Examining the surface roughness and kerf quality of micro-slots cut on the surfaces of Ti-B₄C nanocomposites by WEDM: a desirability approach

Abstract Micro slots and textures are created on Titanium (Ti) composites to improve its surface characteristics. Micro-textured Ti composites are generally recommended for bio implants, automobile, and aerospace components. In the current research, Ti-B₄C nanocomposites were prepared by powder metallurgical route. Micro slots were cut on the Ti-B₄C surfaces by Wire Electrical Discharge Machining (WEDM) Technology by varying the current, pulse-ON time, and pulse-OFF time. Scanning electron microscopy and XRD analysis validates the uniform distribution and inclusion of B₄C nanoparticles in Ti matrix. Response surface methodology was used to plan the experimental runs. Analysis of variance and desirability analysis were employed to identify the most suitable machining factors for obtaining the minimum surface roughness, lower kerf width and higher material removal rate (MRR). Increase in applied current and pulse-ON time, increases the MRR. Increase of pulse-OFF time from 50 μs to 60 μs gradually reduces the MRR and reduce the surface roughness of the cut slots. Contrastingly an increase in pulse-ON time increases the roughness due to an extensive melting and resolidification of Ti nanocomposites. The morphology of the WEDMed surface reveals the recast layer and localized melting zones on the cut surfaces.