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Optimization of process parameters of wire electro discharge machining for Ti49.4Ni50.6 shape memory alloys using the Taguchi technique

Adik Takale (Department of Mechanical Engineering, Rajashri Shahu College of Engineering, Pune, India)
Nagesh Chougule (Department of Mechanical Engineering, College of Engineering, Pune, India)

International Journal of Structural Integrity

ISSN: 1757-9864

Article publication date: 7 June 2019

Issue publication date: 7 August 2019

Abstract

Purpose

Ti49.4Ni50.6 (at. %) shape memory alloy (SMA) is a unique class of smart materials because of unbeatable property which given a wide variety of their applications across a broad range of fields including an orthopedic implant. It plays a very important role in the constructions of novel orthopedic implants application (like dynamic compression plate) because of lower Young’s modulus compared to other biomedical implant materials, high mechanical strength, excellent corrosion resistance and unique property like shape memory effect. Conventional machining of Ti-Ni yields poor surface finish and low dimensional accuracy of the machined components. Hence, wire electro-discharge machining (WDEM) of Ti-Ni has been performed. The purpose of this paper is to investigate the effect of variation of five process parameters, namely, a pulse-on time, pulse-off time, spark gap set voltage (SV), wire feed and wire tension on the material removal rate, surface roughness (SR), kerf width (KW) and dimensional deviation (DD), in the WDEM of Ti49.5Ni50.6 SMA.

Design/methodology/approach

The effect of machining parameters on Ti49.4Ni50.6 has been fully explored using WEDM with zinc coated brass wire as an electrode. In this work, L18 orthogonal array based on Taguchi method has been used to conduct a series of experiments and statically evaluate the experimental data by the use of the method of analysis of variance. Scanning electron microscope images of the machined surface, at the highest and lowest pulse-on time, have been taken to evaluate the quality of surface in terms of their SR values.

Findings

For the highest pulse-on time, it is observed that blow holes, cracks, melted droplets and craters have been formed on the machined surface with an SR of 2.744 µm, while for the lowest pulse-on time, these are not formed with an SR of 0.862 µm. It is seen that the pulse-on time is the most significant process parameter for MRR, SR and KW, while the DD is significantly affected by spark gap SV. The optimal values of the process parameters have been obtained by the method of analysis of mean and the confirmatory experiments have been carried out to validate results of optimization. Energy dispersive spectroscopy analysis of the machined surface of Ti49.4Ni50.6 has shown a certain amount of deposition of material on the machined surface.

Originality/value

This is an original paper.

Keywords

Acknowledgements

The authors would like to thank the Indian Institute of Technology, Bombay, FIE Research Institute, Ichalkaranji, College of Engineering, Pune, India, for providing research facilities.

Citation

Takale, A. and Chougule, N. (2019), "Optimization of process parameters of wire electro discharge machining for Ti49.4Ni50.6 shape memory alloys using the Taguchi technique", International Journal of Structural Integrity, Vol. 10 No. 4, pp. 548-568. https://doi.org/10.1108/IJSI-10-2018-0058

Publisher

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Emerald Publishing Limited

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