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<p>The present study focuses on producing an interface at micro- and nano-level on complex curved and plane features of Ti-6Al-4V (α + β) alloy through wire electric discharge machining (WEDM) which simultaneously does machining and surface modification. The process parameters such as servo voltage, pulse on-time, pulse off-time and wire speed are used as input controls to comprehend the surface attributes of complex curved features at different scales. A thorough statistical, parametric, surface integrity, modified layer, layer hardening, surface porosity and surface spectroscopical analyses are carried out for a comprehensive evaluation of surface properties. Multi-attribute optimization resulted in optimized process settings <i>S</i><sub>V</sub> (70&#xa0;V), <i>P</i><sub>off</sub> (40&#xa0;μs), <i>P</i><sub>on</sub> (8&#xa0;μs) and <i>W</i><sub>S</sub> (6&#xa0;mm/s) achieving 75.51% combined desirability of both responses. The predicted and experimental results are validated under a 95% confidence interval showing less than 5% error. The optimized parametric conditions show 3.58&#xa0;μm surface roughness on curved features and 3.27&#xa0;μm on plane features.</p>

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Investigating the Surface Characteristics of Complex Geometrical Features on Ti-6Al-4V Alloy Processed through WEDM

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年10月8日

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  • Muhammad Umar Farooq,
  • Muhammad Asad Ali,
  • Saqib Anwar,
  • Muhammad Usman,
  • Zulfiqar Ali

摘要

The present study focuses on producing an interface at micro- and nano-level on complex curved and plane features of Ti-6Al-4V (α + β) alloy through wire electric discharge machining (WEDM) which simultaneously does machining and surface modification. The process parameters such as servo voltage, pulse on-time, pulse off-time and wire speed are used as input controls to comprehend the surface attributes of complex curved features at different scales. A thorough statistical, parametric, surface integrity, modified layer, layer hardening, surface porosity and surface spectroscopical analyses are carried out for a comprehensive evaluation of surface properties. Multi-attribute optimization resulted in optimized process settings SV (70 V), Poff (40 μs), Pon (8 μs) and WS (6 mm/s) achieving 75.51% combined desirability of both responses. The predicted and experimental results are validated under a 95% confidence interval showing less than 5% error. The optimized parametric conditions show 3.58 μm surface roughness on curved features and 3.27 μm on plane features.