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Materials 2016, 9(12), 957; doi:10.3390/ma9120957

Effect of Electrical Discharge Machining on Stress Concentration in Titanium Alloy Holes

Department of Mechanical Engineering, National United University, Miaoli 36063, Taiwan
Author to whom correspondence should be addressed.
Academic Editor: Jung Ho Je
Received: 16 September 2016 / Revised: 14 November 2016 / Accepted: 18 November 2016 / Published: 24 November 2016
(This article belongs to the Section Structure Analysis and Characterization)
View Full-Text   |   Download PDF [6274 KB, uploaded 24 November 2016]   |  


Titanium alloys have several advantages, such as a high strength-to-weight ratio. However, the machinability of titanium alloys is not as good as its mechanical properties. Many machining processes have been used to fabricate titanium alloys. Among these machining processes, electrical discharge machining (EDM) has the advantage of processing efficiency. EDM is based on thermoelectric energy between a workpiece and an electrode. A pulse discharge occurs in a small gap between the workpiece and electrode. Then, the material from the workpiece is removed through melting and vaporization. However, defects such as cracks and notches are often detected at the boundary of holes fabricated using EDM and the irregular profile of EDM holes reduces product quality. In this study, an innovative method was proposed to estimate the effect of EDM parameters on the surface quality of the holes. The method combining the finite element method and image processing can rapidly evaluate the stress concentration factor of a workpiece. The stress concentration factor was assumed as an index of EDM process performance for estimating the surface quality of EDM holes. In EDM manufacturing processes, Ti-6Al-4V was used as an experimental material and, as process parameters, pulse current and pulse on-time were taken into account. The results showed that finite element simulations can effectively analyze stress concentration in EDM holes. Using high energy during EDM leads to poor hole quality, and the stress concentration factor of a workpiece is correlated to hole quality. The maximum stress concentration factor for an EDM hole was more than four times that for the same diameter of the undamaged hole. View Full-Text
Keywords: titanium alloy; Ti-6Al-4V; finite element method; electrical discharge machining; stress concentration titanium alloy; Ti-6Al-4V; finite element method; electrical discharge machining; stress concentration

This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Hsu, W.-H.; Chien, W.-T. Effect of Electrical Discharge Machining on Stress Concentration in Titanium Alloy Holes. Materials 2016, 9, 957.

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