Abstract
Machining of high aspect ratio micro-channels and cavities in metals is a challenging task. Micro-electrical discharge milling is a version of micro-electrical discharge machining process which is capable of micro-machining of all electrically conductive materials. The aim of this study is to analyze the effects of non-electrical parameters such as layer thickness (LT), horizontal tool feed rate (HTF), and tool rotational speed (TRS) on material removal rate (MRR) and relative electrode wear (REW) while micro-electrical discharge (μED) milling of stainless steel using tungsten electrode. The study revealed that layer thickness along with tool rotational speed and horizontal feed rate of the tool significantly influences the performance of μED milling.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Minh DN, Rahman M, Yoke SW (2013) Transitions of micro-EDM/SEDCM/micro-ECM milling in low-resistivity deionized water. Int J Mach Tools Manuf 69:48–56. doi:10.1016/j.ijmachtools.2013.03.008
Nguyen MD, Rahman M, Wong YS (2012) Enhanced surface integrity and dimensional accuracy by simultaneous micro-ED/EC milling. CIRP AnnManuf Technol 61:191–194. doi:10.1016/j.cirp.2012.03.011
Bissacco G, Tristo G, Hansen HN, Valentincic J (2013) Reliability of electrode wear compensation based on material removal per discharge in micro EDM milling. CIRP Ann Manuf Tech 62:179–182. doi:10.1016/j.cirp.2013.03.033
Karthikeyan G, Ramkumar J, Dhamodaran S, Aravindan S (2010) Micro electric discharge milling process performance: an experimental investigation. Int J Mach Tools Manuf 50:718–727. doi:10.1016/j.ijmachtools.2010.04.007
Jung JW, Jeong YH, Min BK, Lee SJ (2008) Model-based pulse frequency control for micro-EDM milling using real-time discharge pulse monitoring. J Manuf Sci Eng 130:4–6. doi:10.1115/1.2917305
Karthikeyan G, Garg AK, Ramkumar J, Dhamodaran S (2012) A microscopic investigation of machining behaviour in ED-milling process. J of Manuf Process 14:297–306. doi:10.1016/j.jmapro.2012.01.003
Song KY, Chung DK, Park MS (2010) Micro electrical discharge milling of WC-Co using a deionized water spray and a bipolar pulse. J Micromech Microeng 20:22–31. doi:10.1088/0960-1317/20/4/045022
Lin M, Tsao C, Hsu C, Chiou A, Huang P, Lin Y (2013) Optimization of micro milling electrical discharge machining of Inconel 718 by Grey-Taguchi method. Trans Nonferrous Mater 23:661–666. doi:10.1016/S1003-6326(13)62513-3
Wenwu Z (2010) Intelligent energy field manufacturing: interdisciplinary process innovations. CRC Press, USA
Vahid RA (2012) Net emission coefficient of plasma excited in the electrical discharge machining through liquid nitrogen dielectric medium. IEEE Trans Plasma Sci 40:853–862. doi:10.1109/TPS.2011.2182061
Banker KS, Oza AD, Dave RB (2013) Performance capabilities of EDM machining using aluminium, brass and copper for AISI 304L material. Int J Appl Innov Eng Manag 2:186–191
Banker KS, Parmar SP, Parekh BC (2013) Review to performance improvement of die sinking EDM using powder mixed dielectric fluid. Int J Res Mod Eng Emerg Tech 1:57–62
Moarrefzadeh A (2012) Study of workpiece thermal profile in electrical discharge machining (EDM) process. WSEAS Trans Appl Theor Mech 7:83–92
Kazimierz A, Karol M, Adam M, Stefan L, Marek M (1996) The temperature of a plasma used in electrical discharge machining. Plasma Sources Sci Tech 5:36–742. doi:10.1088/0963-0252/5/4/015
Zhao W, Gu L, Xu H, Li L, Xiang X (2013) A novel high efficiency electrical erosion process-blasting erosion arc machining. Procedia Eng 6:622–626. doi:10.1016/j.procir.2013.03.057
Liu Y, Wang J, Zhao, F, Wang, Y (2010) Research on dielectric breakdown mechanism of micro-EDM. Int Conference on Advanced Tech of Design and Manuf, 282–288. doi. 10.1049/cp.2010.1307
Richardson MT (2009) High resolution lithography—compatible micro-electro-discharge machining of bulk metal foils for micro-electro-mechanical systems. University of Michigan, Dissertation
Chang YF (2002) VSS controller design for gap control of EDM. JSME Int J Ser C, Mech Syst, Mach Elem Manuf 45:12–721. doi:10.1299/jsmec.45.712
Wong YS, Rahman M, Lim HS, Han H, Ravi N (2003) Investigation of micro-EDM material removal characteristics using single RC-pulse discharges. J Mater Process Tech 40:303–307. doi:10.1016/S0924-0136(03)00771-4
Rashed CA, Romoli L, Tantussi F, Fuso F, Bertoncini L, Fiaschi M (2014) Experimental optimization of micro-electrical discharge drilling process from the perspective of inner surface enhancement measured by shear-force microscopy. CIRP J Manuf Sci Tech 7:11–19. doi:10.1016/j.cirpj.2013.10.002
Dhanik S, Suhas SJ (2005) Modeling of a single resistance capacitance pulse discharge in micro-electro discharge machining. J Manuf Sci Eng 127:759–762. doi:10.1115/1.2034512
Dang M, Wong YS (2013) Transitions of micro-EDM/SEDCM/micro-ECM milling in low-resistivity deionized water. Int J Mach Tools Manuf 69:48–56. doi:10.1016/j.ijmachtools.2013.03.008
Mandal A, Dixit AR, Das AK, Mandal N (2015) Modeling and optimization of machining Nimonic C-263 Super Alloy using multi-cut strategy in WEDM. Mater Manuf Process. doi:10.1080/10426914.2015.1048462
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Jafferson, J.M., Hariharan, P. & Ram Kumar, J. Effect of non-electrical parameters in μED milling: an experimental investigation. Int J Adv Manuf Technol 85, 2037–2047 (2016). https://doi.org/10.1007/s00170-015-7933-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7933-1