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<p>Ti6Al4V has found extensive application in fabricating aerospace-related structural components due to its minimal mass density, elevated mechanical strength, and superior corrosion resistance properties. These components are typically designed with numerous hole structures. Electrical discharge drilling (EDD) is an effective method for manufacturing holes in Ti6Al4V. The dielectric selection critically governs the machining performance in EDD. Deionized (DI) water and kerosene are common dielectrics used for EDD. However, undesired features such as increased surface roughness and enlarged overcut frequently occur, mainly attributed to the inherent property constraints of these dielectrics. A novel method for high surface quality and accuracy in EDD of Ti6Al4V using water-in-oil (W/O) nanoemulsion dielectric is presented. In this study, the influence of W/O nanoemulsion dielectric properties on machining performance, including material removal rate (MRR), tool wear rate (TWR) and average overcut (AOC), is investigated during the EDD of Ti6Al4V machining. Moreover, the machined surface roughness (SR) and recast layer morphology are characterized and analyzed. Experimental findings revealed that the W/O nanoemulsion significantly enhanced performance, with AOC levels 23.8% lower than kerosene and 33.3% lower than DI water. Furthermore, the SR showed a 50.4% reduction compared to kerosene and a 35.4% reduction relative to DI water and achieved a minimum recast layer thickness of 5.31&#xa0;μm with minimal surface cracks and debris. The W/O nanoemulsion dielectrics are promising for EDD applications with the dual advantages of excellent surface quality and high dimensional accuracy.</p>

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Improvement of Surface Quality and Accuracy of Electrical Discharge Drilling of Ti6Al4V Using Water-in-Oil Nanoemulsion

  • 期刊论文

  • 发表日期：

    2025年7月28日

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  • Qingsong Zhang,
  • Junren Jia,
  • Yizhou Zhang,
  • Yu Qiu,
  • Jianping Zhou,
  • Hang Dong,
  • Lizhong Wang

摘要

Ti6Al4V has found extensive application in fabricating aerospace-related structural components due to its minimal mass density, elevated mechanical strength, and superior corrosion resistance properties. These components are typically designed with numerous hole structures. Electrical discharge drilling (EDD) is an effective method for manufacturing holes in Ti6Al4V. The dielectric selection critically governs the machining performance in EDD. Deionized (DI) water and kerosene are common dielectrics used for EDD. However, undesired features such as increased surface roughness and enlarged overcut frequently occur, mainly attributed to the inherent property constraints of these dielectrics. A novel method for high surface quality and accuracy in EDD of Ti6Al4V using water-in-oil (W/O) nanoemulsion dielectric is presented. In this study, the influence of W/O nanoemulsion dielectric properties on machining performance, including material removal rate (MRR), tool wear rate (TWR) and average overcut (AOC), is investigated during the EDD of Ti6Al4V machining. Moreover, the machined surface roughness (SR) and recast layer morphology are characterized and analyzed. Experimental findings revealed that the W/O nanoemulsion significantly enhanced performance, with AOC levels 23.8% lower than kerosene and 33.3% lower than DI water. Furthermore, the SR showed a 50.4% reduction compared to kerosene and a 35.4% reduction relative to DI water and achieved a minimum recast layer thickness of 5.31 μm with minimal surface cracks and debris. The W/O nanoemulsion dielectrics are promising for EDD applications with the dual advantages of excellent surface quality and high dimensional accuracy.