OPTIMIZATION OF MACHINING CHARACTERISTICS OF TITANIUM-BASED BIOMATERIALS: APPROACH TO OPTIMIZE SURFACE INTEGRITY FOR IMPLANTS APPLICATIONS

Bharat Singh, Kuldeep K. Saxena, Ishaya M. Dagwa, Piyush Singhal and Vinayak Malik
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Bharat Singh: Department of Mechanical Engineering, IET, GLA University, Mathura, Uttar Pradesh, India
Kuldeep K. Saxena: ��Division of Research and Development, Lovely Professional University, Phagwara, Punjab, India
Ishaya M. Dagwa: ��Department of Mechanical Engineering, University of Abuja, Abuja, Nigeria
Piyush Singhal: Department of Mechanical Engineering, IET, GLA University, Mathura, Uttar Pradesh, India
Vinayak Malik: �Department of Mechanical Engineering, KLS Gogte Institute of Technology, Belagavi 590008, Karnataka, India¶Department of Mechanical Engineering, Visvevaraya Technological University, Belagavi 590018, Karnataka, India

Surface Review and Letters (SRL), 2025, vol. 32, issue 04, 1-11

Abstract: Nowadays, there has been continuous development of metallic biomaterials to meet special needs in the manufacturing of biomedical implants, units and systems so as to function well in the required environment. Developed biomaterials which possess exceptional properties in terms of biocompatibility and biomechanical compatibility require precision processing and machining to obtain the desired dimensional tolerances. Electrical discharge machining (EDM) is the noncontact or nontraditional process of machining that suits the precision machining of biomaterials. In this work, an effort was made to optimize the EDM parameters during machining of titanium-based biomaterials Ti-6AL-4V, so that the multi-objective responses could be obtained. The response surface method was used in designing the experiment, while the grey relational method was used to analyze the effect of multiple objectives into a single unit. The electrical parameters that were considered in this study include peak current, gap voltage, pulse turn-on and duty cycle. These parameters were set within the acceptable limits of the equipment. Three responses were studied, which are tool wear rates (TWRs), material removal rate (MRR) and surface roughness (SR). Using the signal-to-noise ratio and ANOVA optimum tool/electrode wear rate (TWR) is obtained at 5×10−5 g/min with process parameters Ip=6 A, Vg=30 V, Ton=200  μs, D=65%. Optimum values of material removal rate (MRR) are obtained as 0.01035g/min with process parameters Ip=6 A, Vg=60 V, Ton=140  μs, D=50%. Optimum SR is observed as 2.258 μm with EDM process parameters Ip=6 A, Vg=90 V, Ton=200  μs, D=65%. Surface characteristics are verified with SEM micrographs. Whereas, grey relation analysis predicted the multi-objective optimum response characteristics. Based on the grey relation grade, experiment number 7 (Ip=6 A, Vg=90 V, Ton=200  μs, D=65%) secured the first rank among the experiments/trails.

Keywords: Biomaterials; biomedical implants; Ti-6Al-4V; EDM; surface roughness (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X23400085

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