Experimental investigation into electrochemical milling of Ti6Al4V

Electrochemical milling (EC milling) avoids complex electrode design which is often a burden in sinking ECM. In this process material is removed by a simple geometric tool following a predefined path in a layer-by-layer fashion. High strength temperature resistance (HSTR) material like Ti6Al4V is extensively used in different field starting from the defense to bio-medical industry. Study of comparative effects of different electrolytes on various performance characteristics on titanium alloy, is the soul of this paper. Commencement of making simple shape grooves to complex shape i.e 'L' shaped feature was machined by means of electrochemical milling process with layer by layer fashion. In each layer, the tool was controlled to move along a predefined path with a multi downward step. 'L' shaped features were machined on Ti6Al4V using three different electrolytes by varying feed rates and frequency followed by the corresponding effects on various performance characteristics were studied. It was observed that NaCl(0.5 M) + NaNO3(0.5 M) mixed electrolyte gave better result compare to the other two electrolyte as far as accuracy and surface finish of the features were concerned. It was also observed that performance characteristics other than depth and surface finish was improved with increasing feed rate and frequency up to a certain limit and after that short circuit was occurred. After analysing all the graphs and figures, it was concluded that to achieve better accuracy and surface finish, type of electrolytes, feed rate and frequency are the major important factors of EC milling.