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Studies on quality of microholes generated on Al 1100 using micro-electro-discharge machining process

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Abstract

Electro-discharge machining process has found widespread applications in the industry over the last few decades. With growing trends towards miniaturization of machined parts, developments in the area of microelectromechanical systems, and the requirements for microfeatures in difficult to cut materials, micro-EDM has become an important and cost-effective manufacturing process because of its noncontact machining capability using microsized tools. This paper involves understanding of the effects of basic machining parameters on dimensional accuracy of the microholes by measuring top and bottom radial overcuts and taper angle and electrode depletion during micro-electro-discharge machining of aluminium (Al 1100) with tungsten electrode of diameter 300 μm. The microelectrodes have been cut using a foil electrode and shaped using a WEDG system. The experimentation has been designed using Taguchi methodology with gap voltage, capacitance, and pulse ON time as electrical parameters and thickness and electrode rotation as non-electrical parameters. Results obtained have been critically discussed.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Sardar Vallabhbhai National Institute of Technology, Surat, Gujarat, India, 395007

    H. K. Dave, V. J. Mathai, K. P. Desai & H. K. Raval

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  1. H. K. Dave
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  2. V. J. Mathai
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  3. K. P. Desai
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  4. H. K. Raval
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Correspondence to H. K. Dave.

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Dave, H.K., Mathai, V.J., Desai, K.P. et al. Studies on quality of microholes generated on Al 1100 using micro-electro-discharge machining process. Int J Adv Manuf Technol 76, 127–140 (2015). https://doi.org/10.1007/s00170-013-5542-4

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  • DOI: https://doi.org/10.1007/s00170-013-5542-4

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