Integrated Analytical Modeling of Material Removal Rate and Surface Roughness in Magnetic Levitation EDM of Ti-6Al-4V
Keywords:
Electrical Discharge Machining (EDM),, Magnetic Levitation EDM, Material Removal Rate (MRR), Surface Roughness (Ra), Ti-6Al-4V, Multi-objective OptimizationAbstract
Electrical Discharge Machining (EDM) has emerged as a critical non-conventional machining process for difficult-to-machine materials such as Ti-6Al-4V, widely used in aerospace and biomedical applications. However, achieving an optimal balance between material removal rate (MRR) and surface roughness (Ra) remains a significant challenge due to complex thermal, plasma, and electro-physical interactions involved in the process. This study presents an integrated analytical and experimental investigation of MRR and surface roughness in Magnetic Levitation EDM of Ti-6Al-4V under varying discharge conditions. A structured experimental framework was developed by systematically varying peak current, pulse-on time, and pulse-off time while maintaining a constant servo voltage. The results reveal a direct relationship between peak current and MRR, accompanied by a deterioration in surface quality due to increased discharge energy and crater formation. A clear trade-off between machining productivity and surface integrity is observed, consistent with findings reported in advanced machining and surface enhancement processes. The proposed analytical approach, based on discharge energy principles, establishes a predictive framework for evaluating EDM performance. This study contributes toward improved parameter selection and supports multi-objective optimization of machining efficiency and surface quality in high-performance titanium alloys.
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Copyright (c) 2026 Gaurav Sanap, Vishal Sanap, Tanmay Patil, Aryan Kadu (Author)
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