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February 12, 2026Advances in Materials Science and EngineeringOpen Access

Evaluating the Impact of Pulse Dynamics on Titanium Alloy Machining Precision in Micro‐EDM

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Authors

KKK. KalaiarasiSaveetha UniversityRDRatchagaraja DhairiyasamyGraphic Era UniversityDGDeepika GabirielAksum University

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Implication

Evaluates pulse shape effects on machining precision in titanium alloys, suggesting enhanced tool life and surface quality.

Key Points

  • This research aims to analyze how different pulse shapes impact machining performance of titanium alloys in micro-EDM processes.
  • Conducted micro-EDM trials on three titanium alloys: Ti-6Al-4V, Ti-6Al-2Sn-4Zr-6Mo, and Ti-3Al-2.5V.
  • Utilized rectangular, triangular, sawtooth, and reverse-sawtooth pulses at ~80 V with peak currents of 5-25 A and pulse-on times of 20-100 µs.
  • Employed a central composite design for the experiments and validated results using ANOVA and desirability optimization.
  • Rectangular pulses achieved the highest material removal rate (MRR) of 2.5 mm³/min for Ti-6Al-4V at 200 mJ.
  • Reverse-sawtooth pulses reduced tool wear rate (TWR) by 43%–47% and maintained surface roughness (Ra) between 1.9-2.2 μm.
  • Recast layer thickness decreased from 11.2 μm to 4.3 μm with optimal pulse shapes.

Cite This Study

Kalaiarasi et al. (2026) studied this question.

synapsesocial.com/papers/698d6e3c5be6419ac0d53cb8https://doi.org/10.1155/amse/3977537
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