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<p>Micro-electrical discharge machining (micro-EDM) has emerged as a critical method for machining titanium alloys due to their poor machinability using conventional techniques. Despite advancements in pulse shaping, limited work has explored the influence of novel waveform profiles on machining efficiency and precision. This study addresses that gap by investigating the use of a reverse sawtooth-shaped current pulse to enhance Material Removal Rate (MRR) and minimize Overcut (OC) during micro-EDM of Ti-6Al-4&#xa0;V. Central Composite Design (CCD) and Response Surface Methodology (RSM) were employed to model the effects of peak current, pulse-on time, and pulse-off time, while Principal Component Analysis (PCA) was used for multi-response optimization. A maximum MRR of 0.0276&#xa0;mg/min and a minimum OC of 40&#xa0;μm were achieved at optimal conditions (7 A, 70&#xa0;μs Ton, 40&#xa0;μs Toff), with confirmatory trials showing less than 2.5% deviation. Ton emerged as the most influential factor, contributing over 53% to output variation. These findings underscore the potential of engineered waveforms to improve dimensional control and process stability. The results offer a new direction for precision micro-machining and suggest future work in real-time waveform modulation and the inclusion of additional metrics such as tool wear and surface topography.</p>

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Optimization of micro-EDM parameters for titanium alloy material using reverse sawtooth pulse configurations

  • 期刊论文

  • 发表日期：

    2025年7月24日

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  • Kalaiarasi K,
  • Balamurugan Mani,
  • Ratchagaraja Dhairiyasamy,
  • Deekshant Varshney,
  • Subhav Singh,
  • Deepika Gabiriel

摘要

Micro-electrical discharge machining (micro-EDM) has emerged as a critical method for machining titanium alloys due to their poor machinability using conventional techniques. Despite advancements in pulse shaping, limited work has explored the influence of novel waveform profiles on machining efficiency and precision. This study addresses that gap by investigating the use of a reverse sawtooth-shaped current pulse to enhance Material Removal Rate (MRR) and minimize Overcut (OC) during micro-EDM of Ti-6Al-4 V. Central Composite Design (CCD) and Response Surface Methodology (RSM) were employed to model the effects of peak current, pulse-on time, and pulse-off time, while Principal Component Analysis (PCA) was used for multi-response optimization. A maximum MRR of 0.0276 mg/min and a minimum OC of 40 μm were achieved at optimal conditions (7 A, 70 μs Ton, 40 μs Toff), with confirmatory trials showing less than 2.5% deviation. Ton emerged as the most influential factor, contributing over 53% to output variation. These findings underscore the potential of engineered waveforms to improve dimensional control and process stability. The results offer a new direction for precision micro-machining and suggest future work in real-time waveform modulation and the inclusion of additional metrics such as tool wear and surface topography.