MICROANALYSIS OF DEBRIS FORMED DURING ROTARY EDM OF TITANIUM-ALLOY (TI6AL4V) AND DIE STEEL (T-215 CR12)

This paper presents the scanning electron microscopy investigation on formation of debris during rotary electrodischarge machining of titanium alloy and high carbon high chromium die steel. Microanalysis of chemical composition of debris, in the form of globules after resolidification of ejected material from the workpiece surface, has been carried out using qualitative energy-dispersive spectroscopy and electron probe microanalysis. Scanning electron micrographs indicate the various types of debris particles which are collected from the dielectric as well as the particles which remain attached on the workpiece surface. Many distinct types of spheroidal particles (globules) are witnessed and the mechanism of their formation has been discussed. The chemical composition of these particles differs considerably, from its parent material due to migration of material from the rotating tool electrode (copper-tungsten) and the dielectric fluid.