Comparative Study of Dielectric and Debris Flow in Micro-Electrical Discharge Milling Process Using Cylindrical and Slotted Tools
Micro-Electrical Discharge Milling (µED-milling) is a commonly used process to machine intricate micro-channels (µchannels) with high aspect ratio. It can cut blind slots with a simple cylindrical tool, which is difficult using wire EDM. The flushing of machining by-products is the major concern in the process as the interelectrode gap (IEG) is of few microns. Different techniques have been explored by the researchers to enhance debris flushing from the gap. The rotation of the tool electrode is the major driving force for the removal of debris from the gap. In this paper, the flow simulation of dielectric and debris in the IEG are studied using computational fluid dynamics (CFD). Comparative study of the cylindrical and slotted tool is presented with contour plots. The slotted tool is found better as compared to the cylindrical tool as the accretion of particles is very less in case of the slotted tool.
KeywordsMicro-electrical discharge milling Interelectrode gap Dielectric Debris Computational fluid dynamics