Optimization and characterization of boric acid powder mixed electrical discharge machining of Ti-6Al-4V ELI

The powder mixed electrical discharge machining (PMEDM) process is used for enhancing machining efficiency and improving the surface characteristics of the workpiece compared to normal EDM. The present study evaluates the effect of boric acid powder mixed in deionized water in PMEDM of Ti-6Al-4V ELI (extra low interstitial). The PMEDM process is assessed by evaluating material removal rate (MRR) and surface roughness (SR) at varying powder concentration (PC), current and pulse duration ( T on ). Boric acid PMEDM exhibits advantageous for both MRR and SR, where MRR increases and SR decreases with an increase in PC. To simultaneously achieve higher MRR and lower SR, the grey-fuzzy logic method is employed. Initially, the raw input data is normalized into grey numbers and a single index is obtained through grey relational analysis. Subsequently, triangular membership functions are assigned to the inputs and output. Fuzzy logic rules are then formulated, and grey fuzzy relational grade (GFRG) is calculated for each condition. The optimum condition (GFRG = 0.787) is attained at 15 g/l PC, 9 A current and 106 µs T on , resulting in a 63% improvement compared to the initial condition. At the optimum condition, MRR increased by 145% and SR decreased by 29% compared to the initial condition. The effect of boric acid in PMEDM can be visualized through the formation of smooth surfaces, exhibiting reduced SR, smaller and shallower craters, and fewer debris and globules. Additionally, the boric acid PMEDM experiments resulted in the formation of a hard TiB phase on Ti-6Al-4V, thus improving its wear resistance.