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    • Experimental investigation on electric discharge drilling of titanium alloy (Ti–6Al–4V) with a gas-aided rotary tool

      NISHANT K SINGH YASHVIR SINGH ABHISHEK SHARMA

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      In this study, the authors tried to make holes in a titanium-based superalloy by a completely new machining method called electro-discharge drilling (EDD) using a gas-aided multi-hole rotating tool. Successful machining of the titanium work samples is extremely challenging due to its extreme hardness and stiffness. Oneof the key challenges facing the EDD operation is the elimination of spark-eroded matters from the electrodes gap. Arcing happens when the trash is collected in the working passage, which adversely affects the performance of the EDD. In this study, an effort has been made to explore an active flushing mechanism that can improve the flushing activity during the EDD process. Computational fluid dynamics analysis suggested that successful internal flushing by multi-hole rotating tools might result in the efficient removal of the molten material from theelectrodes gap. In addition, in this study, a comparative assessment of the EDD with the gas-aided multi-hole rotary electrode and the EDD with the stationary solid tool was carried out taking into account significant EDD responses. Besides, it was observed from the investigation that increased material removal rate and reduced EWR as well as surface roughness were acquired in the EDD with a gas-aided multi-hole rotating electrode in comparison with the EDD with a conventional stationary solid electrode. Basic analysis of surface morphologyindicates that the development of recast layers and surface cracks is not very likely to occur on specimens machined with a gas-aided multi-hole rotating electrode in comparison with a workpiece machined with a conventional stationary solid electrode. The results indicate that the use of pressured argon gas in EDD with a gas-assisted multi-hole rotating electrode has a beneficial effect on the execution of the procedure

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