Statistical Modeling of the Effective Parameters in Electrical Discharge Machining Process of Ti-6Al-4V Alloy Using the Mixtures of Aluminum Oxide and Silicon Oxide in Dielectric

In this study, the effect of using of aluminum oxide and silicon oxide nanoparticles simultaneously into dielectric has been investigated in the process of electrical discharge machining of titanium alloy Ti-6Al-4V. After analyzing the parameters affecting the process of the electrical discharge machining using nanoparticles, intensity of the current, concentration, pulse on time, and particle composition were considered as input parameters. The effect of each parameters has been investigated on three levels; the material removal rate (MRR), the tool wear rate (TWR) and the surface roughness (SR) of the work piece. With respect to the development of the industry in the use of environmentally friendly dielectrics, deionized water was used as the dielectric fluid. Also, Design Expert software has been employed for the design of the experiments, analysis of the results and optimization of the parameters. The results showed that the best surface morphology is obtained by machining with the addition of nanoparticles in the relative composition of 50%. In this percentage of the composition, the surface roughness has the least value of the crack and the recast layer. In addition, the maximum value of the MRR and minimum value of TWR can be achieved in 12A of current intensity, 100µs of pulse on time and 75% of relative composition.