Titanium alloy Ti-6Al-4 V is used in numerous applications because of its low weight associated with high strength, excellent resistance to fatigue and creep, good resistivity in corrosive environments, and biocompatibility. The Micro-Electro Discharge Machining (MEDM) is one of the finest non-conventional machining processes used for machining Ti-6Al-4 V. In this research article an attempt has been made to study effect of thin film coating of titanium nitride (TiN) on tungsten carbide (WC) micro-electrode on tool wear rate (TWR), over cut (OC) and depth of machining (Z coordinator) during micro-drilling of Ti-6Al-4 V. A detailed experimental investigation has been carried out with the help of Taguchi’s L9 orthogonal array for understanding the mechanism of the process. The process parameters such as voltage, spindle rotation and capacitance are considered to perceive their effect on TWR, OC and Z coordinator. Uncoated WC and TiN-coated WC micro-tool electrodes has been used during machining Ti-6Al-4 V in order to compare listed responses. The experimental results of TiN-coated micro-electrode showed that TWR decreased by 16.32 %, depth of machining increased by 20.83% and OC reduced by 12% as compared to uncoated WC micro-tool electrode.

Enhancing the operational efficacy of electrical discharge machining (EDM) is crucial for achieving optimal results in various engineering materials. This study introduces an innovative solution—the use of coated electrodes—representing a significant advancement over current limitations. The choice of coating material is critical for micro-EDM performance, necessitating a thorough investigation of its impact. This research explores the application of different coating materials (AlCrN, TiN, and Carbon) on WC electrodes in micro-EDM processes specifically designed for Ti-6Al-4V. A comprehensive assessment was conducted, focusing on key quality indicators such as depth of cut (Z), tool wear rate (TWR), overcut (OVC), and post-machining surface quality. Through rigorous experimental methods, the study demonstrates substantial improvements in these quality parameters with coated electrodes. The results show significant enhancements, including increased Z, reduced TWR and OVC, and improved surface quality. This evidence underscores the effectiveness of coated electrodes in enhancing micro-EDM performance, marking a notable advancement in the precision and quality of Ti–6Al–4V machining processes. Among the evaluated coatings, AlCrN-coated electrodes exhibited the greatest increase in Z, the most significant reduction in TWR, and the best OVC performance compared to other coatings and the uncoated counterpart.

Micro-electrical discharge machining (micro-EDM) stands out as a transformative methodology, offering substantial progress in both technical and economic efficiency through the integration of coated electrodes. This study meticulously analyzes various technological parameters in micro-EDM, focusing specifically on Ti-6Al-4V, a widely employed titanium alloy. The application of a titanium nitride (TiN) coating material on a tungsten carbide (WC) electrode is investigated using the Taguchi method of experimental design. This study employs an ANOVA and factorial design methodology to scrutinize the influence of key parameters, namely voltage (V), capacitance (C), and spindle rotation (in revolutions per minute) (RPM) on the tool wear rate (TWR), overcut (OVC), and Z coordinate (depth) within the micro-EDM process. The findings unveil a noteworthy increase in the TWR with an elevated V, C, and RPM, with capacitance exerting a pronounced influence while voltage exhibits the least impact. OVC exhibits notable variations, revealing an inverse relationship with RPM. The Z coordinate (depth) is significantly affected by capacitance, with voltage and RPM each having a relatively negligible impact. A surface quality analysis exposes similarities and numerous defects in both coated and uncoated electrodes, emphasizing the need for further exploration into the effectiveness of coated electrodes in enhancing post-micro-EDM machined surface layers. This study contributes valuable insights to optimize and advance micro-EDM processes, laying groundwork for future innovations in precision machining.

The advancement of modern engineering materials with superior mechanical properties such as hardness, toughness, and brittleness presents significant challenges to conventional machining techniques, often leading to tool failure and poor surface finish. To address these limitations, non-conventional machining method; Electrical Discharge Machining (EDM) has developed. The efficiency of EDM is primarily governed by electrical parameters such as current, gap voltage, and the conductivity of electrodes and dielectric fluids. The conductive powder viz. silicon carbide and aluminium powder mixed in dielectric medium is to improve the surface roughness (SR). The incorporation of conductive powders into the dielectric fluid has shown promise in enhancing EDM performance by stabilizing spark generation, thereby improving surface finish. In this study desirability approach method is used to optimize and identify the best SR value. Moreover, the surface characteristics analysed by measuring recast layer thickness, microhardness. The use of aluminium powder showed the better surface finish than silicon carbide.

Titanium alloy Ti-6Al-4V possesses excellent mechanical and corrosion-resistant properties; therefore, it is widely employed in aerospace, automotive, and biomedical fields. However, its poor machinability restricts traditional processing methods. To overcome this limitation, the current work presents a symmetry analysis approach to evaluate the effects of tool coating on the micro-electric discharge machining (micro-EDM) characteristics of Ti-6Al-4V. Tungsten carbide (WC) microelectrodes were fabricated in three forms: uncoated, copper-coated, and carbon-coated. The chemical vapor deposition (CVD) method was used to coat the carbon layer, and the integrity of the coating was confirmed by Energy-Dispersive X-ray Spectroscopy/Analysis (EDS/EDX). The effect of input variables—namely, voltage, capacitance, and spindle rotational speed—on two responses was studied—the machining depth (Z-axis displacement) and tool wear rate (TWR)—using a Taguchi L9 orthogonal array. Analysis conducted using Minitab statistical software 17 revealed that both voltage and capacitance contributed to the response parameters as optimized variables. The comparative study showed that the copper- and carbon-coated WC microtool could obtain a better Z coordinate and lower tool wear ratio compared with those of the uncoated tool. The findings confirm that applying thin conductive coatings to WC tools can significantly improve the stability, precision, and overall symmetry of the micro-EDM process when machining difficult-to-cut titanium alloys.