-Mg-B composites subjected to mechanical wear
  9. Microstructure and wear behavior of TiAl3 matrix self-lubricating composites by addition of fluoride solid lubricants
  10. Mechanical properties of Ni-nano-Al2O3 composite coatings on AISI 304 stainless steel by pulsed electrodeposition
  11. Improvement of Khorasan mortar with fly ash for restoration of historical buildings
  12. Combined effect of waste colemanite and silica fume on properties of cement mortar
  13. Effect of heat treatment temperature on ground pumice activation in geopolymer composites
  14. Stress intensity factor analysis of epoxy/SWCNTs based on global-local multiscale method
  15. Numerical elastoplastic analysis of the shear stress distribution in the adhesive layer for single-lap joints
  16. Analysis of three-layer composite plates with a new higher-order layerwise formulation
  17. Ceramic-polytetrafluoroethylene composite material-based miniaturized split-ring patch antenna
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  20. Thermal control design for an automated fiber placement machine
  21. Estimate of cutting forces and surface roughness in end milling of glass fiber reinforced plastic composites using fuzzy logic system
  22. Electrical discharge machining of Al-TiB2 with a low-frequency vibrating tool
  23. Vibration behavior of a radially functionally graded annular disc with variable geometry
  24. Buckling behaviors of the impacted composite plates
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