Experimental Investigation on Surface Morphology of Micro-EDMed Ti-6Al-4 V Alloy Ramver, Vineet Kumar Yadav, Pradeep Kumar and Akshay Dvivedi Abstract Micro-machining of titanium alloys by conventional machining processes have limitations, for instance, high tool wear, chatter, vibrations, etc. To overcome these limitations of conventional machining processes, micro-EDM is suitable to machine titanium alloys owing to its ability to machine hard materials. In the present work, micro-EDM was used to drill micro-holes in Ti-6Al-4 V alloy using EDM oil as a dielectric medium. The effect of applied voltage on the morphology of machined surface was investigated. Microscopic characterization of machined surface showed that the surface obtained at higher applied voltage embraces relatively higher non- conformities such as micropore, debris deposition, porosity, uneven surface, etc., as compared to those at lower applied voltage. 1 Introduction In this perpetually evolving world, the demand for miniaturized parts and products has been burgeoning in various industries, like automotive, biomedical, avionics, optics, electronics, etc. These miniaturized components have features with sizes up to a few hundred micrometers. The conventional machining methods like micro- turning, milling, etc., are now applied to produce such features; however, the direct contact between the tool and work surfaces during machining engenders difficul- ties [1, 2]. To overcome these drawbacks, advanced machining processes especially micro-electrical discharge machining (micro-EDM) has been used to fabricate such features on difficult to machine materials such as Ti-6Al-4 V alloys. Micro-EDM pro- cess is possessing the ability to fabricate complex 3D features such as micro-holes, micro-channels, and micro-molds on any electrically conductive work material irre- Ramver · V.K. Yadav (B) · P. Kumar · A. Dvivedi Mechanical and Industrial Engineering Department, Indian Institute of Technology (IIT), Roorkee 247667, India e-mail: vineet437@gmail.com Ramver e-mail: ramver.pme@gmail.com © Springer Nature Singapore Pte Ltd. 2020 A. K. Parwani and PL. Ramkumar (eds.), Recent Advances in Mechanical Infrastructure, Lecture Notes in Intelligent Transportation and Infrastructure, https://doi.org/10.1007/978-981-32-9971-9_8 69