Skip to main content
SpringerLink
Log in

Experimental investigations on the microhole machining of 304 stainless steel by micro-EDM process using RC-type pulse generator

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this research, microhole drilling of stainless steel grade 304 using micro-electrodischarge machining (micro-EDM) drilling has been studied. The machinability has been evaluated by means of material removal rate (MRR), tool wear rate (TWR), and accuracy of the machined microholes. During the micro-EDM drilling process, the thermal properties of the work materials were found to have a significant influence on the quality and accuracy of the microholes. Moreover, the performance parameters were also found to be influenced greatly by the thermal properties of the materials like thermal conductivity, melting point, thermal expansion coefficient, and behavior of the material at high temperature. From the observation of SEM micrographs, it is found that at a lower range of current and pulse-on time, the topographical condition of the microholes is better, and as the current and pulse-on time are increased, the microhole condition gets deteriorated.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Brousseau EB, Dimov SS, Pham DT (2010) Some recent advances in multi-material micro- and nano-manufacturing. Int J Adv Manuf Technol 47:161–180

    Article  Google Scholar 

  2. Masuzawa T (2000) State of the art of micromachining. CIRP Ann 49:473–488

    Article  Google Scholar 

  3. Liu K, Lauwers B, Reynaert D (2010) Process capabilities of micro-EDM and its applications. Int J Adv Manuf Technol 47:11–19

    Article  Google Scholar 

  4. Natarajan N, Arunachalam RM (2011) Optimization of micro-EDM with multiple performance characteristics using Taguchi method and Grey relational analysis. J Sci Ind Res 70:500–505

    Google Scholar 

  5. Tiwary AP, Pradhan BB, Bhattacharyya B (2014) Study on the influence of micro-EDM process parameters during machining of Ti–6Al–4V superalloy. Int J Adv Manuf Technol. doi:10.1007/s00170-013-5557-x

    Google Scholar 

  6. Masuzawa T, Tsukamota J, Fujino M (1989) Drilling of deep microholes by EDM. CIRP Ann 38:195–198

    Article  Google Scholar 

  7. Paul G, Roy S, Sarkar S, Hanumaiah N, Mitra S (2013) Investigations on influence of process variables on crater dimensions in micro-EDM of γ-titanium aluminide alloy in dry and oil dielectric media. Int J Adv Manuf Technol 65:1009–1017

    Article  Google Scholar 

  8. Nguyen MD, Rahman M, Wong YS (2012) An experimental study on micro-EDM in low-resistivity deionized water using short voltage pulses. Int J Adv Manuf Technol 58:533–544

    Article  Google Scholar 

  9. Kim DJ, Yi SM, Lee YS, Chu CN (2006) Straight hole micro EDM with a cylindrical tool using a variable capacitance method accompanied by ultrasonic vibration. J Micromech Microeng 16:1092–1097

    Article  Google Scholar 

  10. Li Y, Guo M, Zhou Z, Hu M (2002) Micro electro discharge machine with an inchworm type of micro feed mechanism. Precis Eng 26:7–14

    Article  Google Scholar 

  11. 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 Technol 140:303–307

    Article  Google Scholar 

  12. Wang D, Zhao WS, Gu L, Kang XM (2011) A study on micro-hole machining of polycrystalline diamond by micro-electrical discharge machining. J Mater Process Technol 211:3–11

    Article  Google Scholar 

  13. Nagahanumaiah, Ramkumar J, Glumac N, Kapoor SG, Devor RE (2009) Characterization of plasma in micro-EDM discharge using optical spectroscopy. J Manuf Process 11:82–87

    Article  Google Scholar 

  14. Jahan MP, Rahman M, Wong YS (2011) A review on the conventional and micro-electro discharge machining of tungsten carbide. Int J Mach Tools Manuf 51:837–858

    Article  Google Scholar 

  15. Li X, Wang J, Li W (2007) Current state and prospect of micro-machining. In: Proceedings of the IEEE International Conference on Automation and Logistics August 18–21, 2007, Jinan, China, pp. 1414–1419

  16. Wansheng Z, Zhenlong W, Shichun D, Guanxin C, Hongyu W (2002) Ultrasonic and electric discharge machining to deep and small hole on titanium alloy. J Mater Process Technol 120:101–106

    Article  Google Scholar 

  17. Maity KP, Singh RK (2012) An optimisation of micro-EDM operation for fabrication of micro-hole. Int J Adv Manuf Technol 61:1221–1229

    Article  Google Scholar 

  18. Azad MS, Puri AB (2012) Simultaneous optimisation of multiple performance characteristics in micro-EDM drilling of titanium alloy. Int J Adv Manuf Technol 61:1231–1239

    Article  Google Scholar 

  19. Pradhan BB, Masanta M, Sarkar BR, Bhattacharyya B (2009) Investigation of electro-discharge micro-machining of titanium super alloy. Int J Adv Manuf Technol 41:1094–1106

    Article  Google Scholar 

  20. Payal HS, Choudhary R, Singh S (2008) Analysis of electro discharge machined surfaces of EN-31 tool steel. J Sci Ind Res India 67:1072–1077

    Google Scholar 

  21. Liu HS, Yan BH, Huang FY, Qiu KH (2005) A study on the characterization of high nickel alloy micro-holes using micro-EDM and their applications. J Mater Process Technol 169:418–426

    Article  Google Scholar 

  22. Han F, Wachi S, Kunieda M (2004) Improvement of machining characteristics of micro-EDM using transistor type isopulse generator and servo feed control. Precis Eng 28:378–385

    Article  Google Scholar 

  23. Amorim FL, Weingaertner WL (2005) The influence of generator actuation mode and process parameters on the performance of finish EDM of a tool steel. J Mater Process Technol 166:411–416

    Article  Google Scholar 

  24. Liao YS, Huang JT, Chen YH (2004) A study to achieve a fine surface finish in wire-EDM. J Mater Process Technol 149:165–171

    Article  Google Scholar 

  25. Marafona J (2007) Black layer characterisation and electrode wear ratio in electrical discharge machining (EDM). J Mater Process Technol 184:27–31

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Muthayammal College of Engineering, Rasipuram, Namakkal District, 637 408, Tamil Nadu, India

    N. Natarajan

  2. Department of Mechanical Engineering, Karpagam College of Engineering, Coimbatore, 641 032, Tamil Nadu, India

    P. Suresh

Authors
  1. N. Natarajan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. Suresh
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to N. Natarajan.

Appendix

Appendix

The program used for the microhole drilling operation is given below.

G 90

(Absolute Dimensioning)

G 55

(Work Coordinate Offset 2)

G 00 x 6.0 y 0.0

(Rapid Traverse)

M 03 s 100

(Spindle Start Clock Wise)

M 08

(Coolant On)

M 201

 

M 211

 

G 00 z 2.0

 

G 01 z 0.04 f 5.0

(Linear Interpolation)

G 231 z −3.0 e 3.0

 

G 10 p 2 z 0

(Programmable Data Input)

G 201 z −0.42 e 0.5

 

G 201 z −18.0 e 1.5

 

G 201 z −19.0 e 0.5

 

G 00 z 15.00

 

M 200

 

M 05

(Spindle Off)

M 09

(Coolant Off)

M 30

(Program Stop)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Natarajan, N., Suresh, P. Experimental investigations on the microhole machining of 304 stainless steel by micro-EDM process using RC-type pulse generator. Int J Adv Manuf Technol 77, 1741–1750 (2015). https://doi.org/10.1007/s00170-014-6494-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-6494-z

Keywords

Search

Navigation