Investigation on the impact of sub-zero treated electrodes in EDM

Owing to the challenges faced during conventional machining of Titanium (Ti) alloys due to their low thermal conductivity and high chemical reaction, non-conventional machining techniques are used. Electrical Discharge Machining (EDM) is a promising solution that can precisely machine hard materials into intricate geometries but faces lower material removal rate, higher tool wear rate, and poor surface quality. In this research work, the effect of sub-zero treatments on EDM electrodes was investigated, and experimental investigations were conducted to identify the impact of sub-zero treated electrodes during EDM of Ti-6Al-4V under different discharge energy regimes. Peak Current, Pulse-On-Time and Gap Voltage were varied in 3 levels to evaluate the effect on MRR and TWR. A comprehensive study on EDMed surfaces has been assessed using the morphological and metallurgical observations from SEM micrographs, EDAX and XRD patterns. Sub-zero treated electrodes outperformed the Untreated (UT) electrodes regarding erosion rates and surface quality.