Improving the surface quality of electrical discharge machined Ti6Al4V alloy by magnetic abrasive finishing technique

With the advances in technology, the expectations from engineering parts increase. Components used in engineering applications are expected to have superior mechanical properties, as well as geometric properties such as tolerance, accuracy and surface quality. Traditional manufacturing methods are insufficient to meet these expectations. It has become mandatory to use nontraditional manufacturing methods especially in the difficult to cut materials. In this study, Ti6Al4V alloy, which is frequently used in areas where high technology is used such as aviation, space and medical, was machined by electrical discharge machining (EDM) method and the surface qualities of the machined surfaces were improved by magnetic abrasive finishing (MAF) method. In the study, the effects of ultrasonic support, machining time, SiC abrasive size, spindle speed and magnetic field amount parameters on material removal rate, surface roughness improvement rate and white layer thickness were investigated experimentally. The experimental results obtained were evaluated statistically by variance analysis and gray relational analysis methods. In the first chapter of the study, the subject was introduced, and in the second chapter, information was given about the EDM method. In the third chapter, the MAF method is introduced and in the fourth chapter, studies on EDM and MAF methods and the place of the present study in the literature are emphasized. In the fifth chapter, methods related to experimental studies are given. In the sixth chapter, the relationships between the findings obtained in experimental studies and machining parameters are discussed. In the seventh chapter, the statistical analysis of the results of the experiment has been made with analysis of variance and gray relational analysis. In the last section, general results of the study and recommendations for future studies are presented.